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X0E-28197-P1

X0B-28197-000

DIC142p

SERVICE MANUAL

This manual has been created as a guideline for maintenance

service to be performed at the dealers before and after the sale.

Please refer to it together with the Owner’s Manual.

For Electric Wheelchair, Electric Power Assist Unit for Wheelchairs

Nickel Metal Hydride Battery JWB2

Lithium Ion Battery ESB1

Nickel Metal Hydride Battery JWB2

Lithium Ion Battery ESB1

Decon Wheel AB

Södra Ekeryd 119, 314 93 Hyltebruk

Tel: +46 (0)345 40880

Fax: +46 (0)345 40895

E-mail: [email protected]

Summary of Contents for ESB1

Page 1: ...rformed at the dealers before and after the sale Please refer to it together with the Owner s Manual For Electric Wheelchair Electric Power Assist Unit for Wheelchairs Nickel Metal Hydride Battery JWB2 Lithium Ion Battery ESB1 Nickel Metal Hydride Battery JWB2 Lithium Ion Battery ESB1 2020 06 ...

Page 2: ...ed in This Manual Items concerning proper handling are indicated with the following symbols Other Precautions For product improvement purposes the descriptions and specifications in this manual are subject to change without notice Due to changes in the specifications some of the photos and descriptions may differ from the actual product This manual is intended for use by persons possessing the bas...

Page 3: ...2 Lithium Ion Battery 10 2 1 Names of Parts and Circuits 10 2 2 Function of the Battery 11 3 Specifications 15 3 1 Nickel Metal Hydride Battery Charger JWC 2 15 3 2 Charger for Lithium Ion ESC1 20 3 3 Charger for Lithium Ion and Nickel Metal Hydride Battery ESC3 26 4 Specifications 30 4 1 Specifications 30 ...

Page 4: ...ement controller Thermistor Temperature fuse White Narrow Red Narrow Blue Narrow Black Narrow Black Narrow Black Black Sticker Battery management system Battery unit TX RX Internal wiring diagram Indicator switch Capacity indicator lamp Release button Battery fuse 20A blade type Screw Contacts 20A fuse Backup battery fuse ...

Page 5: ...eases below 60 the fourth segment will also stop turning ON CAUTION If the capacity gauge shows that the battery has deteriorated prematurely perform a simple diagnosis in the service mode which will be described later CAUTION If 1 segment of the capacity gauge blinks residual capacity warning instruct the user to immediately charge the battery or replace it with a spare battery After the battery ...

Page 6: ... the capacity gauge will be unable to indicate the precise capacity Therefore the capacity gauge will blink to inform you that the battery tem perature is beyond the guaranteed temperature range 2 If the temperature sensor that is built into the battery fails the fourth LED will blink 3 If the temperature of the battery becomes abnormally high the LEDs 1 3 and 5 will blink CAUTION If the battery w...

Page 7: ...e switch Service Mode Shows all LEDs turned ON LED check Any of the 5 LEDs turn ON 3 seconds later Shows a combination of LEDs that turn ON and blinking 30 seconds later Simple Battery Diagnosis Table Deterioration Level Indication 30 seconds later 30 seconds later Shows a combination of LEDs that turn ON and blinking Reference Item Use Frequency Indication Service mode ends Before the capacity in...

Page 8: ...0 299 300 349 350 399 Over 400 ON OFF Blinking Indication of the deterioration level may not be correct in case the refresh charging has not been performed appropriately This indicates the deteriorated state of the battery in terms of the ratio to the capacity of a new battery Refresh charge has not been performed or the capacity learn failed Advise the customer to be sure to perform refresh charg...

Page 9: ...ct a person in charge of service Eliminate cause of the blown fuse then replace the fuse Charge the battery The indicator switch is broken Repair the open circuit of the board lead wire or the failed or detached connector Disassemble the battery case Yes No No Yes No Yes No Yes 4 Troubleshooting the Battery Management System If the battery management system cannot show the capacity or is unable to...

Page 10: ...ystem Battery management controller Connector cover Connector for charger Manufactured date underside Protective cap Capacity indicator lamp Indicator switch Gripping handle Contacts 2 Lithium Ion Battery 2 1 Names of Parts and Circuits ...

Page 11: ...rmation Communication The battery management system has a built in function to establish communication with the drive unit and the charger and exchanges various types of information while using the wheelchair or during a charge cycle Battery Life Management The battery management system of the lithium ion battery remembers its cumulative usage time and integral charge capacity In order to use the ...

Page 12: ...hen release the switch The capacity indication will turn OFF in 5 seconds Keep on pushing the switch Service Mode The indications change after the number of seconds shown below elapse or when the indicator switch is pressed Shows all LEDs turned ON LED check Any of the 5 LEDs turn ON 3 seconds later Shows a combination of LEDs that turn ON and blinking 30 seconds later Simple Battery Diagnosis Tab...

Page 13: ... time OFF ON blinking 2 second interval OFF ON blinking 2 second interval OFF ON blinking 2 second interval blink 0 2 second interval Normal Charge current error Thermistor error High temperature error Battery voltage error Measurement mismatch error Low temperature regenerative overcharge 1 8 9 19 20 39 40 59 60 79 80 100 0 49 times 50 99 times 100 149 times 150 199 times 200 249 times 250 299 ti...

Page 14: ... it in a dry place at a temperature between 10 and 25 C 6 State of Charge During Shipment and Storage Period The charge capacity at the time of shipping from the factory has been adjusted to 25 to 30 of its full capacity To reduce electricity consumption during the transport the residual capacity indicator show a zero capacity regardless of the true state of charge capacity until the first charge ...

