Prelude Service Manual.indd
Contents
1. guide for the Quickie Prelude Pho tographs and content may differ from the actual products in some cases due to changes in specifications and other factors There are warning symbols used in this document to fo cus attention on any hazard that could effect the safety of the in dividual troubleshooting the chairs covered in this Service Manual This Service Manual is intended for use by persons with a basic working knowledge and the Skills required in servicing and maintaining Power Wheelchairs Persons without a General Working Knowledge and expertise in the servicing of this product should not carry out trou bleshooting procedures This can result in problems with future servicing and or damage to the unit Parts and configuration or specifications of Products included in this Service Manual are subject to change without prior notice SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 0 1 VR2 Controller VR2 Controller Buttons OOOO Battery Gauge CP Oo A series of ten LED s which O O indicate charge level F N On Off Key Press to power on I or off the power chair or Control Ce H ler Horn Key Activates a warning horn Speed Profile indicator A se ries of five LED s which display speed and profile settings Speed Profile Decrease Used to decrease the Speed Profile setting Speed Profile Increase Used to Increase the Speed Profile setting SUNRISE MEDICAL PRELUDE SERVI2. CE MANUAL 2006 PAGE 0 2 Plugs Connectors charger port 4 Red 1 24 Vdc 3 Yellow 2 0 Vdc 3 Inhibit 1 Programmer Charger port Outside View Motor Plug MOTOR 1 Brake ve Brake ve Cu oe Motor ve Motor ve VR2 Controller M1 RIGHT SIDE MOTOR M2 LEFT SIDE MOTOR J SM J OYSTICK MODULE INH 2 INHIBIT 2 A1 ACTUATOR 1 A2 ACTUATOR 2 BATTERY AOOO WA A A SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 0 3 Basic Tool List amp Main Wiring Diagram Basic Tool List The following list of tools should enable any task to be dealt with Some will only occasionally be needed but it is advisable to own or have access to them e 17mm Deep Socket wrench e 13mm combination wrench e Cutter for zip tie e Needle nose pliers e 5mm Allen wrench e 3 8 combination wrench e Phillips screwdriver 2 e 18mm combination wrench e Flat blade screwdriver e 19mm socket wrench e 5mm socket wrench Wiring Diagram for VR2 Controller Package LEFT MOTOR BATTERY SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 0 4 h Troubleshooting No Power 1 1 Circuit Breaker Reset e If On off button is pressed and no light or bar is shown check for tripped circuit breaker see figure A1 1 1 and make sure all connections are clean and tight including the batteries If the problem persists then perform the following diagnos
3. E MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 10 Understanding VR2 Controller Diagnostics Codes cont 4 9 Nine Bars Solenoid Brake Trip The parking brakes have a bad connection Check the parking break and motor connections Make sure the con trol system connections are secure Measure the two small contacts on the four pin motor connector fig 4 9 1 If both motor connectors read approximately 60 ohms then re place the controller Otherwise replace the motor that does not read approximately 60 ohms EI A ON o If both motor connectors read approximately 60 ohms then replace the controller Otherwise replace the motor that does not read approximately 60 ohms 4 10 Ten Bars High Battery Voltage An excessive voltage has been applied to the control system This is usually caused by a poor battery connec tion Check the battery connections a land HEJ Battery Fault Check that the batteries are fully charged the correct volt age and in good condition Take a voltage reading from pin 1 and pin 2 of the charger port of the VR2 controller see figure A4 10 1 If the meter reads more than 30 volts then check the charger Otherwise replace your controller if the meter reads more than 30 volts replace the charger If the Batteries connections and voltage level are correct replace the controller JEG SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 11 Disassembly Reassembly and A
