z-bop_service_manual..
Contents
1. 17 2006 Sunrise Medical ST PS POWER BASE SECTION 6 Unscrew four shroud retaining screws fy 1 40 7 Pull front shroud forward slightly fo 1 41 8 Lift and remove shroud assembly fy 1 42 2006 Sunrise Medical 18 POWER BASE SECTION ST amp PS The battery connection uses a 2 way connector with a White J umper to give the series connection of 24 volt Ithas a clearly designated RED and BLACK connector which connect to the Positive for RED and the Nega tive for the BLACK with J UMPER White joining the system The system has a 100 amp non removable fuse built into the Cable and a removable 15 amp fuse for Auxiliary P ower Inspecting the Fuses Remove caps on each of the two 15 amp fuses and Aa visually inspect fg 1 44 Insure there are no breaks 4 in the fuse material If continuity is still in doubt unplug _ fuse from holder and check resistance across fuse lt C dd blades Zero resistance indicates a usable fuse Infnite GEL MG resistance indicates a non usable fuse 4 ge The 100 amp fuses Fig 1 45 19 2006 Sunrise Medical ST PS POWER BASE SECTION Battery Chargers Chargers and Charging e Use the wheelchair manufacturer s automatic charger for all routine charging The best recharge point for deep cycle batteries is roughly at 50 discharge e Never run batteries completely fht total discharge Do not purchase automotive chargers They are not designed2. Men EA MULE Dr 1 ul 5 a a i LET pr nn 2 s r ir m a ee a nn an ot Se po 8 cE January 2007 SUNRISE MEDICAL www sunrisemedical com 2006 Sunrise Medical Table of Contents INTRODUCTION Me 4 VERE 4 Basic Setup aaa aana eaaa 5 Multimeter Tutorial naine ns 6 The Multimeter ssn 6 TO CS sasaran ana Na aaa oc eee 6 The Poris een mn esse 6 10 010 EEE EN 7 Health and Safety sss 8 Good Working Practices 8 Battery Safety 8 Battery Chargers ccccssccccssssseeeceeeseesceeseeessesseees 9 EMI NAMN aar 9 POWER BASE SECTION Z Bop Power Base sass 11 PAA 11 Battery Diagnostics 12 Battery INDES his 13 Accessing the Batteries 14 Changing the Battery sass 15 Replacing SOL ies a 16 Battery Connectors aaa eaaa eaaa aane aana 19 Battery Chargers 20 Desktop 8 Amp Fully Automatic Charger 20 Lightweight Charger sss 21 Trouble Shooting sss 21 MOS e 22 Checking the Motor BrusheSs 22 Checking Motor Resistance and Continuity 22 Motor Remo
3. The higher the immunity level the less the risk of EMI It is believed that a 20 V m immunity level will protect the power wheelchair user from the more common sources of radio waves The confguration tested and found to be immune to at least 20 V m is Quickie Rhythm and Groove power wheelchairs with a right handed mounted joystick system 18 seat width 18 seat depth dual post height adjustable armrests fxed tapered legrests with one piece solid footplate and Gp 24 gel cell batteries The following dealer installed speciality input devices have an unknown effect on the immunity level because they have not been tested with the Delphi control system Breath Control Sip n Puff Tri Switch Head Array e Proximity Head Array e Proportional Mini J oystick Chin Control Buddy Button e Wafer Board 2006 Sunrise Medical 10 ST amp PS POWER BASE SECTION Z Bop Power Base Batteries Safety If mishandled batteries can be dangerous and hazardous All mobility batteries whether wet type or gel sealed type contain lead and sulfuric acid Both of these materials are toxic and in the case of Sulfuric acid highly corrosive Additionally when batteries are charged they produce hydrogen gas which is highly fammable and can cause explosion This is why proper handing is mandatory at all times e Battery explosion This Is frequently the result of too low an acid electrolyte level in the batter
4. This is a programmable feature that can be Enabled or Disabled Default Disabled The lock is engaged by de pressing and holding the On Off switch for a period of greater than 10 seconds and then simultaneously pushing the joystick forwards The lock is disengaged by depressing and holding the On Off switch for a period of greater than fe seconds and then simultaneously pulling the joystick backwards Audio acknowledgment of the lock engaged operation is by sounding the horn for 50ms Audio acknowledgment of the lock disengaged operation is by sounding the horn for 50ms three times with 50ms spacing between the tones Battery Diagnostic Threshold e Battery under voltage Error Threshold Range 13 23 volts normally set to 16 volts This is the voltage at which the control will monitor for a specifed period of time and will execute an error of 1 bar fhsh Battery Voltage Error Period Range setting of 0 100 seconds normally set to 30 seconds This is the period of time in which the control will look at a lower voltage parameter and count a time out prior to execution of error e Battery Voltage Low Warning Threshold Range setting of 13 23 volts normally set to 18 volts This is the voltage at which the control will give a Low Voltage warning normally set higher than the Under voltage Error Threshold ECM Errors LED UT state Errors are indicated by the LED associated with the ch 00 e Mode Button Flashing GREEN
