You are on page 1of 56

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Integrated Controllers

This section will cover diagnostic procedures for power chairs that use the Pilot, VSI, and DL50 electronics. Refer to figures 2.2, 2.3, and 2.4 respectively. All of these systems have a built-in diagnostic system that will allow the electronics to detect what the system considers a critical fault. These faults are interpreted by the electronics and displayed on the battery indicator by a certain number of flashing lights or LEDs. In both the Power Chair Owners Manual and the diagnostic material, you will find a listing of these individual error messages that will help you to diagnose a problem within the power chair system.

All of these systems utilize a 9-pin connector (power interface harness), so the troubleshooting process for them is very similar. See figure 2.1. Individual differences, such as the fault codes, will be addressed when they occur in each situation.

8
9

Figure 2.1. 9-pin Connector

In this guide, we will address the troubleshooting process in several different scenarios as well as each individual fault code. Within the diagnostic testing material, a toolbox icon will appear after each test. The text included with will offer

the toolbox will prompt the correct action to be taken in lieu of the outcome of the test. The light bulb icon, additional hints and tips.

If at any time you need further assistance, please contact Pride Power Chair Technical Service at 1-877-800-1248.

16

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Battery Condition Meter


A series of ten LEDs, which indicate charge level

On/Off Key
Press to power on or off the power chair and controller.

Speed/Profile Indicator
A series of five LEDs, which display the speed/profile setting

Horn Key
Activates a warning horn.

Speed/Profile Decrease
Used to decrease the speed/ profile setting

Speed/Profile Increase
Used to increase the speed/ profile setting

Joystick
Controls the speed and direction of the power chair.

FRONT VIEW

Charger Inhibit Harness Provides battery charging voltage to the controller and provides the charger inhibit signal. Off-board Charger/ Programming Socket
Connects to Battery Charger Plug or Programmer.

Ferrite Core Reduces electromagnetic emissions 9-Pin Beau Connector Harness Main power cable which accepts battery voltage and sends motor signals to the power chair.
Figure 2.2. VSI Controller

RevB/Jan04

www.prideservice.com

17

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Battery Condition Meter


A series of ten color-coded LEDs which indicate charge level.

On/Off Switch
Toggles the system on or off.

Joystick
Controls the speed and direction of the power chair.

Speed and Response Adjustment Knob


Controls the acceleration of the power chair.

Integral Harness Connection Provides battery charging voltage to the controller and provides the charger inhibit signal.

Beau Connector Harness Main power cable which accepts battery voltage and sends motor signals to the power chair.

Figure 2.3. Pilot Controller

18

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE


On/Off Button

Joystick
Controls the speed and direction of the power chair.

Press to power on or off the power chair and controller.

Battery Gauge
A series of ten LEDs, which indicate charge level

Speed and Response


Adjustment Knob Controls the acceleration of the power chair.

Beau Connector Harness Main power cable which accepts battery voltage and sends motor signals to the power chair.
Figure 2.4. DL50 Controller

Integral Harness Connection Provides battery charging voltage to the controller and provides the charger inhibit signal.

RevB/Jan04

www.prideservice.com

19

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Situation 1 No LEDs light up


The first scenario will be turning on the power chair but no LEDs light up. If the power chair is hooked up properly (all connections including batteries), the power button is pressed, and the joystick does not light up, several tests can be performed to detect the cause of the problem. Take a reading. First, set the meter to DC volts and take a voltage reading from pins 1 and 2 of the XLR connector port located on the front of the joystick. See figures 2.5 and 2.6.

Figure 2.5. VSI

Figure 2.6. Pilot

If the total battery voltage is approximately 24 volts DC with proper polarity, replace the joystick. If no voltage is present, proceed to the next step.

Check battery connections. Make sure they are tight and the battery terminals have no corrosion on them. If the connections are good, check to see if the circuit breaker button is popped out. If it is, the battery voltage path has opened and this will prevent the controller from receiving the proper turn on voltage. Reset the circuit breaker by pushing the button back in. The unit may power up, but you should still take a resistance reading from the circuit breaker.

A circuit breaker problem? The circuit breaker could appear to be working properly by a visual inspection, but the problem may be internal. To check the circuit breaker first locate the two phillips-head screws off of the circuit breaker. Set the meter to an ohms or resistance scale. Take a reading with the red lead of the meter on one of the phillips screws and the black lead of the meter on the other phillips screw. See figure 2.7. The reading should indicate less than one ohm of resistance if the circuit breaker is operating properly. The meter reads_______ohms.
Figure 2.7. Circuit Breaker

If an open circuit or more than 3 ohms are detected, replace the circuit breaker.

Although this is the most accurate test, it may not be the most practical for the power chair you are working with. Here are two checks that will help. 20 www.prideservice.com RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

On some models, the circuit breaker is directly wired to the batteries. To obtain a resistance reading on these units, disconnect the circuit breaker from the batteries and measure resistance across the two wires. See figure 2.8. The meter reads________ohms. The circuit breaker is used to make the series connection between the two 12 volt batteries by connecting the positive of one battery to the negative of the other battery. You can obtain the circuit breaker resistance from the positive of one battery input connector to the negative of the other battery input connector on the utility tray. See figure 2.9. The meter reads________ohms. Turn the meter to a DC volt scale. Place the red lead of the meter on the positive terminal of one battery and the black lead of the meter on the negative terminal of the other battery. See figure 2.10.
It is possible to get an initial reading of zero volts. If this is the case, it is the series connection. If this reading appears, move to the other positive and negative and you should get a total battery voltage of approximately 24 volts. Figure 2.8. Circuit Breaker

The meter reads________volts DC.

Figure 2.9. Battery Input Connectors

Figure 2.10. Battery Terminals

RevB/Jan04

www.prideservice.com

21

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

If this is not the case, you may need to recharge the batteries. If after attempting to recharge the batteries the reading is still unexpected, you may have a problem with the batteries or in the battery charging system. To test the batteries, unhook them from the power chair and perform a standard battery load test. If the batteries fail the load test, replace and charge the new batteries and try to power up the chair. To test the charging system, unplug the chargers larger white 3-pin connector from the black 3-pin connector. Plug the charger into a wall outlet and take a volt reading across the two outside pins of the white 3-pin connector. See figure 2.11. A reading of 25 volts DC minimum to 30 volts DC should appear.

Figure 2.11. Charger Output Harness When taking the output voltage from the charger, allow the reading to normalize before documenting the reading.

The meter reads________volts DC.


If the reading is outside tolerance, replace the battery charger.

If the reading is within tolerance, take a DC voltage reading off of the two outside pins of the black 3-pin connector. See figure 2.12. The total battery voltage of approximately 24 volts DC should appear. The meter reads________volts DC. If the meter reads 0VDC, locate and remove the charger fuse. See Appendix J.

Notes:

Figure 2.12. 3-pin Charger Harness

22

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Set the meter to the resistance scale and place the red lead of the meter on one side of the fuse and the black lead of the meter on the other side of the fuse. See figure 2.13. A reading of less than one ohm should appear.
Even if a fuse appears to be intact by a visual inspection, this doesn't always mean the fuse is working properly. Always check the fuse with a meter.

The meter reads_______ohms.


Figure 2.13. Charger Fuse Test If the meter reads open, replace the fuse. If the fuse test is within tolerance, proceed to the next step.

Reconnect the charger to the charger harness. Unplug the 3-pin connector that branches off of the 9-pin connector of the controller and take a voltage reading from the two outside pins. See figure 2.14. Read the total battery voltage.

The meter reads________volts DC.


If the meter reads total battery voltage, replace the charger harness. If not, proceed to the next step.