4. ELUDE SERVICE MANUAL 2006 PAGE 6 Understanding VR2 Controller Diagnostics Codes 4 1 One Bar Low Battery Voltage This code could indicate discharged batteries failed batteries or poor battery connections Begin by recharging the bat teries and then refer to Section 1 to check batteries and connections 4 2 Two Bars Right motor Disconnect Low battery voltage Programmer will indicate left motor fault Motor faults are reversed on this unit If the chair runs while two bars are flashing chair indicates low battery voltage Refer to section 4 1 If the chair does not run while flashing two bars check the connections from the right motor to the controller look for a loose or damaged connector Use a volt meter to check the resistance across the two bottom contacts with connector for plug on upside of plug as shown in figure a4 2 2 If the meter reads between 0 1 5 then proceed by swapping the motor leads into the controller Turn unit off and back on and if two bar flash is still present replace the controller If the meter does not read between 0 1 5 proceed by Swapping the motor leads into the controller Turn unit off and back on if two bar flash becomes a four bar flash replace the right motor DIGITAL MJLTI ETER If none of the above corrects the problem replace the left motor If the meter reads between 0 to 1 5 ohms then replace the controller SUNRISE MEDICAL PREL
5. Quickie Prelude Service Manual SUNRISE MEDICAL MOBILITY PRODUCTS DIVISION QUICKIE PRELUDE 2007 Sunrise Medical Inc 103748 Rev A Quickie Prelude Service Manual Contents Introduction 0 1 VR2 Controller 0 2 Plugs Connectors r rranrrrnrnrrrrrnnnrenrnnrvennnnnr 0 3 Basic Tool List amp Main Wiring Diagram 0 4 Section 1 Troubleshooting No Power 1 1 1 Circuit Breaker Reset rrrrnnrnnnnronnnrnnnnrnnnnrn 1 1 2 Test Joystick rrrnnonrnnrrrnnnernnnrrrrnnrevnnnrnnnnnennnnre 1 1 3 Battery Test 1 1 4 Battery Connection Test 2 1 5 Circuit Breaker Test 3 1 6 Check Battery Wire Harness 3 1 6 Main Harness ranrnnnrnnanenanennnrnnnrnnnnnnanennnennn 4 Section 2 Chair is not Charging 5 2 1 Not Charging rrrrrronrrrrrnnnverranrrnrnnnnennnnnnenn 5 Section 3 Understanding VR2 Controller Display 6 3 1 The Speed Profile Indicator Ripples Up and DOWN EE 6 3 2 The Speed Indicator Flashes 6 3 3 Battery Gauge is Steady 6 3 4 Battery Indicator Ripples up and off 6 3 5 Battery Gauge Blinks Once Every 2 5 Sec Me 6 3 6 Battery Gauge Flashes Rapidly 6 Section 4 Understanding VR2 Controller Diagnostics Codes iii 7 4 1 One Bar Low Battery Voltage 7 4 2 Two Bars Right motor Disconnect Low b
6. Tire 1 Supportthe wheel chair base 2 Use a 17mm socket wrench to remove the nylock nut washer and drive wheel fig 58 1 3 Use two 13mm socket wrenches to remove the three wheel hub fasteners fig 58 2 4 Separate the wheel hubs and remove the tire Reassembly Ensure the Motor Shaft Key is properly inserted and re verse above instructions SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 17
7. UDE SERVICE MANUAL 2006 PAGE 7 Understanding VR2 Controller Diagnostics Codes cont 4 3 Three bars Right Motor Wiring Trip Low battery voltage amp Programmer will indicate left motor fault Motor faults are reversed on this unit Check that the batteries are fully charged and in good condition and check all cables and connections Check the connections to the left motor look for a loose or damaged connector Measure the resistance from the bottom contact of the red thick wire on the 4 pin left motor connector to each of the top contacts of the connector see figure A4 3 1 Measure the resistance from the bottom contact of the black thick wire on the 4 pin left motor connector to each of the top contacts of the connector see below right If all of the readings are open then replace the controller If any of the readings are short then replace the left motor Test3 Emms Test4 cm If all of the readings are open then replace the controller If any of the readings are short then replace the left motor SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 8 Understanding VR2 Controller Diagnostics Codes cont 4 4 Four Bars Left Motor Disconnected Programmer will indicate right motor fault Motor faults are reversed on this unit Check the connections from the left motor to the controller look for a loose or damaged connector Use a volt meter to check the resistance across the