5. Remove top shroud and unplug motor controller to expose batteries ff 1 5 General Battery Maintenance Keep terminals free of corrosion and insure wiring connections are secure Check for frayed or loose contacts 2006 Sunrise Medical 14 POWER BASE SECTION 1 Firmly grasp the red battery connector and pull apart 2 Firmly grasp the black battery connector and pull apart 3 Firmly grasp the smaller white battery connector and pull apart 4 Using provided strap carefully lift battery from chair Rear battery is removed at an angle due to seat assembly To install batteries reverse above procedures Insure all wiring is clear of battery compartment before replac ing batteries in compartment 15 2006 Sunrise Medical ST PS POWER BASE SECTION Fairing Lift and remove fairing fy 1 33 attached with Velcro Battery Cover 1 Remove seat See Accessing Batteries section 2 Use screwdriver to unlock top shroud 3 Detach motor controller harness connectors 4 Lift up and away fp 1 34 Main Shroud Assembly 1 Remove locking pins to release front uprights Fy 1 35 2006 Sunrise Medical 16 POWER BASE SECTION ma HEE Sunrise Training and Education Programmes 2 Lift and remove front uprights fy 1 36 3 Remove locking pins to release rear uprights fy 137 4 Lift and remove rear uprights fy 1 38 5 Lift and remove rear transit bracket fy 1 39
6. Try another charger Remove power wait ten minutes and then reapply power Yellow LED Battery charger overheated Physically check all connections blinks 5 times Look for shorts or burning smell If power is re applied and fault re occurs change charger Check for good continuity of cable Yellow amp Green Battery not connected to charger Check for good battery LED s blink Too low of voltage less than 6 volts Voltage at charger port Make sure voltage simultaneously Reverse Polarity on meter is reading positive no reverse polarity 21 2006 Sunrise Medical POWER BASE SECTION ST PS Checking Motor Resistance and Continuity Motor Connector Chair Motor Resistance 0 2 ohms Brake Solenoid Motor Fig 1 51 Fig 1 52 Fig 1 53 Checking the Motor Brushes Note When removing brushes from the motor for inspection please note orientation and location of the brushes as they are removed from the motor fy 1 54 The brushes are burned in to the commutator and reinstallation in a location or orientation not matching the pre inspection location may negatively affect motor operation Checks How smooth is the brush surface did it create C shaped groove If there is less than 1 4 brush material left the Brushes should be replaced How the wire between the coil looks did it discolor Fig 1 54 fg 1 55 e Did the Top soldered joint melt fy 1 56 How does the commutator look after the
7. brush has been contacting the surface fy 1 57 Commutator Inspection FE I H EH 6 9 3 Wire between Coil Top Solder Wil Fig 1 56 2006 Sunrise Medical 22 POWER BASE SECTION Disassembly Note For ease of disassembly set the base frame on a block where all six wheels are at least 1 inch above the ground a Unwrap the wire looms from the motor and pull the motor connector out figure 1 58 b Depress the motor connector locking tab and un plug it c Use a 5mm hex key to remove the six mounting screws figure 1 59 d Hold the motor wheel assembly and tilt the cog re WUD lease rod toward the center of the base to get around the motor mount then pull the motor wheel assembly out through the bottom of the frame e Straighten the lock washer tab of the drive wheel f Use a 17mm deep socket wrench to remove the drive wheel retention nut then pull the drive wheel out from the motor shaft Note If the drive wheel is difficult to remove then re move the wheel plate screws Phillips Head Reassembly a Perform the reverse of instructions above Note Torque specifications Motor mounting screws 15 20 ft lbs Wheel retention nut 35 40 ft lbs Wheel plate screw 15 20 ft lbs Adjustment Note There is a Suspension bumper on the frame to limit the motor s movement figure 1 60 It also changes the pre load on the front caster a Use a 13mm open wre
8. electric brakes and corroded wiring are just some of the factors that may affect battery life and performance Battery Servicing and Replacement Automobile batteries which are used for starting are tested with a load tester to assure a high rate of energy production in a short burst The voltmeters on load testers are not accurate enough to establish a state of charge Deep cycle batteries produce energy more slowly and are designed to hold up to constant discharging and recharging Testing a deep cycle wheelchair or scooter battery requires different procedures than an automobile battery A routine for testing deep cycle batteries should follow these guidelines Never replace just one battery ata time This will create an imbalance when charging and ultimately damage both batteries Check batteries for a voltage difference A voltage difference of more than 4 volts D C iS a true indicator of a bad battery Voltage test A dead battery cannot be effectively tested yet many people mistakenly try to do just that Any battery that reads 11 0 volts or less is technically dead To perform any testing especially a load test A Batteries must be charged B The top charge must be taken from fully charged batteries if charge rate has just fnished Load Test This test can only be done on fully charged batteries and can diagnose one type of problem an internal short e Capacity Discharge Test This is the only accurate