Figure 2.14. 3-pin Controller Charger Harness Notes:

RevB/Jan04

www.prideservice.com

23

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Move to the rectangular 9-pin connector. Take a volt reading from pins 5 to 7 by placing the red lead of the meter in pin 5 and the black lead of the meter in pin 7. See figure 2.15. Read the total battery voltage.

The meter reads________volts DC.

Figure 2.15. 9-pin Connector (Power Interface Harness)

Next, place the red lead of the meter in pin 6 and the black lead of the meter in pin 8. See figure 2.16. Read the total battery voltage. The meter reads________volts DC.

Figure 2.16. 9-pin Connector (Power Interface Harness) If any of these readings are outside tolerance, replace the 9-pin harness. If readings are within tolerance, replace the controller.

Notes:

24

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Power chair turns on, but will not move.


When the power button is depressed, the LEDs light up; but when the joystick is activated, nothing happens. To determine the cause of the problem, first explore the operation of the Low Enable, No Drive Away feature. This keeps the power chair from running while plugged into a wall outlet. Because of this feature, a power chair will only operate while the center charger line is connected to the most negative battery terminal. To identify where this error is, find the open in the charger inhibit line. This inhibit is the line that comes off of the center pin of the 3-pin charger harness. Test the inhibit line of the battery charger for continuity using the resistance scale of the volt meter. On a power chair with a 9-pin controller, this will be from the center pin of the 3-pin amp connector in the rear utility tray to the black 3-pin amp connector that the charger is plugged into. See figure 2.17. A reading of less than one ohm should appear.

Situation 2

Figure 2.17. Charger Harness

The meter reads_______ohms.

If the meter reads an open, replace the charger harness. If the reading is within tolerance, proceed to the next step.

Test the fuse for continuity. The fuse should read less than one ohm of resistance. See figure 2.18.

The meter reads_______ohms.


If the fuse is bad, replace it. If the fuse is good, you may have a problem with the inhibit circuit of the charger or controller. Figure 2.18. Charger Fuse Test Unplug the larger white 3-pin connector of the charger from the charger harness. From the black 3-pin connector of the charger harness, jump between the center pin and the outside negative pin. If the chair runs, replace the charger.

RevB/Jan04

www.prideservice.com

25

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Flash Code Indications: Pilot, Remote, Integral, and VSI: ONE Red flashing LED. DL-50: ONE flash of battery indication LED.
If a power chair demonstrates a low battery flashcode, the batteries are nearly discharged. Always assume the batteries need to be recharged. Plug the power chair into a standard wall outlet, ensure that the ammeter rises and allow the batteries to charge 8 - 14 hours. The battery indicator should then return to a full charge and the power chair should work properly. If this is not the case, perform the charger diagnostics from Situation One: no power to the power chair and replace the appropriate component.
Notes:

Situation 3 Low Battery Voltage

26

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Flash Code Indications: Pilot, Remote, Integral, and VSI: TWO Red flashing LEDs. DL-50: THREE flashes of battery indication LED.
The power chair controller interprets different faults by monitoring voltages and resistance values within the system. This error indicates that the power chair detects an open in the left motor or left motor wiring. In order to determine exactly where the fault lies, you must first unplug the 9-pin connector that stems off the controller from the rear utility tray. Turn the meter to a resistance scale and take a reading from pin 3 to pin 4 of the 9-pin harness. See figure 2.19. If the system is working properly, you should get a reading of approximately .5 to 1.5 ohms.

Situation 4 Left Motor Disconnected

The meter reads_______ohms.


Figure 2.19. 9-pin Harness (Power Interface Harness) If the reading appears within tolerance, replace the controller assembly. If not, move to the 4-pin motor connector.

Take a resistance reading from the heavy gauge red and black wires that run to the motor coil.
Some chairs have red and black connectors attached to these wires.

The reading across the motor coil should read between approximately .5 and 1.5 ohms. See figure 2.20.

The meter reads_______ohms.

Figure 2.20. Motor Connector

If the reading is outside tolerance, check the motor brushes. If the brushes appear good, replace the motor. If the reading appears within tolerance, replace the 9-pin power interface harness.

RevB/Jan04

www.prideservice.com

27

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Flash Code Indications: Pilot, Remote, Integral, and VSI: THREE Red flashing LEDs.
Three flashing LEDs indicate a left motor wiring fault. The controller determines that there is a wiring fault error when it detects that the wiring between the motor and the brake is incorrect. Take a reading from pin 3 to pin 9 and pin 3 to pin 7 or 8. The reading should indicate an open on all of these connections. See figure 2.21.

Situation 5 Left Motor Wiring Fault

The meter reads_______ohms.

Figure 2.21. 9-pin Harness (Power Interface Harness)

If you get an open reading for all of the readings, replace the controller. If you get a short on any readings, proceed to the next step.

Unplug the 4-pin connector coming from the left motor. Take a resistance reading from the heavy gauge red wire to each thin gauge brake wire on the motor side of the 4-pin harness. See figure 2.22.
Some models have colored connectors attached to these wires. Red and Black represent the motor coil, and the two white represent the brake coil.

Then, take a resistance reading from the heavy gauge black wire to each thin gauge brake wire on the motor side of the 4-pin harness.
Figure 2.22. Motor Connector

The meter reads_______ohms.

If you get an open reading for all of the readings, replace the 9-pin power interface harness. If you get a short on any readings, replace the left motor assembly.

Notes:

28

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Flash Code Indications: Pilot, Remote, Integral, and VSI: FOUR flashing LEDs. (3 RED, 1 YELLOW) DL-50: FOUR flashes of battery indication LED.
Four flashing bars indicate that the controller detects no continuity across the right motor coil. Move to the 9-pin power interface harness in the rear utility tray and take a reading across pins 1 and 2. See figure 2.23. If the unit is operating properly, you should read approximately .5 to 1.5 ohms across the motor coil.

Situation 6 Right Motor Disconnected

Figure 2.23. 9-pin Harness (Power Interface Harness)

The meter reads_______ohms.

If the reading appears within tolerance, replace the controller. If not, move to the 4-pin motor connector of the right motor.

Take a resistance reading from the heavy gauge red and black wires that run to the motor coil. See figure 2.24.
Some chairs have red and black connectors attached to these wires.

The reading across the motor coil should read approximately .5 to 1.5 ohms.

The meter reads_______ohms.

Figure 2.24. Motor Connector

If the reading is outside tolerance, check the motor brushes. If the brushes appear good (a good brush should be at least 1/2 in length, no sign of chips or damage, and no sign of over heating), replace the motor. If the reading appears within tolerance, replace the 9-pin power interface harness.

Overheating in the brush can be identified by discoloration of the braided copper wire.

RevB/Jan04

www.prideservice.com

29

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Flash Code Indications: Pilot, Remote, Integral, and VSI: FIVE Red flashing LEDs. (3 RED, 2 YELLOW)
Five flashing bars indicate that the controller detects an incorrect wiring fault between the motor and the brake. Move to the 9-pin power interface harness in the rear utility tray and take a reading across pins 9 and 2. See figure 2.25. Take a reading from pin 2 to pin 9, pin 2 to pin 7 or 8. The reading should indicate an open on all of these connections

Situation 7 Right Motor Wiring Fault

The meter reads_______ohms.

Figure 2.25. 9-pin Harness (Power Interface Harness)

If you get an open reading for all of the readings, replace the controller. If you get a short on any readings, proceed to the next step.

Unplug the 4-pin connector coming from the right motor. Take a resistance reading from the heavy gauge red wire to each thin gauge brake wire on the motor side of the 4-pin harness. See figure 2.26. Then, take a resistance reading from the heavy gauge black wire to each thin gauge brake wires on the motor side of the 4-pin harness. The meter reads_______ohms.
Some models have colored connectors attached to these wires. Red and Black represent the motor coil, and the two white represent the brake coil.