8. all of the readings Test 2 Test2 mm are open then replace the controller If any of the readings gt are short then replace the right motor Test3 Km Test 4 If all of the readings are open then replace the controller If any of the readings are short then replace the right motor 4 6 Six Bars Inhibit Active The wheelchair is being prevented form driving by an external signal One possibility is the battery charger is connected or possibly an actuator inhibit 4 7 Seven Bars A Joystick Trip is Indicated Seven bar flash with speed indicator flashing Inspect wiring between joystick module and main controller Replace the control cable first and then try a joystick module If the problem persists replace the controller Make sure that the joystick is in the center position before switching on the control system Examine the joystick for damage This fault can be caused by a joystick that fails to center itself due to being dirty bent or broken If this is the case replace the joystick If the joystick fails to center because it is bent or broken replace the joystick module 4 8 Eight Bars Possible Control System Trip Controller Fault A control system trip is indicated Make sure that all connections are secure Check that the batteries are fully charged and in good condition and check all joystick connections and cables If this does not correct the prob lem then replace the controller SUNRIS
9. arger If the voltage meter reads below 12 volts charge the batteries SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 1 Troubleshooting No Power cont 1 4 Battery Connection Test 4 Check that the female VR2 control cable has voltage Un plug joystick from control cable Set the volt meter to DC volts and measure the voltage using the red lead in port 1 and the black lead in port 4 as shown in figure 1 5 1 If the voltage meter reads approximately 24 volts then replace the joystick If the voltage reads 12 volts or less measure the corresponding pins on the VR2 controller as shown in figure 1 5 3 If the voltage meter reads full volt age then replace the jumper cable If the voltage meter reads approximately 24 volts replace the control cable If the voltage reads 12 volts or less then proceed to measure the voltage from the battery harness plugging into the controller If the voltage measures approx imately 24 volts replace the controller If it reads 12 volts or less proceed to the next step Ifall of the measurements read full voltage then replace the controller SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 2 Troubleshooting No Power cont if the meter reads more than one ohm change the Battery harness A 1 5 Circuit Breaker Test A To check the circuit breaker remove the left rear shroud by unscrewing the two Phillips head screws figure A1 8 1 Set the
10. attery voltage 7 4 3 Three bars Right Motor Wiring Trip Low battery voltage 8 4 4 Four Bars Left Motor Disconnected 9 4 5 Five Bars Left Motor Wiring Trip 10 4 6 Six Bars Inhibit Active 10 4 7 Seven Bars A Joystick Trip is Indicated 10 4 8 Eight Bars Possible Control System Trip EEE 10 4 9 Nine Bars Solenoid Brake Trip 11 4 10 Ten Bars High Battery Voltage 11 Section 5 Disassembly Reassembly and Adjustment 12 Step 1 Seat removal 12 Step 2 Footrest adjustment and removal 13 Step 3 Shroud removal 14 Step 4 Battery removal 15 Step 5 Controller removal 15 Step 6 Motor removal 16 Step 7 Caster Fork removal 17 Step 8 Changing Drive Tire 17 Introduction Please read and follow instructions in this service manual before attempting to troubleshoot or repair this product for the first time f there is anything in this Service Manual that is not Clear or if you require additional Technical assistance contact Sunrise Medical at 800 333 4000 option 2 then option 1 Safely troubleshooting and or repair of this product depends on your diligence in following the instructions within this manual Sunrise Medical is not responsible for injuries or damage resulting from a person s failure to exercise good judgement and or common Sense This Service Manual is intended as a troubleshooting
11. djustment Step 1 Seat removal Disassembly 1 Unplug joystick at the base of the chair figure s1 1 Note Remember to lay cables on the seat otherwise they may become tangled when taking off the seat 2 Unlatch the seat and rotate slightly figure 51 2 3 Lift the seat verticaly to remove figure 51 3 x mT N APRELUDE r NNN N 1 2 SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 12 Disassembly Reassembly and Adjustment Step 2 Footrest adjustment and removal To adjust footplate position 1 Remove the two attachment bolt fy s2 1 2 Slide footrest assembly up or down to desired position and reinsert attachment bolts To adjust footplate angle 1 turn screw in or out fy 52 3 SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 13 Disassembly Reassembly and Adjustment cont Step 3 Shroud removal a ii a i m hl p Se Main shroud 1 Remove seat post pin and lift out the seat post fp 53 1 2 Lift the shroud from the velcro and remove f0 53 2 Fender shroud 1 Loosen and remove the two philips screws holding the fender shroud in place fy 53 3 2 Remove fender shroud Rear shroud 1 Loosen and remove the two philips screws holding the rear shroud in place fy 53 4 2 Remove rear shroud EN PAGE 14 SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 Disassembly Reassembly and Adjustment cont Step 4 Battery rem