9. iii ST PS Health and Safety Good Working Practices While working on powered mobility products it is essential to observe good working practices Below are a Series of Safety guidelines and recommendations Please note that these precautions are intended to serve only as a guide not to supersede or replace any Safety statute NHS or other safety regulations General Always wear suitable protective clothing when handling batteries AN Always wear suitable eye protection when drilling or inspecting A When safe to do so wear protective gloves when handling the running gear or batteries as these parts are exposed to paths parks etc If the drive wheels have to be raised off the fbor always use a pair of axle stands to secure the vehicle Battery Safe Use extra caution when working with batteries e Always make sure that the batteries are disconnected from the vehicle before commencing work e Always check that the battery charger is disconnected from the vehicle batteries before commencing work Do not smoke e Keep batteries away from all sources of ignition Do not place objects on the battery tops e Always try to keep someone within earshot of your work area so that they may come to your assistance if needed e Always wear personal protection when handling batteries including eye face protection and gloves e Make sure there is easy access to Soap and water in
10. relating to electrical equipment e Never operate the battery charger in wet or damp conditions e If you think that the charger has been exposed to water or excessive dampness do not use it Return the unit to the dealer supplier for inspection replacement o Ifyou think the battery charger is defective or is visibly damaged return the unit to the dealer supplier for inspection e EMI means electromagnetic EM interference EMI comes from radio wave sources such as radio transmitters and transceivers A transceiver is a device that both sends and receives radio wave signals e There are a number of sources of intense EMI in our daily environment Some of these are obvious and easy to avoid Others are not and we may not be able to avoid them e Powered wheelchairs although tested in accordance with EMC guidelines may be susceptible to electromagnetic interference EMI emitted from sources suchas radio stations TV stations amateur radio HAM transmitters two way radios and cellular phones e EMI can also be produced by conducted sources or electro static discharge ESD INTRODUCTION What effect can EMI have 1 EMI without warning can cause a power chair to Release its electronic brakes e Move by itself Move in unintended directions If any of these occur severe injury could result 2 EMI can damage the control system of a power chair resul
11. to charge deep cycle batteries and will quickly ruin gel sealed batteries e Do not use chargers designed for wet battery charging with gel sealed batteries their charging voltages are different Desktop 8 Amp Fully Automatic Charger DC Output Connector Pin 2 rind Negative P sitive Pin 3 Inhibit Line Red Light Green Light Function lm CHARGE SLOW BLINK UNDER 00 No AC power or no battery connected STATUS FAST BLINK OVER 80 Light test when AC connected 2 Slow Blink Charging lt 80 charged Off Fast Blink Charging gt 80 charged Normal charge completed Under voltage shut off lt 18 0 volts Slow Blink Over voltage shutoff gt 33 96 volts Fast Blink Max timer shutoff gt 16 hours See owner s manual Troubleshooting Tips 1 Check for battery voltage at chair s charger input 2 Check for continuity between cable DC output and connection inside 3 Check for AC voltage 1 Check for possible blown fuse 2006 Sunrise Medical 20 POWER BASE SECTION STEPS The Lightweight Charger is a switched mode 8 amp output charger Because of its compact size it uses a forced air cooling system Upon connection to a battery and AC power the charger frst evaluates the battery s state of charge If the battery is already charged the charger goes into standby mode and continuously monitors the battery s terminal voltage If the battery needs charging the charger begins its charge cycle After