Figure 2.26. Motor Connector

If you get an open reading for all of the readings, replace the 9-pin power interface harness. If you get a short on any readings, replace the right motor assembly. Notes:

30

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Flash Code Indications: Pilot, Remote, Integral: SIX flashing LEDs. (3 RED, 3 YELLOW) VSI: Speed LEDs flash.
The Inhibit Active fault indicates a short on the programmer port. If a remote charger is not connected and this occurs (on Pride Products), the controller must be replaced.

Situation 8 Inhibit Active

Flash Code Indications: Pilot, Remote, Integral, and VSI: SEVEN flashing LEDs. (3 RED, 4 YELLOW) DL-50: SEVEN flashes of battery indication LED.
If the controller gives this error, the problem could be with the joystick. This error will also be present if the joystick is out of center when powered up. On a Pilot, Integral, and VSI, the battery indicator will scroll up and down twice then flash seven bars. On a DL-50 the battery indicator lights will flash seven times. If you experience these symptoms, you must first make sure there is no physical damage to the joystick preventing it from returning to the center position. Then turn the power off and back on again (making sure the joystick is not depressed in any direction).
If the joystick repeats this error, the controller must be replaced.

Situation 9 Possible Joystick Fault

Flash Code Indications: Pilot, Remote, Integral, and VSI: EIGHT flashing LEDs. (3 RED, 4 YELLOW, 1 GREEN) DL-50: SIX flashes of battery indication LED.
Controller fault is an indication of an internal problem within the controller. The controllers do hundreds of internal tests. A controller fault is an indication of a problem with one or more of those tests.
For most scenarios, it is more efficient to replace the controller assembly.

Situation 10 Controller Fault

RevB/Jan04

www.prideservice.com

31

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Flash Code Indications: Pilot, Remote, Integral, and VSI: NINE flashing LEDs. (3 RED, 4 YELLOW, 2 GREEN) DL-50: FIVE flashes of battery indication LED.
Solenoid brake fault indicates a possible problem with the power chairs braking system. The power chair is set up with two individual brake assemblies, one on each motor. When the joystick is pushed in any direction, the controller sends total battery voltage to each brake coil. Because the controller has only one output for both brakes, the brake assemblies are electrically in parallel. To determine if the brake assemblies are operating properly, unplug the 9-pin harness which stems from the controller, from the 9-pin rectangular harness located in the rear utility tray. Turn the meter to a resistance scale and take a reading from pin 9 (center pin on the rectangular plug) of the 9-pin connector to pin 7 of the 9-pin connector. Then take a reading from pin 9 (center pin on the rectangular plug) of the 9-pin connector to pin 8 of the 9-pin connector. See figure 2.27. A reading of approximately 30 ohms should appear for both. The meter reads_______ohms.
Figure 2.27. 9-pin Harness (Power Interface Harness)

Situation 11 Solenoid Brake Fault

If the reading appears within tolerance, replace the controller. If the readings are not within tolerance, move to the motor connectors.

To take a reading at the 4-pin motor connectors of each motor, unplug each connection and take a reading from the black thin gauge wires of each motor connector. See figure 2.28. Start with the right brake assembly, then test the left if necessary.
Some models have white connectors attached to these wires.

If the brake coils are intact, you should read approximately 60 ohms across each brake coil.

Figure 2.28. Motor Connector

The meter reads_______ohms.


If the resistance is outside tolerance, replace the right motor brake assembly. If the resistance is within tolerance, perform the same test on the left motor 4 - pin connector.

32

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

See figure 2.29 if the resistance is within tolerance for the right motor brake assembly.

Figure 2.29 Motor Connector

The meter reads_______ohms.


If both motor brakes test within tolerance, replace the 9-pin power interface harness from the rear utility tray. If the left motor brake assembly reading is not within tolerance, replace the brake assembly.

Notes:

RevB/Jan04

www.prideservice.com

33

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Flash Code Indications: Pilot, Remote, Integral, and VSI: TEN flashing LEDs. (3 RED, 4 YELLOW, 3 GREEN) DL-50: TWO flashes of battery indication LED.
Ten flashing bars indicate high battery voltage. This only appears if the output of the battery charger is over 32 volts. For a controller to interpret a high battery voltage, the batteries must read in excess of 16 volts each. In order to test the voltage output, unplug the white 3-pin connector of the battery charger from the black 3-pin connector of the charger harness. Plug the battery charger into a standard wall outlet and take a volt reading across the two outside pins of the white 3-pin charger harness. See Figure 2.30. If the charger is operating properly, you should read approximately 25 volts to a maximum of 30 volts DC.

Situation 12 High Battery Voltage

Figure 2.30. Charger Output Harness When taking the output voltage from the charger, allow the reading to normalize before documenting the reading.

The meter reads________volts DC.


If the reading is 30 volts or higher, replace the charger.

Notes:

34

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Adjusting the Programming


Most power chair models are programmable power base chairs. This means that the internal programming of the electronics can be adjusted to accommodate the needs of an individual patient. Adjusting the pre-programmed factory settings requires the use of either a HHP or PP1 programmer. These programmers will allow you to adjust internal performance settings of the power chair and will also help in some areas of troubleshooting and maintenance. See Appendix A. The power chair utilizes two different programmers. The PP1 is used with the Pilot and Remote Plus control system, which plugs directly into the front of the Pilot controller. You can set the desired speed by adjusting the maximum and minimum forward speed to the specific level the patient desires. Scroll down to the screen labeled Read Fault Log. This is the screen that scrolls through any error codes that have occurred in the power chair system. The fault log can be very helpful in determining intermittent problems since it keeps an internal record of the last 8 faults to occur. Scroll down to the screen labeled preset unit and select yes. This will bring the power chair back to factory settings. For a DL-50 controller, you must use a HHP programmer. See Appendix F.

RevB/Jan04

www.prideservice.com

35

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Remote Plus Controllers


This guide was written for power chairs that utilize the Remote Plus Electronics. This system has a built-in diagnostic system that will allow the electronics to detect what the system considers a critical fault. These faults are interpreted by the electronics and displayed on the battery indicator by a certain number of flashing LEDs. In both the owners manual and the diagnostic material is a listing of these individual error messages that will help you diagnose a problem within the power chair system. In this guide, we will address the troubleshooting process in several different scenarios as well as each individual fault code. Within the diagnostic testing material, a toolbox icon will appear after each test. The text included with will offer

the toolbox will prompt the correct action to be taken in lieu of the outcome of the test. The light bulb icon, additional hints and tips.

If at any time you need further assistance please contact Pride Power Chair Technical Service at 1-877-800-1248.

36

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

On/Off Button
Press to power on or off the power chair and controller.

Battery Condition Meter


Indicates the approximate amount of battery life using color-coded LED bars.

Mode Button
Used to select the various functions available with the Remote Plus.

Horn Button
Activates a warning horn.

Speed Indicator
Series of five colored LEDs which display the speed setting.

Actuator Indicators Four LEDs indicate recline, tilt, power leg rests, and elevating seat actuator modes.

Joystick
A multi-functional tool used to control speed, direction, and actuator adjustment.

BACK VIEW

Mounting Bracket Access


An alternate Remote Plus mounting option may be available with your power chair.

Harness Connector Port


Used to connect the Remote Plus to the power base.

Figure 2.31. Remote Plus Controller

RevB/Jan04

www.prideservice.com

37

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

No LEDS light up
No LEDs Light Up means that once the power chair is hooked up properly (all connections including batteries) and the power button is pressed, the joystick does not light up. This can stem from a number of different problems. Set the meter to DC volts and take a voltage reading from pins 1 and 2 of the XLR connector port located on the front of the joystick. See figure 2.32.