12. meter to ohms and measure the resistance or check for a tone continuity If you are not getting a tone or the resistance measures more then 1 ohm re place the circuit breaker If meter gives a tone or resis tance measures less then 1 ohm proceed to next step DIGITAL MULTIMETER If the meter reads more than 1 ohm then change the circuit breaker 1 6 Check Battery Wire Harness Check that the battery wire harness has the polarity cor rect Set the meter to DC volts and measure the voltage with the red lead in the white connector and the black lead in the black connector as shown in figure 1 6 1 If both wiring harnesses have approximately 12 volts and polarity is correct replace the main battery harness plugging into the controller If voltage is less then 10 volts proceed to section 1 3 DIGITAL MULTIMETER If polarity is reversed correct battery wiring SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 3 Troubleshooting No Power cont 1 7 Main Harness If the previous steps did not correct the problem check the main harness Disconnect the main harness from the front and rear battery harness Check the continuity between the white rear connector figure 1 9 1 and the black front con nector Next check the continuity between the black rear connector figure 1 9 2 and the left contact on the controller plug Next check the continui
13. oval 1 Remove seat step 3 2 Remove main shroud step 3 3 Disconnect battery harnesses fy 54 1 4 Carefully lift batteries and remove fy 54 2 Step 5 Controller removal 1 Remove main shroud step 3 2 Disconect battery harnesses fp 54 1 3 Remove front battery 4 Gently remove controller from velcro inside battery tray fy 55 1 5 Unplug all connectors from the controller 6 Remove controller from battery tray SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 15 Step 6 Motor removal 1 Complete steps 1 3 5 removal of seat shrouds batter les and controller 2 Unplug the motor connector from the controller and remove any zip ties holding the cable harness to the frame 3 Remove battery tray from velcro fig 56 1 4 Use a 17mm socket wrench to remove the drive wheel fig 56 2 5 Using two 13mm wrenches remove the four bolts and nuts 56 3 holding motor plate to the frame 6 Remove the cotter pin A fig 56 4 holding the cog release handle B to the cog release lever arm C Warning If motor plate is removed form the gear box the gear box plate may come off SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 16 Disassembly Reassembly and Adjustment cont Step 7 Caster Fork removal 1 Remove caster cap fig 57 1 2 Use a 19mm socket wrench to remove the caster nut fig 57 2 Step 8 Changing Drive
14. tick forwards until the control system chirps and deflect the joystick in reverse until the control system chirps Release the joystick there will be a long beep The wheelchair is now locked 2 The Speed Indicator Flashes This indicates that the chair is charging via on board charger The chair will be ready to drive as soon as the charger is unplugged 3 Battery Gauge is Steady This indicates the battery level and that all is well and chair Is ready to drive 3 4 Battery Indicator Ripples up and off Indicates the wheelchair batteries are being charged with the offboard charger You will not be able to drive the wheelchair until the charger is disconnected and you have reset the control system by switching off the power and then powering up again 3 5 Battery Gauge Blinks Once Every 2 5 Seconds The control system has gone to sleep because the wheelchair has not been driven for a period of time The time period depends on the programming of the system To re start reset the system by switching off the power and then powering up again 6 Battery Gauge Flashes Rapidly Make sure the J oystick is completely released The control system safety circuits have been activated and the control system has been prevented from moving the wheelchair This indicates a system trip i e the VR2 has detected a problem somewhere in the wheelchair s electrical system Please refer to Section 3 VR2 Controller Diagnostics SUNRISE MEDICAL PR