12. way to test a deep cycle battery for adequate running time The problem with this test is that it is time consuming e Current Voltage check with a regular interval check Another way of truly knowing how much time your battery will last is also time consuming 2006 Sunrise Medical 12 5 5 REMEMBER IT IS THE RESPONSIBILITY OF THE INSTALLER TO KNOW WHAT KIND OF BATTERIES TO INSTALL IN THE CUSTOMER S WHEELCHAIR Deep cycle batteries are designed to be discharged and recharged on a regular basis Starting or automotive type batteries use a rapid burst of power to start an engine and are quickly recharged by an alternator or generator They are rated by cold cranking amps a measure that has no relevance to wheelchair application Marine and RV batteries frequently are not deep cycle as they are often used for starting engines Only use Deep Cycle sealed type batteries in a wheelchair Battery Size Batteries function as a power wheelchair s fuel tank The larger the group size the farther the wheelchair will go Use the size specifed by the wheelchair manufacturer Never use undersized batteries POWER BASE SECTION 50 Ahr 13 2006 Sunrise Medical POWER BASE SECTION Accessing the Batteries 1 Pull out the safety pin A from the left front seat post fy 1 1 2 Lift up on both front seat latches fy 1 2 3 Tilt the seat back fp 1 3 slide it forward and remove from the base f 1 4 4
13. 4 Adjust seat depth per Frame Depth Seat Depth Chart fy 3 11 5 Replace rear back plate through bolt and nut fD 3 9 6 Replace forward back plate through bolt and nut fy 3 10 SEATING SECTION Frame Seat Depth an am Kr 31 2006 Sunrise Medical SEATING SECTION 2006 Sunrise Medical 38 5 5 Acronym or Term ACM BSOC CAN CRD DC ECM ED GUI HCM HHP IR LED LCD MCM MHCM PWM SAE SCIM APPENDIX A Acronyms for Delphi APPENDIX A Defnition Attendant Control Module Battery State Of Charge Controller Area Network Customer Requirements Document Direct Current Environmental Control Module Enhanced Display Graphical User Interface Hand Control Module Hand Held Programmer Infra Red Light Emitting Diode Liquid Crystal Display Motor Control Module Mini Hand Control Module Pulse Width Modulated Society of Automotive Engineers Specialty Control Input Module 39 2006 Sunrise Medical 303 218 4600 800 333 4000 2006 ya jan aa y 800 263 3390 in Canada ev
14. Batteries are concave overcharged Check motor connector Check Armature Resistance Switch Motor Leads Replace Brushes Replace Motor Check motor connector Check Armature Resistance Switch Motor Leads Replace Brushes Replace Motor Park Brake 1 or Park Brake Reconnect brake 2 open circuit or Short Check brake resistance Switch motor leads replace motor Check to see if client has their hand on remote R eset Power check integrity of oystick Gimbal If bent Replace out Replace oystick Module Check wiring connections Check all bus connections Check diagnostic readings Replace compo nents causing failure if constant problem Motor Controller Internal 7 Bars every 2 seconds Motor Controller Internal Replace Control module Module Error Left to Right Module Error Check all connections Motor Controller High Tem perature Warning Invalid System Confgura tion 1 Green far right green 2 Green right to left tion Error is TRUE Motor Controller High Tem perature Warning is TRUE Invalid System Confgura Stop Chair Check Motor Connections Check Motor resistance Refer to Section 4 Check all connections Replace Control Module Check to see if Module is compatible with system If using QC control and hooking up non proto col device error will occur If compatible with system try another control module unplug Device Drive Lockout External 3 Green right to left Drive Lockout Source is Co
15. Drive Profles to choose After depression of Mode Button push the J oystick in any of the four directions to choose what Drive Profie to be in When you select a drive profile the small light for that drive profie will glow red to indicate that it has been selected After you select a drive profle the wheel chair automatically goes back into drive mode and any further movement of the joystick will begin to move the wheelchair 27 2006 Sunrise Medical QUICKIE ELECTRONICS SECTION QR 2 Button Mini Hand Control P N 020009 The Delphi Mini J oystick features comprehensive posi tioning hardware that greatly enhances the user s ability to personalize their ft The control box attaches to the armrest The mini joystick comes standard with the Enhanced Display QR ED Quickie Enhanced Display P N 020024 e Driving information e Access to the electronic menu tree Remote control of InfraRed IR compatible devices TVs DVD players stereos X10 house hold lighting systems etc Included with all Specialty Control Packages 2006 Sunrise Medical 28 5 5 Mounting Wiring QR Hand Controls can be mounted on either side of the Wheelchair to accommodate Left Handed and Right Handed Users QR Hand Controls must be mounted using three M5 x 14 button head screws Before making any connections to the Hand Control disable the Wheelchair by disconnecting the Batteries and or elevating the driv