Situation 1

The meter reads_______volts DC.


If you have a total battery voltage of approximately 24 volts DC with proper polarity, replace the joystick. If no voltage is present, proceed to the next step.

Figure 2.32. Remote Plus Controller

Make sure all of the battery connections are tight and the battery terminals have no corrosion on them. If the connections are good, check to see if the circuit breaker button is popped out. If it is, the battery voltage path has opened and this will prevent the controller from receiving the proper turn-on voltage. Reset the circuit breaker by pushing the button back in. The unit may power up, but you should still take a resistance reading from the circuit breaker. The circuit breaker could appear to be working properly by a visual inspection, but the problem may be internal. To check the circuit breaker first locate the two phillips-head screws off of the circuit breaker. Set the meter to an ohms or resistance scale. Take a reading with the red lead of the meter on one of the phillips screws and the black lead of the meter on the other phillips screw. See figure 2.33. The reading should indicate less than one ohm of resistance if the circuit breaker is operating properly. The meter reads_______ohms.
Figure 2.33. Circuit Breaker

If an open circuit or more than 3 ohms are detected, replace the circuit breaker.

Notes:

38

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Although this is the most accurate test, it may not be the most practical for the power chair you are working with. Here are two checks that will help. On some models the circuit breaker is directly wired to the batteries. To obtain a resistance reading on these units, disconnect the circuit breaker from the batteries and measure resistance across the two wires. See figure 2.34. The meter reads________ohms.

Figure 2.34. Circuit Breaker

The circuit breaker is used to make the series connection between the two 12 volt batteries by connecting the positive of one battery to the negative of the other battery. You can obtain the circuit breaker resistance from the positive of one battery input connector to the negative of the other battery input connector on the utility tray. See figure 2.35. The meter reads________ohms.
Figure 2.35. Battery Input Connectors

Turn the meter to a DC volt scale. Place the red lead of the meter on the positive terminal of the one battery and the black lead of the meter on the negative terminal of the opposite battery. See figure 2.36. It is possible to get an initial reading of zero volts. If this is the case, it is the series connection. If this reading appears, move to the other positive and negative and you should get a total battery voltage of approximately 24 volts. The meter reads________volts DC.
Notes:

Figure 2.36. Battery Test

RevB/Jan04

www.prideservice.com

39

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

If this is not the case, you may need to recharge the batteries. If after attempting to recharge the batteries the reading is still unexpected, the problem may be with the batteries or in the battery charging system. To test the batteries, unhook them from the power chair and perform a standard battery load test. If the batteries fail the load test, replace and charge the new batteries and try to power up the chair. To test the charging system, unplug the chargers larger white 3-pin connector from the black 3-pin connector. Plug the charger into a wall outlet and take a volt reading across the two outside pins of the white 3-pin connector. See figure 2.37. A reading of 25 volts DC minimum to 30 volts DC should appear.

Figure 2.37. Charger Output Harness When taking the output voltage from the charger, allow the reading to normalize before documenting the reading.

The meter reads________volts DC.


If the reading is outside tolerance, replace the battery charger. If the reading is within tolerance, proceed to the next step.

Take a DC voltage reading off of the two outside pins of the black 3-pin connector (Figure 2.38). The total battery voltage of approximately 24 volts DC should appear. The meter reads________volts DC. If the meter reads 0VDC, locate and remove the charger fuse. See Appendix J.
Notes:

Figure 2.38 3-pin Charger Harness

40

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Set the meter to the resistance scale and place the red lead of the meter on one side of the fuse and the black lead of the meter on the other side of the fuse. See figure 2.39. A reading of less than one ohm should appear.

Even if a fuse appears to be intact by a visual inspection, this doesn't always mean the fuse is working properly. Always check the fuse with a meter.

The meter reads_______ohms.

Figure 2.39. Charger Fuse Test

If the meter reads an open, replace the fuse. If the fuse test is within tolerance, proceed to the next step.

Reconnect the charger harness and move to the power module (refer to owners manual for location of the power module). See Appendix I. Unplug the 2-pin connector located directly in the top center of the power module. See figure 2.40.

Take a voltage reading across the two terminals of this harness. The reading should indicate the total battery voltage. The meter reads________volts DC.
Figure 2.40 Remote Plus Power Harness If the reading is outside tolerance, check the batteries or replace the battery harness.

Notes:

RevB/Jan04

www.prideservice.com

41

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Power chair turns on, but will not drive.


The power chair turns on but will not move means that when you press the power button on the joystick the LEDs light up, but when the joystick is depressed in any direction nothing happens. This is the only other system fault that will not be interpreted by the power chair electronics. The power chair is set up with a Low Enable, No Drive Away feature that will keep it from running while plugged into a wall outlet. Because of this feature, a power chair will only operate while the center charger line is connected to the most negative battery terminal. To identify where the error is, find the open in the charger inhibit line. This is the line that comes off the center pin of the 3-pin charger harness. Test the inhibit on the charger for continuity. On a power chair with Remote Plus Electronics, this is from the center pin of the 3-pin connector under the rear utility tray to the black 3-pin amp connector that plugs into the charger. See figure 2.41. A reading of less than one ohm should appear.

Situation 2

The meter reads_______ohms.

Figure 2.41 Charger Harness

If the reading is outside tolerance, replace the charger harness. If the reading is within tolerance, proceed to the next step.

Test the fuse for continuity. The fuse should read less than one ohm of resistance. See figure 2.42.

The meter reads_______ohms.


If the fuse is bad, replace it. If the fuse is good, you may have a problem with the inhibit circuit of the charger or controller. Figure 2.42. Charger Fuse Test Unplug the larger white 3-pin connector of the charger from the charger harness. From the black 3-pin connector of the charger harness, jumper between the center pin and the outside negative pin. If the chair runs, replace the charger.

42

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Situation 3 Low Battery Voltage


ONE flashing red LED
If you encounter a power chair with a low battery warning, the batteries are nearly discharged. Always assume the batteries need to be recharged. Plug the power chair into a standard wall outlet and allow the batteries to charge overnight. The battery indicator should then return to a full charge and the power chair should work properly. If this is not the case, perform the charger diagnostics from Situation One: No power to the power chair and replace the appropriate component.

Notes:

RevB/Jan04

www.prideservice.com

43

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Situation 4 Left Motor Disconnected


TWO flashing red LEDs
The power chair interprets different faults by monitoring voltages and resistance values within the system. This error indicates that the power chair detects an open in the left motor or the left motor wiring. In order to determine exactly where the fault lies, you must first unplug the 4-pin harness on the top left (M1 harness) of the power module. See Appendix I. Plug the harness back in and make sure that it has a good connection. Cycle the power on and off and see if the fault is still occurring. If it is, unplug this harness one more time and turn the meter to a resistance scale. Take a reading across motor positive and motor negative on the M1 harness (two larger pins) after removing it from the power module. See figure 2.43. If the system is working properly, you should get a reading approximately .5 to 1.5 ohms. The meter reads_______ohms.
Figure 2.43. M1 Harness

If the reading is within tolerance, replace the power module. If not, check the 4-pin connector to the motor to see if there is a bad connection.

Take a resistance reading from pin 1 to pin 2 of the heavy gauge red and black wires that run to the motor coil. See figure 2.44.
Some chairs have red and black connectors attached to these wires.

The reading across the motor coil should read approximately .5 to 1.5 ohms.

The meter reads_______ohms.

