Sunrise Medical Melody Manuel utilisateur

Quickie Melody Service Manual

101975 Rev A

Quickie Melody Service Manual Contents

Introduction.....................................................0.1

VR2 Controller ...............................................0.2

Plugs/Connectors...........................................0.3

Basic Tool List & Main Wiring Diagram .........0.4

Section 1

Troubleshooting: No Power...............................1

1.1 Circuit Breaker Reset ....................................1

1.2 Test Joystick..................................................1

1.3 Battery Test....................................................1

1.4 Not Charging ...............................................2

1.5 Battery Connection Test ...............................3

1.6 Check Battery Wire Harness........................4

1.7 Battery Fuse.................................................4

1.8 Circuit Breaker Test......................................4

1.9 Main Harness ...............................................4

Section 2

Understanding Controller Display........................5

2.1 The Maximum Speed Indicator Ripples.......5

2.2 The Maximum Speed Indicator Flashes.......5

2.3 Battery Gauge is Steady...............................5

2.4 Battery Gauge Flashes Slowly .....................5

2.5 Battery Gauge Steps Up...............................5

2.6 Battery Gauge Blinks Once Every

2.5 Seconds.........................................................5

2.7 Battery Gauge Flashes Rapidly ...................5

Section 3

Understanding Controller Diagnostics Codes...6

3.1 One Bar - Low Battery Voltage ....................6

3.2 Two Bars - Left Motor Disconnected ...........6

3.3 Three Bars - Left Motor Wiring Trip..............7

3.4 Four Bars- Right Motor Disconnected.........8

3.5 Five Bars - Right Motor Wiring Trip.............9

3.6 Six Bars - Charger Connected....................9

3.7 Seven Bars - Possible Joystick Trip ..........9

3.8 Eight Bars - Possible Control System Trip...9

3.9 Nine Bars - Solenoid Brake Trip..................10

3.10 Ten Bars - High Battery Voltage ...............10

3.11 Eleven Bars - Communication Error .........10

Section 4

Disassembly/Reassembly, and Adjustment..... 11

Step 1 - Seat removal & Frame Separation.......11

Step 2 - Shroud removal....................................12

Step 3 - Frootrest removal.................................13

Step 4 - Battery removal....................................13

Step 5 - Motor removal......................................14

Step 6 - Caster removal.....................................15

Step 7 - Anti-tip removal....................................15

Step 8 - Main wiring harness removal...............16

Step 9 - Rear bumper removal..........................16

MELODY SERVICE MANUAL PAGE 0.1

2006SUNRISE MEDICAL

Please read and follow instructions in this service manual before attempting to troubleshoot

or repair this product for the first time. If there is anything in this Service Manual that is not

clear, or if you require additional Technical assistance, contact Sunrise Medical at: (800)

333-4000 option 2, then option 1.

Safely troubleshooting and/or repair of this product depends on your diligence in following

the instructions within this manual. Sunrise Medical is not responsible for injuries or

damage resulting from a person’s failure to exercise good judgement and/or common

sense.

This Service Manual is intended as a troubleshooting guide for the Quickie Melody. Photo-

graphs and content may differ from the actual products in some cases due to changes in

specifications 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 trou-

bleshooting procedures. This can result in problems with future servicing, and/or damage

to the unit.

Parts and configuration or specifications of Products included in this Service Manual are

subject to change without prior notice.

There are warning symbols used in this document to fo-

cus attention on any hazard that could effect the safety of the in-

dividual troubleshooting the chairs covered in this Service Manual.

Introduction

MELODY SERVICE MANUAL PAGE 0.2

2006SUNRISE MEDICAL

VR2 Controller

VR2 Controller Buttons

Battery Gauge

A series of ten LED’s, which

indicate charge level.

Speed/Profile indicator- A se-

ries of five LED’s, which display

speed and profile settings

On/Off Key- Press to power on

or off the power chair or Control-

ler.

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.