16. OAY Module Communication Error T 5 System Confguration Error 7 nn an Drive Lockout External a 1 mM X indicates blinking MER Under Voltage Error Zn or Battery Over Voltage Error 70 80 60 70 31 2006 Sunrise Medical QUICKIE ELECTRONICS SECTION Delphi Diagnostics Trouble Shooting Chart Symptom Code Flash Diagnosis Solution Battery Voltage has Dropped Lower or Raised Higher Than Operating Voltage Disconnect Left Motor Con nection Disconnect Right Motor Connection Disconnect of Left or Right Brake Connection or Brake over current Active Input Not Neutral At Power On Error Loss of Communication 1 Bar every 2 seconds Left to Right Batteries Depleted battery Bad Cells Overcharged Batteries 2 bars every 2 seconds Left to Right 3 bars every 2 seconds Left to Right 4 bars every 2 seconds Left to Right Circuit 5 Bars every 2 seconds Left to Right Power On Error 6 Bars every 2 seconds Left to Right with Bus Line Devices on Bus Loose or Disconnected Motor 2 Open Circuit Motor 1 Open Circuit Active Input Not Neutral At Loss of Communication Recharge batteries Test with Volt Meter Load Test Batteries Check Connections Replace batteries with New Set Check Battery Condition for Overcharged You will notice Sides of
17. case of acid spills Avoid touching eyes or unprotected parts of the body while working on batteries Remember that non sealed batteries can contaminate any packaging housing or boxes they may have been transported in so handle all packaging with care especially during disposal If battery acid should come into contact with bare skin or clothing be sure to wash contacted area immediately using plenty of soap and water If battery acid enters the eyes fush with running cold water for as long as possible while medical help iS being sought e When the tops of batteries are exposed take extra care when working on or around the terminals Do not allow metal tools to drop on to or touch the exposed terminals of the batteries or other exposed connections as this could cause a short circuit which may result in an explosion 2006 Sunrise Medical 8 ST PS Remove personal items of jewelry such as rings watches chains etc before working on batteries Such items could cause short circuits resulting in serious burns e Batteries are constructed of heavy materials Therefore moving batteries requires appropriate lifting techniques Safety footwear should also be worn In addition disposal of old batteries requires correct procedures Contact your local authority for their recommendations Battery Chargers e Remember battery chargers are connected to household current e Always observe all guidelines and laws
18. cket set 22 Torque wrench 2 SAE socket set 23 Steel engineering rule 3 Hexagon wrenches SAE amp metric 21 Tape measure 4 3 5 8mm fht screwdriver 25 Tire pump 5 No 0 cross head screwdriver 26 Tire pressure gauge 6 No 1 cross head screwdriver 27 Personal safety gear 7 No 2 cross head screwdriver 28 Wire strippers cutters 8 Metric combination spanner set 5 25mm 29 Tag crimper 9 SAE combination spanner set 1 8 1 30 Multi meter 10 Vice grips 31 Battery tester 11 Long nose pliers 32 Quickie HHP 12 Adjustable spanner 33 Parts manuals amp Tech Service manuals 13 Combination pliers 31 Tire levers 11 Cir clip pliers 35 9 inch diagonal cutters 15 Hammer small amp large 36 Schrader valve stem puller 16 Soft hammer rubber hide or nylon 2006 Sunrise Medical ST PS 7 INTRODUCTION When setting up the components of the chair complete the following checklist to ensure proper and safe operation of the equipment Check o Are the batteries fully charged a Test battery voltage with D C meter across the terminals of batteries The measurement should be above 12 volts D C b If not fully charge the batteries Are all necessary power components installed and connected Input device normally J oystick Bus cable from oystick to the controller Control Module for the Z Bop located under the battery cover o Are all necessary connections fast
19. completing the charge cycle it goes into standby mode and continuously monitors the battery s terminal Fig 1 49 voltage If the charger is left connected to the battery it will keep the battery topped off by beginning a trickle charge of about 2 amps whenever the terminal voltage falls below 25 7 volts APA Bose gas F 5 Ma CMMOR Deconnecdt fa suppfr bekee maiang or kanaka core i C AC POWER D SC CHARGING Trouble Shooting E STAND BY The following checklist should help you to troubleshoot any of the problems with the charger Make sure to le FAULT observe all Safety instructions ee IA Symptom No Power Unit not plugged in Try a Known good outlet LED s do not Bad Outlet Try another charger turn on Blown Fuse internal to charger Try another AC cord D C internal board faulty Yellow LED Battery s rated capacity exceeds charger rating Try another set of batteries blinks 1 time Battery may be damaged or old Try another charger Yellow LED Battery s rated capacity exceeds charger rating Try another set of batteries blinks 2 times Battery may be damaged or old Try another charger Yellow LED Unit may be damaged is removed and blinks 3 times re applied and does not work Try another set of batteries Battery s rated capacity exceeds charger rating Try another charger Yellow LED Battery voltage exceeds charger 0 Try a specifed set of batteries blinks 4 times operating range