Figure 2.44. Motor Connector

If the reading appears outside tolerance, check the brushes. If the brushes appear good (a good brush should be at least 1/2 in length, with no sign of chips or damage and no sign of overheating), replace the motor. If the reading is within tolerance, replace the M1 harness. Overheating on a brush can be identified by discoloration of the braided copper wire. Notes:

44

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Situation 5 Left Motor Wiring Fault


THREE flashing red LEDs
Three flashing LEDs indicate that there is a wiring fault in the left motor. This is most likely caused by a short between the motor and the brake. Take a resistance reading from the motor positive (heavy gauge red wire) to each of the brake wires (thin gauge black wires) of the M1 harness. See figure 2.45. The reading should indicate an open between each of these connections. Take a reading from the motor negative (heavy gauge black wire) to each of the brake wires (thin gauge black wires). The reading should indicate an open between each of these connections. The meter reads_______ohms.
If you get an open for all of these readings, replace the power module. If you get a short on any of these readings, proceed to the next step. Figure 2.45. M1 Harness

Unplug the 4-pin connector coming from the left motor. Take a resistance reading from the heavy gauge red wire to each thin gauge brake wire, on the motor side of the 4-pin harness. See figure 2.46.
Some models have colored connectors attached to these wires. Red and Black represent the motor coil, and the two white represent the brake coil.

Then, take a resistance reading from the heavy gauge black wire to each thin gauge brake wire on the motor side of the 4-pin harness.
Figure 2.46. Motor Connector

The meter reads_______ohms.

If you get an open reading for all of the readings, replace the M1 harness. If you get a short on any readings, replace the left motor assembly. Notes:

RevB/Jan04

www.prideservice.com

45

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Situation 6 Right Motor Disconnected


FOUR flashing LEDs (3 red, 1 yellow)
This fault indicates that there is a bad connection in the right motor. Make sure that the M2 harness connection to the power module is good. Unplug this harness and then plug it back in and see if a fault is still occurring. Also, check the connection from the M2 harness to the 4-pin motor harness. See Appendix I. Take a resistance reading across the motor positive and motor negative (two larger pins) on the M2 harness. See figure 2.47. If the unit is operating properly, you should read approximately .5 to 1.5 ohms.

The meter reads_______ohms.

Figure 2.47. M2 Harness

If the reading is within tolerance, replace the power module. If not, proceed to the 4-pin motor connector.

Take a resistance reading from the heavy gauge red and black wires that run to the motor coil. See figure 2.48.
Some chairs have red and black connectors attached to these wires.

The reading should read approximately .5 to 1.5 ohms.

The meter reads_______ohms.

Figure 2.48. Motor Connector

If the reading appears outside tolerance, check the brushes. If the brushes appear good (a good brush should be at least 1/2 in length, with no sign of chips or damage and no sign of overheating), replace the motor. If the reading is within tolerance, replace the M1 harness. Overheating on a brush can be identified by discoloration of the braided copper wire.

Notes:

46

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Situation 7 Right Motor Wiring Fault


FIVE flashing LEDs (3 red, 2 yellow)
Five flashing LEDs indicate that the controller detects an incorrect wiring between the motor and the brake on the right motor. Take a resistance reading from the motor positive (heavy gauge red wire) to each of the brake wires (thin gauge black wires) of the M2 harness. See figure 2.49. The reading should indicate an open between each of these connections. Now take a reading from the motor negative (heavy gauge black wire) to each of the brake wires (thin gauge black wires). The reading should indicate an open between each of these connections. The meter reads_______ohms.
If you get an open for all of these readings, replace the power module. If you get a short on any of these readings, proceed to the next step. Figure 2.49. M2 Harness

Unplug the 4-pin connector coming from the right motor. Take a resistance reading from the heavy gauge red wire to each thin gauge brake wire, on the motor side of the 4-pin harness. See figure 2.50.
Some models have colored connectors attached to these wires. Red and Black represent the motor coil, and the two white represent the brake coil.

Then, take a resistance reading from the heavy gauge black wire to each thin gauge brake wire on the motor side of the 4-pin harness.
Figure 2.50. Motor Connector

The meter reads_______ohms.

If you get an open reading for all of the readings, replace the M2 harness. If you get a short on any readings, replace the right motor assembly.

Notes:

RevB/Jan04

www.prideservice.com

47

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Situation 8 Inhibit Active


SIX flashing LEDs (3 red, 3 yellow)

The Inhibit Active fault indicates a short on the programmer port. If a remote charger is not connected and this occurs (on Pride Products), the controller must be replaced.

Situation 9 Possible Joystick Fault


SEVEN flashing LEDs (3 red, 4 yellow)
If the joystick gives this error, it could be a problem with the joystick. This error will also be present if the joystick is out of center when powered up. On a Remote Plus the battery indicator will scroll up and down twice then flash seven LED lights. If you experience these symptoms, make sure there is no physical damage to the joystick preventing it from returning to the center position. Once you have checked for damage, try turning the power off and back on again making sure that the joystick is not depressed in any direction.
If the problem persists, replace the joystick assembly on the Remote Plus unit.

Situation 10 Controller Fault


EIGHT flashing LEDs (3 red, 4 yellow, 1 green)
Eight flashing LEDs indicate a possible power module fault. The Penny & Giles controllers do hundreds of internal tests on the power module. The eight flashing LEDs can indicate one or more errors.
For most scenarios, it is more efficient to replace the entire power module when this error code is given.

Notes:

48

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Situation 11 Brake Fault: NINE flashing LEDs


(3 red, 4 yellow, 2 green)
A brake fault indicates a possible problem with the power chairs braking system. The power chair is set up with two individual brake assemblies, one on each motor. When the joystick is pushed in any direction, the controller sends 24 volts to each brake coil. To determine if each brake assembly is operating properly, unplug both the M1 and M2 harnesses from the power module. See Appendix I. Turn the meter to a resistance scale and take a reading from the brake negative and the brake positive of the M1 harness (two smaller pins) for the left motor. See figure 2.51. A reading of approximately 60 ohms should appear. The meter reads_______ohms.
Figure 2.51 M1 Harness

If the reading is outside tolerance, proceed to the 4-pin motor connector. If the reading is within tolerance, skip the next step and proceed to the M2 harness.

To take a reading from the 4-pin motor connector, unplug the connection and take a reading from the thin gauge black wires that run to the brake coil. See figure 2.52.
Some chairs have white connectors attached to these wires.

If the brake coils are intact, you should read approximately 60 ohms.

Figure 2.52. Motor Connector

The meter reads_______ohms.

If the reading is outside tolerance, replace the motor brake assembly. If the reading is within tolerance, replace the M1 harness. Notes:

RevB/Jan04

www.prideservice.com

49

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Take a reading from the brake negative and the brake positive (two smaller pins) of the M2 harness for the right motor. See figure 2.53. A reading of approximately 60 ohms should appear.

The meter reads_______ohms.


Figure 2.53. M2 Harness If the reading is within tolerance, replace the power module. If not, proceed to the 4-pin motor connector.

To take a reading from the 4-pin motor connector, unplug the connection and take a reading from the thin gauge black wires that run to the brake coil. See figure 2.54.
Some chairs have white connectors attached to these wires.

If the brake coils are intact, you should read approximately 60 ohms.

The meter reads_______ohms.

Figure 2.54 Motor Connector

If the reading is outside tolerance, replace the motor brake assembly. If the reading is within tolerance, replace the M2 harness.

Notes:

50

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Situation 12 High Battery Voltage


TEN flashing LEDs (3 red, 4 yellow, 3 green)
Ten flashing LEDs indicate a high battery voltage. This only appears if the output of the battery charger is over 32 volts. For a controller to interpret a high battery voltage, the batteries must read in excess of 16 volts a piece. In order to test the battery chargers voltage output, unplug the white 3-pin connector of the battery charger from the black 3-pin connector of the charger harness. Plug the battery charger into a standard wall outlet and take a volt reading across the two outside pins of the white 3-pin connector from the charger. See figure 2.55. If the charger is operating properly, you should read approximately 25 and a maximum of 30 volts DC.