15. tics 1 2 Test Joystick Check that voltage is going to the controller Set the meter to DC volts and take a voltage reading using the red lead in pin 1 and the black lead in pin 2 of the charger port on the VR2 joystick See figure Al 2 1 If the voltage meter reads approximately 24 volts try replacing the joystick If the meter reads 12 volts or less proceed to the next step Note Make sure the polarity is correct If polarity is reversed proceed to step 1 5 1 3 Battery Test Check that the batteries are fully charged and in good working condition Remove the seat and battery cover Usea volt meter to check the voltage across the battery terminals See figure al 3 1 The batteries should measure within 2 or 3 tenths of a volt of each other If the batteries are not within 2 3 tenths of a volt load test the batteries and replace if necessary If the batteries measure below 10 volts replace the batteries or remove the batteries and charge with a 12 volt charger Batteries must be connected in parallel to charge with a 12 volt charger Connect the positive terminal of the first battery to the positive terminal of the second battery as well as connecting the negative terminal of the first battery to the negative terminal of the second battery Charge batteries until the voltage in each battery measures approximately 12 volts Connect batteries back into chair and complete charge with standard on board or off board ch
16. two bottom contacts with connector for plug on upside of plug as shown in figure a4 4 2 If the meter reads between 0 1 5 then proceed by Swapping the motor leads into the controller Turn unit off and back on and if four bar flash is still present replace the controller If the meter does not read between 0 1 5 proceed by Swapping the motor leads into the controller Turn unit off and back on if four bar flash becomes a two bar flash re place the left motor DIGITAL MJLTD TER If the meter reads between 0 and 1 5 ohms then replace the controller If this does not correct the problem then replace the right motor SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 9 Understanding VR2 Controller Diagnostics Codes cont 4 5 Five Bars Left Motor Wiring Trip Programmer will indicate right motor fault Motor faults are reversed on this unit Check that the batteries are fully charged and in good condition and check all cables and connections Check the connections to the right motor look for a loose or damaged connector Measure the resistance from the bottom contact of the red thick wire on the 4 pin right motor connector to each of the nu MNT i DIGITAL MULTIMETER top contacts of the connectors see figure A4 5 1 Measure es the resistance from the bottom contact of the black thick wire on the 4 pin right motor connector to each the top con tacts of the connector below right If
17. ty between the white rear connector figure 1 9 3 and the right contact on the controller plug If the meter reads more than 1 ohm in any of the above tests replace the main harness DIGITAL MUL TIMETER SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 4 Chair is not Charging 2 1 Not Charging ie If the chair is not charging through the charging port Insure that the three pin charger socket is properly connected and in good condition Then test the voltage coming out of the joystick refer to section 1 2 If voltage at joystick charger socket on the VR2 joystick is less then 18 volts refer to section 1 3 If the voltage is greater then 18 volts refer to you charger troubleshooting manual Ifall of the measurements read full voltage then replace the controller SUNRISE MEDICAL PRELUDE SERVICE MANUAL 2006 PAGE 5 Understanding VR2 Controller Display 3 1 The Speed Profile Indicator Ripples Up and Down Indicates that the wheelchair is locked To unlock the wheelchair deflect the joystick forwards until the control system chirps Then deflect the joystick in reverse until the control system chirps Release the joystick there will be a long beep The wheelchair is now unlocked To lock the wheelchair while the control system is switched on depress and hold the on off button After 1 second the control system will chiro Now release the on off button deflect the joys
Download Pdf Manuals
Related Search