20. e wheels Use only Sunrise Medical approved wiring Harnesses to connect the Hand Control Wiring should be suitably restrained and fastened to the wheelchair to prevent snagging and to ensure that there is no strain on connectors Take particular care when routing and securing cables on moveable structures such as Tilt Lift and Recline etc Such moving structures have the potential to crush and shear wiring causing potential electrical issues To maintain EMC compliance ensure that wires are routed as per Sunrise Medical recommendations Note bottom two pins 3 amp 4 can be used to measure battery voltage QUICKIE ELECTRONICS SECTION Quick Disconnect Bus Cable Additional Bus Connection Programming Connector 2006 Sunrise Medical QUICKIE ELECTRONICS SECTION Programmable Ranges Menu tem Description range Device Drive input when profie is Active Power Determines allowable current for Motor torque limiting 20 100 High Speed Torque Determines the maximum amount of torque available at the highest speed 20 100 Low Speed Torque Determines the maximum amount of torque available at the lowest speed 20 100 Device Type of input control utilized hand control 3 Button SCIM1 ECM or compact joystick Forward Speed The maximum speed setting for the control module and the minimum setting to drive the chair in the forward d
21. ed positive probe to this port when using any volt age readings resistance readings or when check ing wire continuity explained in more detail later in the tutorial 3 Current up to 300mA This port is used for counting electrons in a circuit and thus their rate of fbw current being the fbw of electrons You ll notice that this side is fused so that you don t end up melting the meter s circuits 4 Current up to 10A Same as above except it can take more current as the name suggests 2006 Sunrise Medical ST PS MULTIMETER PROBES PORTS LE A 600V EF 1000 CATI 10A EE COM STEPS INTRODUCTION This section describes the basic symbols used in a typical multimeter AC This symbol means alternating current Use this when you want to test something that has AC current running through it Typically you d want to test the voltage of an inverter for cold cathodes or neons or a similar device DC This means Direct Current This is the type of electrical power produced by ds a battery With a battery connector the black wires should be connected to gt the negative terminal of the battery and should be considered the common ground The red wire s should be connected to the positive terminal of the battery and is considered the hot lead Voltage This means Voltage or Potential Difference This measures the potential difference betwe
22. en the two probes To measure voltage connect the positive probe to a port that is marked V or Voltage Note mV means millivolts 001 Voltage Current Technically this term is incorrect It should be I but since current is measured in Amps and the readout value Is in amps the symbol makes sense This measures the current that is fbwing through the part of the circuit between the two probes the meter itself Typically you need to plug the positive terminal into a port marked A or Current You need to put the meter In Series in the circuit to use this feature correctly Resistance This symbol means Resistance and is measured in Ohms You can use this setting to measure the resistance between two points for example across a piece of wire or a resistor to check its value If you don t have a continuity check then this can be used to check for shorts Any value below 0 05 Ohms constitutes a short meaning that whatever the probes are attached to is connected electrically Continuity A commonly used function Basically what it does is put a current through the two terminals the same as the Ohm meter function and if the resulting value is within the contact range it will beep This feature found on some multimeters enables you to check for shorts without taking your eyes off your work Other meters may have a light that turns on when a short Is found 7 2006 Sunrise Medical INTRODUCTION
23. ened or inserted Battery connectors to the batteries Power harness to battery connectors and controller Cable between oystick and the Control Both Motor Connectors to the Control Module D 0 oo H o ls the Freewheel Mechanism engaged a With the power off the chair should not move if pushed from behind b If the chair moves when pushed refer to Freewheel Mechanism section for proper operation Does 7 bar Display light up when Power On Off switch is depress a If no recheck the 4 checks listed above then refer to Diagnostics b If yes the Power Wheelchair is ready to drive 5 2008 Sunrise Medical INTRODUCTION Multimeter Tutorial The Multimeter The multimeter is one of the most useful tools in the toolbox It can be used to check wires shorts voltages resistance all manner of electrical circuits This tutorial is designed to help clarify the symbols and socket op tions found on various multimeters The Probes Probes connect the meter to the circuit Simply touch them to the connections you want to measure and read the display Obviously this depends on how the meter is Set up and what Is being measured The Ports 1 The Common Port Generally the black probe plugs in here negative and as the name suggests its the common ele ment to all of the testing circuits Think of it as the ground rail 2 Voltage Resistance and Continuity port This is commonly used option Connect the r