The meter reads________volts DC.


Figure 2.55. Charger Output Harness

When taking the output voltage from the charger, allow the reading to normalize before documenting the reading.

The meter reads________volts DC.


If the reading is 30 volts or higher, replace the charger. Notes:

RevB/Jan04

www.prideservice.com

51

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Adjusting the Programming


Most power chair models are programmable power base chairs. This means that the internal programming of the electronics can be adjusted to accommodate the needs of an individual patient. Adjusting the pre-programmed factory settings requires the use of a PP1 programmer. This programmer will allow you to adjust internal performance settings of the power chair and will also help in some areas of troubleshooting and maintenance. The PP1 is used with the Pilot control system, the Remote Plus and the VSI. By programming the power chair, you can adjust the settings per the users needs. You can set the desired speed by adjusting the minimum and maximum forward speed to the specific level the patient desires. Scroll down to the screen labeled Read Fault Log. This is the screen that scrolls through any error codes that have occurred in the power chair system. The fault log can be very helpful in determining intermittent problems since it keeps an internal record of the last 8 faults to occur. Scroll down to the screen labeled preset unit and select yes. This will bring the power chair back to factory settings. See Appendix F.

52

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Dynamic Controllers
This guide was written for power chairs that utilize Dynamic Electronics. This system has a built-in diagnostic system that will allow the electronics to detect what the system considers a critical fault. These faults are interpreted by the electronics and displayed on the system status LED as a series of flashes and pauses. Both the Owners Manual and the diagnostic material contain a listing of these individual error messages that can help you to diagnose a problem with the power chair system. In this guide, we will address the troubleshooting process in several different scenarios as well as each individual fault code. Within the diagnostic testing material, a toolbox icon will appear after each test. The text included with will offer

the toolbox will prompt the correct action to be taken in lieu of the outcome of the test. The light bulb icon, additional hints and tips.

If at any time you need further assistance please contact Pride Power Chair Technical Service at 1-877-800-1248.

RevB/Jan04

www.prideservice.com

53

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Battery Gauge
A series of six LEDs which indicate charge level.

System Status LED


Indicates the On/Off status of the power chair and flashes to indicate system faults.

Drive Program Select Switch


Cycles through and selects one of the five drive programs or the Actuator Mode.

On/Off Switch

I/O
LED

I/O

Drive Program & Actuator Display


7-segment display for showing the selected drive program. Also displays Drive Inhibit & Actuator Mode when applicable.

Toggles system power on and off when Magnetic Key Lock System is not in use.

Magnetic Key Lock System & LED


Magnetic key used to power off the unit to prevent unauthorized driving.

Lighting Switches
These switches control the selection of lighting functions and are equipped with their own LED indicators.

Horn Switch
Activates the warning horn if pressed while system power is on.

LEDs

Magnetic Key
Used to lock and unlock the DX System.

I/O

Joystick
Controls speed and direction also can be used for actuator control and selection.

FRONT VIEW

REAR VIEW

Battery Connection Socket


Connects to Battery Charger Plug.

DXBUS Sockets
Connects the DXBUS cable to the remainder of the DX System.

Figure 2.56 Dynamic Europa Controller

54

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Status LED
Indicates On/Off Status, and flashes to indicate system faults.

Left & Right Indicator Switches & LEDs Battery Gauge


A series of ten LEDs, which indicate charge level Press the appropriate switch to activate turn indicator. Press again to turn off. LED flashes when activated.

On/Off Switch
Toggles the system on or off.

Drive Program Display


A 7-segment display shows the currently selected drive program.

Horn Switch
Press to activate warning horn.

Remote Status LED


Indicates status of Dolphin Remote.

Light Switch & LED


Toggles the head/tail/side lights on or off. LED is lit when activated.

Drive Program Select Switch


This switch will scan through and select one of five drive programs.
seat height leg rest adjust (right & left) back tilt seat tilt

Hazard Light Switch & LED


Press to make both indicators flash simultaneously. Press again to turn off. LED flashes when activated.

Actuator Select Switches


5 switches for actuator selection. Not used for actuator operation, only selection. LED above switch lights up when activated.

Magnetic Key Lock & LED


Locks DX System to prevent unauthorized use. Upon reactivation of unit, LED will flash until magnetic key is used to unlock system.

Joystick
Controls the speed and direction of power chair, as well as actuator control when selected.

Magnetic Key
Used to lock and unlock the DX System.

Battery Connection Socket


Connects to Battery Charger Plug.

BACK VIEW

DXBUS Sockets
Enables DXBUS cable to be used to interconnect to the remainder of the DX System.

Figure 2.57 Dynamic Dolphin Controller

RevB/Jan04

www.prideservice.com

55

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

No LEDs light up
No power to the Power Chair means that once the power chair is hooked up properly (all connections including batteries) and the power button is pressed, the joystick does not light up. This can stem from a number of different problems. Set the meter to DC volts and take a voltage reading from pins 1 and 2 of the XLR connector port located on the front of the joystick. See figure 2.58.
If you have a total battery voltage of approximately 24 volts DC with proper polarity, replace the joystick. If no voltage is present, proceed to the next step.

Situation 1

Figure 2.58. Dynamic Europa

Check battery connections. Make sure they are tight and the battery terminals have no corrosion on them. If the connections are good, check to see if the circuit breaker button is popped out. If it is, the battery voltage path has opened and this will prevent the controller from receiving the proper turn on voltage. Reset the circuit breaker by pushing the button back in. The unit may power up, but you should still take a resistance reading from the circuit breaker. The circuit breaker could appear to be working properly by a visual inspection, but the problem may be internal. To check the circuit breaker first locate the two phillips-head screws off of the circuit breaker. Set the meter to an ohms or resistance scale. Take a reading with the red lead of the meter on one of the phillips screws and the black lead of the meter on the other phillips screws. See figure 2.59. The reading should indicate less than one ohm of resistance if the circuit breaker is operating properly.

Figure 2.59. Circuit Breaker

The meter reads_______ohms.


If an open circuit or more than 3 ohms are detected, replace the circuit breaker.

Although this is the most accurate test, it may not be the most practical for the power chair you are working with. Here are two checks that will help. 56 www.prideservice.com RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

On some models, the circuit breaker is directly wired to the batteries. To obtain a resistance reading on these units, disconnect the circuit breaker from the batteries and measure resistance across the two wires. See figure 2.60. The meter reads________ohms.

Figure 2.60. Circuit Breaker

The circuit breaker is used to make the series connection between the two 12 volt batteries by connecting the positive of one battery to the negative of the other battery. You can obtain the circuit breaker resistance from the positive of one battery input connector to the negative of the other battery input connector on the utility tray. See figure 2.61. The meter reads________ohms.
Figure 2.61. Battery Connectors

Turn the meter to a DC volts scale. Place the red lead on the positive terminal of one battery and the black lead on the negative terminal of the opposite battery. See figure 2.62. It is possible to get an initial reading of zero volts. If this is the case, it is the series connection and not the most negative battery terminal. If this reading appears, move to the other positive and negative terminal and the meter should read the total battery voltage of approximately 24 volts.
Figure 2.62. Battery Test

The meter reads________volts DC.