Page 15: ...rger discharges the battery completely before charging This restores battery performance by improving the internal activation of the battery The communication function that is built into the JWC 2 charger receives optimal refresh timing in the form of data from the battery management system Thus this function informs the user of when the battery should be refresh charged The JWC 2 charger is desig...

Page 16: ...harger will be unable to charge Then it will inform the user by indicating the malfunction Refer to the Malfunction Indication which will be described later The timing in which the refresh lamp blinks varies with the way in which the battery is used It blinks after the battery is used approximately 10 to 30 cycles Refresh charging a fully charged battery takes approximately 13 to 15 hours Therefor...

Page 17: ... a new one Charger Malfunction 1 Blink in the sequence of green green and yellow Replace the charger with a new one Charger Malfunction 2 internal high temperature malfunction Blink in the sequence of green green green and yellow Replace the charger with a new one Replace the cooling fan 6 Indication Function List of Lamp Indications State Green Lamp Yellow Lamp Pre charging or temperature standby...

Page 18: ...r repair Charger is able to charge a normal battery Charger failure Replace charger Battery management system failure inside the battery Proceed to the trouble shooting of the battery management system No Yes No No Yes Yes Yes No 8 Diagnosing Charger Communication Malfunction If the charger is unable to charge due to a communication malfunction perform a diagnosis by referring to the flowchart bel...

Page 19: ...y switch on the battery 4 times within 2 seconds Insert the battery in the charger The refresh lamp of the charger blinks While the refresh lamp of the charger is blinking press the refresh switch This forced refresh charging may speed up the deterioration of the battery or may damage it Therefore forced refresh charging is not recommended unless it is necessary This function does not exist in the...

Page 20: ...r a deep discharge it will take 1 2 to 1 3 times longer than normal to charge the battery If a battery is post charged because it was charged at a high temperature the post charging for replenishment purposes could take as much as 1 5 hours longer Furthermore the capacity indication during charging will take a longer time to blink the topmost segment fully charged In addition the charging time var...

Page 21: ...the battery Therefore the charger controls the charging based on the battery temperature data that is sent by the battery management system The temperature of the battery at which the charger can start charging is between 0 and 40 C The charger will abort charging when the battery temperature exceeds 50 C NOTE The power will turn OFF automatically after 12 hours even if it is connected NOTE Immedi...

Page 22: ... battery voltage is low below 18 2V at the start of charging the charger will automatically charge at low amperage It will start a normal charge once the voltage recovers The low amperage charging will take longer time than normal NOTE When the temperature of the battery is out of the temperature range that is suitable for charging and the temperature does not recover after a predetermined length ...

Page 23: ...conds OFF 2 seconds ON for 10 sec OFF for 2 sec No charging amperage Battery fuse 5 Red ON 15 seconds OFF 2 seconds ON for 15 sec OFF for 2 sec BMC hardware malfunction or charger AC reset operation Battery or BMC slowly disconnect and reconnect the plug 6 Red Blinking slowly continuously 0 5 sec Slow blinking 1 blink per sec 0 5 sec Internal temperature of the charger has risen Charger charge in ...

Page 24: ...ormally damaging the battery or the charger Once you have checked the blinking pattern of the malfunction indicator lamp unplug the power cable and remove the charger cable from the battery CAUTION LED Color Indication ON or Blinking Cause of Malfunction Inspection or Replacement Location 9 Red Blinking quickly continuously 0 1 sec 0 1 sec Fast blinking Communication disabled due to a contact poin...

Page 25: ...e a normal battery Charger failure Replace charger Battery management system failure inside the battery Proceed to the trouble shooting of the battery management system Yes No Yes Yes No No 4 Diagnosing Charger Communication Malfunction If the charger is unable to charge due to a communication malfunction perform a diagnosis by referring to the flowchart below ...

Page 26: ...imately 13 to 19 hours 2 Refresh Function The function is only for the Nickel Metal Hydride Battery With refresh charging the charger discharges the battery completely before charging This restores battery performance by improving the internal activation of the battery The communication function that is built into the ESC3 charger receives optimal refresh timing in the form of data from the batter...

Page 27: ...mperature of the battery at which the charger can start charging is between 0 and 40 C The charger will abort charging when the battery temperature exceeds 45 C NOTE If a malfunction is displayed on the charger Temporarily unplug the AC cable and the charger cable and check for damaged insulation If the charger cable is damaged a short circuit between the terminals may damage the battery Before ch...

Page 28: ...n is flashing 5 times per second Charge lamp green Flashing On Indicates timeout of charge standby The charger has remained in standby mode for a long time and has stopped charging the battery Re locate the charger and try to charge the battery again Lit or flashing red Charge lamp red Off The charger has detected a problem in the charger or the battery and is unable to charge Stop charging by dis...

Page 29: ...gement system Yes No Yes Yes No No 5 Diagnosing Charger Communication Malfunction If the charger is unable to charge due to a communication malfunction perform a diagnosis by referring to the flowchart below Charger lamp indication Battery capacity indicator lamps Description Refresh lamp orange is on Refresh lamp orange Turn off succes sively Indicates refresh charging The remaining electricity i...

Page 30: ... normal charging 2 5 3 5 hr Approx 4 5 hr Time for refresh charging 3 15 hr The Ni MH battery and Li ion battery each have a dedicated charger The dedicated chargers are not interchangeable Battery and Charger Nickel Metal Hydride Lithium ion Battery Charger Ni MH and Li ion combind charger Model ESC3 Charging method Automatic Charging controlled by the microprocessor Rated output during charging ...

Page 31: ...Memo ...

Page 32: ...Decon Wheel AB Södra Ekeryd 119 314 93 Hyltebruk Tel 46 0 345 40880 Fax 46 0 345 40895 E mail info decon se ...

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