24. ill be asked to enter your account number or if you don t have your account number press then 1 for Customer Services 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 has been compiled as a troubleshooting guide for the Quickie Z Bop Photographs and content may differ from the actual products in some cases due to changes in speciftations and other factors 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 troubleshooting procedures This can result in problems with future servicing and or damage to the unit Parts and confguration or speciftations of Products included in this Service Manual are subject to change without notice Tools Required The following list of tools should enable any task to be dealt with Some will only occasionally be needed but Feeler gauges metric amp SAE Utility knife a 19 Pin punches it is advisable to own or have access to them 20 Electric drill 21 Drill bits metric amp SAE 1 Metric so
25. irection Reverse Speed The maximum speed setting for the control module and the minimum setting to drive the chair in the reverse direction Turning Speed The maximum speed setting for the control module and the minimum setting to drive the chair in the left or right direction Accel Fwd amp Rev How quickly the chair reaches the selected speed up to the maximum Settings are in 1 increments Decel Fwd amp Rev How quickly the chair comes to a stop from forward or reverse directions Settings are in 1 increments Turn Acceleration How quickly the chair reaches maximum turning speed or how quickly the chair responds to a turn command This parameter is extremely important as to how sensitive the chair is to input device movements and how easy It Is for the user to control the chair Turn Deceleration How quickly the chair comes to a stop from a turn Also very important in the control of the chair Settings are 1 increments Torque Limit Determines amount of demand or current applied to output of control to motors in response to Drive Input com mands Turn Deceleration Determines Turn Decel Rate 0 100 2006 Sunrise Medical 30 5 5 Power On Off Options This button turns the wheelchair control on and off You can see if the wheelchair control is on by looking at the lights just under the on off button If any of the lights are visible the control is on QUICKIE ELECTRONICS SECTION Keyless Lock Feature
26. nch to loosen or tighten the jam nut and make the proper adjustment operator preference b Install wire tie on back inside corner of gear box 23 2006 Sunrise Medical POWER BASE SECTION Disassembly 1 Use a 16mm wrench and 19mm wrench to remove the motor mount pivot bolt figure 1 61 2 Slide the motor mount out from the base frame pivot bracket Reassembly a Reverse above instructions Hint Insure the suspension cable is properly seated on the pulley wheel fig 1 62 Note Torque specifications on the pivot bolt and the mounting bolt are 40 in Ibs 2006 Sunrise Medical 24 STEPS Pull Cog Release rearward to disengage motor POWER BASE SECTION wi Disengage Push Cog Release forward to engage motor Drive Wheels Changing Drive Wheel Assembl Disassemble 1 Straighten the lock washer tab of the drive wheel 2 Use a 17mm deep socket wrench to remove the drive wheel retention nut then pull the drive wheel out from the motor shaft Note If the drive wheel is difficult to remove then re move the wheel plate screws Phillips Head Reassembly Perform the reverse of instructions above Note Torque specifications Wheel retention nut 35 40 ft lbs Fig 1 64 Wheel plate screw 15 20 ft lbs 25 2006 Sunrise Medical POWER BASE SECTION Motor Bumper Note There is a Suspension bumper on the frame to limit the motor s movement figure 1 65 It also changes the p
27. nnection to source of inhibit such as tilt Source True system Recline In Charger is Plugged in Ripples up from 1st LED to Charger Plugged In Top LED 7 hibit Circuit Disconnect Charger Check wiring for Common Pin 2 and Pin 3 2006 Sunrise Medical short SEATING ST P5 1 Remove rear back plate through bolt fy 3 1 2 Adjust back to desired angle 3 Replace rear back plate through bolt 33 2006 Sunrise Medical SEATING SECTION ST PS 1 Remove seat 2 Remove four cross member through bolts A and nuts fy 3 2 3 Adjust width see chart amp fy 3 3 4 Replace four cross member through bolts ETO ETE gt 12 3 14 15 te Tube Hole Saddle A 6 a C PIN 055011 001 4 1 te 78 P N 055011 003 P N 055011 004 2006 Sunrise Medical 34 STi PS SEATING SECTION 1 Remove seat 2 Remove four cross member end bolts A fy 3 4 3 Adjust frame depth see chart amp fp 3 5 4 Replace four cross member end bolts SEAT FRAME DEPTH SHORT 13 16 STANDARD 15 18 EXTENDED 17 20 35 2006 Sunrise Medical SEATING SECTION 5 T amp PS 1 Remove forward back plate through bolt A and nut fy 3 6 2 Place bolt A in place holder location to prevent back angle shift fy 3 7 3 Remove rear back plate through bolt B and nuti fy 3 7 amp fy 3 8 2006 Sunrise Medical 36 ST P5