Notes:

RevB/Jan04

www.prideservice.com

57

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

If this is not the case, recharge the batteries. If the reading is still unexpected after recharging the batteries, the problem may be with the batteries or in the battery charging system. To test the batteries, unhook them from the power chair and perform a standard battery load test. If the batteries fail the load test, replace and charge the new batteries and try to power up the chair. To test the charging system, unplug the chargers larger white 3-pin connector from the black 3-pin connector. Plug the charger into a wall outlet and take a volt reading across the two outside pins of the white 3-pin connector. See figure 2.63. A reading of approximately 25 volts DC minimum to 30 volts DC should appear.

Figure 2.63. Charger Output Harness When taking the output voltage from the charger, allow the reading to normalize before documenting the reading.

The meter reads________volts DC.


If the reading is outside tolerance, replace the battery charger. If the reading is within tolerance, take a DC voltage reading off of the two outside pins of the black 3-pin connector.

The total battery voltage of approximately 24 volts DC should appear. See figure 2.64.

The meter reads________volts DC.

Figure 2.64. Controller Charger Harness

If the meter reads 0VDC, locate and remove the charger fuse. See Appendix J.
Notes:

58

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Set the meter to the resistance scale and place the red lead of the meter on one side of the fuse and the black lead of the meter on the other side of the fuse. See figure 2.65. A reading of less than one ohm should appear.
Even if a fuse appears to be intact by a visual inspection, this doesn't always mean the fuse is working properly. Always check the fuse with a meter.

The meter reads_______ohms.

Figure 2.65. Charger Fuse Test

If the meter reads an open, replace the fuse. If the fuse test is within tolerance, proceed to the next step.

Reconnect the charger harness and move to the power module (refer to owners manual for location of the power module). Unplug the 4-pin connector located directly in the top center of the power module. See Appendix H. Take a voltage reading across the two outside terminals of this harness. The reading should indicate the total battery voltage of approximately 24 volts. See figure 2.66. Taking a voltage reading across the two inside terminals should show a total battery voltage of approximately 24 volts.

Figure 2.66. Dynamic Power Harness

The meter reads________volts DC.

If the reading is outside tolerance, check the batteries or replace the battery harness.

Notes:

RevB/Jan04

www.prideservice.com

59

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Power chair turns on, but will not drive.


The power chair turns on but will not drive means when you press the power button on the joystick, the LEDs light up and the drive mode is designated by a dash. When the joystick is depressed in any direction nothing happens. This is the only other system fault that will not be interpreted by the power chair electronics. The power chair is set up with a Low Enable, No Drive Away feature that will keep it from running while plugged into a wall outlet. Because of this feature, a power chair will only operate while the center charger line is connected to the most negative battery terminal. To identify where the error is, find the open in the charger inhibit line. This is the line that comes off the center pin of the 3-pin charger harness. Set the meter to a resistance scale. The charger harness is the 3-pin harness that the charger plugs into. The other end of the harness connects to a 3-pin connector under the tray of the power chair. Take a resistance reading from the middle pin of one side of the charger harness to the middle pin of the other end of the charger harness. See figure 2.67. The reading should indicate less than one ohm. The meter reads_______ohms.

Situation 2

Figure 2.67. Charger Harness

If the reading is outside tolerance, replace the charger harness. If the reading is within tolerance, proceed to the next step.

Test the fuse for continuity. See figure 2.68. The fuse should read less than ohm of resistance.

The meter reads_______ohms.


If the fuse is bad, replace it. If the fuse is good, you may have a problem with the inhibit circuit of the charger or controller. Figure 2.68. Charger Fuse Test

Unplug the larger white 3-pin connector of the charger from the charger harness. From the black 3-pin connector of the charger harness, jumper between the center pin and the outside negative pin. If the chair runs, replace the charger.

60

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Situation 3 Dx Module Fault


ONE flash of status LED
If this fault occurs, it could mean that an auto download has occurred in the RemG80 joystick. This is designed to minimize the programming requirements associated with module servicing by downloading the correct programming to a replacement Dynamic module. When you replace a Dynamic module, it is likely that the replacement module could have different programming than the one that it will be replacing. This could put the power chair in a dangerous condition. The Dynamic system will automatically detect when a Dynamic module swap has occurred, and then the programmed data from the old module will be transferred to the module you are replacing it with.
If this fault occurs, recycle the power off and then on and see if the fault still appears on the status LED. If the fault is still occurring, proceed to the next step.

Another cause of this fault is if the RemG80 joystick is not programmed correctly for what the power chair requires. Dynamic systems require that the RemG80 joysticks be programmed for the specific power chair and accessories of that chair for it to work properly. If you receive a replacement joystick and it is not programmed correctly, this fault will occur. Also, if you have an existing power chair and wish to add accessories to this chair such as power seat, tilt, or lights you will need to have the RemG80 joystick programmed to accommodate these changes. If after you have performed these tests and the fault is still occurring, it could be a DXBUS connection or an internal fault in one of the Dynamic modules. First check the DXBUS connections for any damage, if the connections are good, move to the Dynamic modules in the system. Each module has a status LED. If any of these modules LEDs are flashing, replace the module.

Situation 4 Dx Accessory Fault


TWO flashes of status LED
This fault indicates that there is an error in an accessory device that is attached to the Dynamic system (this excludes the power module).
Check the status indicator LED on accessory modules. If accessory module(s) indicates a fault, replace the module. If the status LED remains solid, move to the Clam harness.

Check the slow / stop inputs on the Combined Light and Actuator Module (CLAM) harness. See figure 2.69. On this harness there are two run plugs which need to be attached in order for the system to work when using this module. These plugs should be located on the slow stop #1 and slow stop #2 of this harness, if they are not present it will cause this fault to occur.

Figure 2.69. CLAM Module and Harness

RevB/Jan04

www.prideservice.com

61

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Situation 5 Left Motor Fault:


THREE flashes of status LED
The power chair interprets different faults by monitoring voltages and resistance values within the system. This error indicates that the power chair detects an open in the left motor or the left motor wiring. In order to determine exactly where the fault lies, unplug the 4-pin M1 harness of the power module. See Appendix H. Plug the harness back in and ensure that it has a good connection. Cycle the power on and off and see if the fault is still occurring. If it is, unplug this harness and turn the meter to a resistance scale. Take a reading across motor positive and motor negative on the M1 harness (two larger pins) after removing it from the power module See figure 2.70. If the system is working properly, you should get a reading approximately .5 to 1.5 ohms.

The meter reads_______ohms.

Figure 2.70. M1 Harness

If the reading appears within tolerance, replace the power module. If not, check the 4-pin connector to the motor to see if there is a bad connection.

Take a resistance reading from the heavy gauge red and black wires that run to the motor coil. See figure 2.71.
Some chairs have red and black connectors attached to these wires.

The reading across the motor coil should read approximately .5 to 1.5 ohms.

The meter reads_______ohms.

Figure 2.71. Motor Coil

If the reading appears outside tolerance, check the brushes. If the brushes appear to be good (a good brush should be at least 1/2 in length, with no sign of chips or damage and no sign of overheating), replace the motor. If the reading is within tolerance, replace the M1 harness.

Overheating in the brushes can be identified by discoloration of the braided copper wire.

62

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Situation 6 Right Motor Fault:


FOUR flashes of status LED
This fault indicates that there is a bad connection in the right motor. Make sure that the M2 harness connection to the power module is good. See Appendix H. Unplug this harness and then plug it back in and see if a fault is still occurring. If it is, unplug this harness and turn the meter to a resistance scale. Take a resistance reading across the motor positive and motor negative (two larger pins) on the M2 harness. See figure 2.72. If the unit is operating properly, you should read approximately .5 to 1.5 ohms. The meter reads_______ohms.

Figure 2.72. M2 Harness

If the reading appears within tolerance, replace the power module. If not, move to the 4-pin harness that connects to the right motor.

Take a resistance reading from the heavy gauge red and black wires that run to the motor coil. See figure 2.73.
Some chairs have red and black connectors attached to these wires.

The reading across the motor coil should read approximately .5 to 1.5 ohms.

The meter reads_______ohms.

Figure 2.73. Motor Connector

If the reading appears outside tolerance, check the brushes. If the brushes appear to be good (a good brush should be at least 1/2 in length, with no sign of chips or damage and no sign of overheating), replace the motor. If the reading is within tolerance, replace the M1 harness. Overheating in the brushes can be identified by discoloration of the braided copper wire.

Notes:

RevB/Jan04

www.prideservice.com

63

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Situation 7 Left Brake Fault:


FIVE flashes of status LED
Five flashes indicates a possible problem with the power chair braking system. The power chair is set up with two individual brake assemblies, one on each motor. When the joystick is pushed in any direction, the controller sends total battery voltage to each brake coil. To determine if the brake assembly is operating properly, unplug the M1 harness from the power module. See Appendix H. Turn the meter to a resistance scale and take a reading from brake positive to brake negative (two small center pins) of the M1 harness. See figure 2.74. A reading of approximately 60 ohms should appear. The meter reads_______ohms.
Figure 2.74. M1 Harness

If the reading appears to be within tolerance, replace the power module. If the reading is outside tolerance, move to the motor connector.

Take a reading from the 4-pin motor connector. Unplug the connector from the M1 harness and take a reading from the thin gauge black wires that run to the brake coil. See figure 2.75.
Some chairs have white connectors attached to these wires.

A reading of approximately 60 ohms should appear.

The meter reads_______ohms.


Figure 2.75. Motor Connector If the reading is outside tolerance, replace the motor brake assembly. If the reading is within tolerance, replace the M1 harness.

Notes:

64

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Situation 8 Right Brake Fault:


SIX flashes of status LED
Six flashes indicates that the system has detected a fault in the right motor brake. The power chair system is set up with two individual brake assemblies. One on each motor. When the joystick is pushed in any direction, the controller sends total battery voltage to each brake coil. To determine if the right brake assembly is operating properly, unplug the M2 harness from the power module. See Appendix H. Turn the meter to a resistance scale and take a reading from brake positive to brake negative (two small center pins) of the M2 harness. See figure 2.76. A reading of approximately 60 ohms should appear.

Figure 2.76. M2 Harness

The meter reads_______ohms.

If the reading appears to be within tolerance, replace the power module. If the reading is outside tolerance, move to the motor connector.

Take a reading at the 4-pin motor connector. Unplug it from the M2 harness and take a reading from the thin gauge black wires that run to the brake coil. See figure 2.77.

Some chairs have white connectors attached to these wires.

If the brake coils are intact, you should read approximately 60 ohms across the brake coil.

The meter reads_______ohms.

Figure 2.77. 4-pin Motor Connector

If the reading is outside tolerance, replace the motor brake assembly. If the reading is within tolerance, replace the M2 harness. Notes:

RevB/Jan04

www.prideservice.com

65

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Situation 9 Low Battery Fault:


SEVEN flashes of the status LED
If you encounter a power chair with seven flashes, the batteries are nearly discharged. The battery either needs charging or there is a bad connection to the battery.
Always assume that the batteries need to be recharged.

Plug the power chair into a standard wall outlet. Allow the batteries to charge 8 - 14 hours. The battery indicator should return to a full charge and the power chair should work properly. If this is not the case, the total battery voltage is less than 18 volts. Perform a standard battery load test on each battery. If they check good under a load, test the battery charging system. Use tests from Situation 1 and replace the appropriate component.

Situation 10 High Battery Voltage Fault:


EIGHT flashes of the status LED
Eight flashes indicate high battery voltage. This only appears if the output of the battery charger is over 32 volts. In order for the controller to interpret a high battery voltage, the batteries must read in excess of 16 volts each. In order to test the voltage output, unplug the white 3pin connector of the battery charger from the black 3pin connector of the charger harness and take a voltage reading from the two outside pins of the white 3-pin connector. See figure 2.78. If the charger is operating properly, you should read approximately 25 to 30 volts.
When taking the output voltage from the charger, allow the reading to normalize before documenting the reading.

The meter reads________volts DC.

Figure 2.78. Charger Output Harness If charger output exceeds 30 volts, replace the charger.

66

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

NINE flashes of the status LED


Nine flashes indicates that the system has detected an invalid voltage on the DXBUS CANL line. To check for this fault, perform a continuity test of the DXBUS harness.
If the harness has continuity on all four pins of the harness the problem could lie in the power module. In this case you will need to replace the power module.

Situation 11 CANL Fault:

Situation 12 CANH Fault:


TEN flashes of the status LED
Ten flashes of the status LED indicates that the system has detected an invalid voltage on the DXBUS CANH line. When this occurs communication is not possible between the RemG80 and the power module. Check for continuity from the four pins located on one end of the DXBUS harness to the four pins located in the opposite end of the DXBUS harness.
If you do not have continuity, replace the harness, if you do it could be a problem with the power module. If this is the case you will need to replace the power module.

Another cause of this fault would be if the hazard lights were turned on when the Dynamic system was turned on. If this is the case, turn the hazard lights off and cycle the power off and then on again and see if the fault is still occurring.

Situation 13 Stall Timeout Fault:


ELEVEN flashes of the status LED
Eleven flashes of the status LED occurs when the motor current has been at, or is close to the current limit for longer than the Stall Timeout Parameter value. The Dynamic system has a feature called a Stall Timeout Parameter, which in turn means that the controller has a time limit in which current from the motors is allowed before the controller faults to protect the motors and control system. To test if this fault is caused by the wheels binding up, place the power chair in freewheel and see if it rolls freely with no drag from the wheels. If there is a drag the resistance could be caused by an internal gear problem with the motors, or something is binding the wheels. If this is the case replace the component which is binding up and causing the drag. Another possibility is that the chair is binding up while driving. This can be caused by operating the power chair while it is bound by an obstacle. The Dynamic controller is designed to protect the motors and electronics by stalling out the chair.
Stall out is when the controller disables the drive functions and displays an error on the status LED.

This can be reset by correcting the source of the fault and cycling the power off and on again.

RevB/Jan04

www.prideservice.com

67

TECHNICAL TROUBLESHOOTING GUIDE

POWER CHAIR DIAGNOSTICS

Situation 14 Module Mismatch:


TWELVE flashes of the status LED
Twelve flashes of the status LED occur when the data held by the RemG80 is incorrectly programmed for the power chair it is being used on. Try having the RemG80 joystick reprogrammed for the specific model of power chair and the accessories that go with the chair. Another problem could be compatibility between the Dynamic modules in the system. If this happens, the power chair will be disabled by the electronics. If this happens, assure that the programming is correct for the chair and the accessories on the chair.
In this case, contact Pride Power Chair Technical Service at 1-877-800-1248. Notes:

68

www.prideservice.com

RevB/Jan04

POWER CHAIR DIAGNOSTICS

TECHNICAL TROUBLESHOOTING GUIDE

Adjusting the Programming


All power chair models are programmable power base chairs. This means that the internal programming of the electronics can be adjusted to accommodate the needs of an individual patient. Adjusting the pre-programmed factory settings requires the use of a HHP programmer. This programmer will allow you to adjust the internal performance settings of the power chair and will also help in some areas of troubleshooting and maintenance. See Appendix G. The HHP is used exclusively with the Dynamic control system and the DL-50 system.
Notes:

RevB/Jan04

www.prideservice.com

69

TECHNICAL TROUBLESHOOTING GUIDE

NOTES

70

www.prideservice.com

RevB/Jan04