28. re load on the front caster a Use a 13mm open wrench to loosen or tighten the jam nut and make the proper adjustment operator preference Rear Caster Bumper Note There is a Suspension bumper on the rear caster assembly to limit rocking motion figure 1 66 a Use a 13mm open wrench to loosen or tighten the jam nut to make the proper adjustment operator preference 2006 Sunrise Medical ST amp PS QUICKIE ELECTRONICS SECTION Quickie Electronics by Delphi Hand Control Types and Functionality Joystick Descriptions All joysticks use a Centered Power On Off button which have a delay for Power up No delay for Power down All J oysticks have a Horn which is programmable for volume levels The operation of up or back Drive Through Condition is achieved by defkcting the J oystick in the reverse direction The forward direction will allow the customer to come back to starting position QR3 Three Button Rehab Control SUNRISE PART 020012 Works with all Quickie Rehab Motor Controls Mode Select On Off and Horn Buttons only Program system through programming port in front of hand control or through any other available Bus port e Programming via HHP or PCSS e LED Indicators for Mode Status Mode selection Seating function and Battery SOC Keyless Lock Mode Sleep and Power Off Modes Switch oystick option with Latched control Drive Profie Mode There are 4 separate
29. ting in a safety hazard and or costly repairs 9 2006 Sunrise Medical INTRODUCTION Sources of EMI 1 Hand Held Transceivers The antenna is usually mounted directly on the unit These include Citizens band CB radios 58 Security fre and police radios e Cellular phones e Laptop computers with phone or fax e Other personal communication devices Note These devices can transmit signals while they are on even if not in use The wheelchair should be switched off when not in use 2 Medium Range Mobile Transceivers These include two way radios used in police cars fre engines ambulances and taxi cabs The antenna is usually mounted on the outside of the vehicle 3 Long Range Transceivers These include commercial radio and TV broadcast antenna towers amateur HAM radios and alarm systems in department stores NOTE The following are Not likely to cause EMI problems Lap top computers without phone or fax cordless phones TV sets or AM FM radios CD or tape players EM energy rapidly becomes more intense as you get closer to the source For this reason EMI from handheld devices is of special concern A person using one of these devices can bring high levels of EM energy very close to a power chair without the user s Knowledge Immunity level The level of EM is measured in volts per metre V m Every power wheelchair can resist EMI up to a certain level This is called its immunity level
30. val and Replacement 23 The Freewheel Mechanism 25 Drive Wheels veces 2 ane 25 Changing Drive Wheel Assemb Yy 25 STE 1 9 o EE 26 QUICKIE ELECTRONICS SECTION Quickie Electronics by Delphi 27 Hand Control Types and Functionality 27 QR3 Three Button Rehab Control 27 QR 2 Button Mini Hand Control 28 QR ED Quickie Enhanced Display 28 Delphi Diagnostics Trouble Shooting Chart 32 SEATING Z Bop Seating SYS IBM session 33 Back Angle Adjustment sss 33 Seat Width Adjustment sass 34 Seat Frame Depth Adjustment sss 35 Seat Depth Adjustment 36 Frame Depth Seat Depth Position 37 APPENDIX A Acronyms for Delphi 28 880 39 THE LATEST VERSION OF THE TECHNICAL SERVICE MANUAL CAN BE FOUND AT www sunrisemedical com 2006 Sunrise Medical INTRODUCTION Introduction Please read and follow instructions in this service manual before attempting to troubleshoot or repair this product for the frst time If there is anything in this Service Manual that is not clear or if you require additional technical assistance contact Sunrise Medical at 1 800 333 4000 At the prompt you w
31. y which allows high concentrations of hydrogen to build up This is possible with all batteries if improper charging or battery failure occurs but not common in gel sealed batteries e lt KEEP SPARKS AND FLAMES AWAY FROM BATTERIES gt e Burns dropping a wrench or screwdriver across battery terminals results in Sparks and intense heat Improper assembly of battery boxes or battery box wiring may short the battery through the wiring and produce a possible electrical fre Electronic damage batteries that are improperly wired can short out electronic chair components resulting in expensive repairs e Pollution improper disposal of batteries could damage the environment All batteries should be disposed of through a reliable battery recycler Battery Charge Cycle Illustration Typical Flooded Battery Discharge E li fh POS Ppso4 POS PbO2 ll j NEG 04 NEG Pb i M ACID H20 ACID H2502 T Recharge As battery discharges the sulfate from the electrolyte forms on the plates As battery recharges the sulfate is driven back into the electrolyte 11 2006 Sunrise Medical POWER BASE SECTION 7 Battery Diagnostics How Long Should Batteries Last An average of 1 to 1 5 years Factors that affect battery performance e Maintenance Poor maintenance e Charging Improper charging shortens battery life e Chair Components Malfunctioning electronics bad motors
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