MELODY SERVICE MANUAL PAGE 0.3

2006SUNRISE MEDICAL

Plugs/Connectors

1 = 24 Vdc

2 = 0 Vdc

3 = Inhibit 1/ Programmer

1 = Black (-)

2 = White

3 = Yellow

4 = Red (+) 21

charger port

Motor Plug

Charger port

Outside View

4-pin

M1 = RIGHT SIDE MOTOR

M2 = LEFT SIDE MOTOR

JSM = JOYSTICK MODULE

INH-2 = INHIBIT 2

A1 = ACTUATOR 1

A2 =ACTUATOR 2

OBC = ON BOARD CHARGER

+ - =BATTERY

VR2 Controller

MELODY SERVICE MANUAL PAGE 0.4

2006SUNRISE MEDICAL

Basic Tool List & Main Wiring Diagram

LEFT MOTOR

24vBRAKE

SOLENOID RIGHT MOTOR

24vBRAKE

SOLENOID

CHARGER

/C INPUT

LEFT BATTERY

CIRCUIT

BREAKER

LEFT BATTERY

FUSE FUSE

FUSE

Wiring Diagram for VR2 Controller Package

Basic Tool List

The following list of tools should enable any task to be

dealt with. Some will only occasionally be needed, but it

is advisable to own or have access to them.

• 17mm Deep Socket wrench

• 10mm combination wrench

• 13mm combination wrench

• Cutter for zip-tie

• Needle nose pliers

• 4mm Allen wrench

• 5mm Allen wrench

• 3/8 combination wrench

• Phillips screwdriver #2

• 18mm combination wrench

• Flat blade screwdriver

• 19mm socket wrench

• 5mm socket wrench

MELODY SERVICE MANUAL PAGE 1

2006SUNRISE MEDICAL

Section 1

Troubleshooting: No Power

Check that the voltage is going to the controller, set the me-

ter to dc volts and take a voltage reading from pin 1 (using

the red lead) and pin 2 (using the black lead) to the charger

port of the VR2 joystick (see figure A1.2.1) If the voltage

meter reads approximately 24 volts, replace the controller, if

the meter reads less than 12 volts, proceed to the next step.

Note: Make sure the polarity is correct. If the read-

ing is intermittent, there is a connection or Control-

ler problem. If polarity is reversed proceed to step 1.6

1.2 Test Joystick

1.1 Circuit Breaker Reset

A1.2.1

IfOn/offbuttonis pressedandno lightorbar isshown,check

for tripped circuit breaker (see figure A1.1.1) and make sure

all connections are clean and tight (including the batteries). If

the problem persists, then perform the following diagnostics.

A1.1.1

1.3 Battery Test

Check that the batteries are fully charged and in good condi-

tion. Remove the battery box, and the battery cover, use the

meter to check the voltage across the battery terminals (see

figureA1.3.1). If the voltage meter reads between 12 -13.5

volts, then proceed to next step. If the voltage meter reads

below 12 volts, charge the batteries.

Note: To find a bad battery, use a battery load tester.

A1.3.1

If the voltage meter reads below 12 volts, charge the batteries.

MELODY SERVICE MANUAL PAGE 2

2006SUNRISE MEDICAL

Section 1

If the chair is not charging check the charging port (fig

1.4.1) on the battery case. If the meter reads less than 12

volts, check the corresponding pins on the controller (fig

1.4.3) if the meter reads less than 12 volts, proceed to the

next step.

1.4 Not Charging

A1.4.1

If the charging port is OK check that the battery fuse is in

good condition. With the batteries disconnected remove

the fuse cap, inspect the fuse to see if the fuse is blown.

To make sure the fuse is not blown, set the meter to ohms

and measure the resistance across the fuse. See (figure

A1.4.2). If the meter reads more than one ohm, change the

fuse, or else proceed to the next step..

A1.4.2

Troubleshooting: No Power (cont.)

A1.4.3

MELODY SERVICE MANUAL PAGE 3

2006SUNRISE MEDICAL

Troubleshooting: No Power (cont.)

1.5 Battery Connection Test

Check that the female VR2 Bus plug on the chair has volt-

age. Set the meter to dc volts and measure pins 4 (using

the red lead of the meter) and 1 (using the black lead of the

meter) as shown in (figureA1.5.1)

A1.5.1

A1.5.2

If the voltage meter reads full voltage, then replace the controller.

If the voltage meter reads full voltage, then replace the joy-

stick module

If the voltage meter reads zero voltage measure the cor-

responding pins on the VR2 controller as shown in (figure

1.5.2).

If the voltage meter reads full voltage, then replace the

jumper cable. If the voltage meter reads zero, then mea-

sure the Battery Connector as shown in (fig 1.5.3)

If the voltage meter reads full voltage, then replace the con-

troller, or else proceed to the next step.

A1.5.3

MELODY SERVICE MANUAL PAGE 4

2006SUNRISE MEDICAL

Section 1

1.6 Check Battery Wire Harness

Check that the battery wire harness has the polarity cor-

rect. Set the meter to dc volts and measure the connector

with the red lead on the positive terminal and the black lead

on the negative terminal as shown in (figure 1.6.1) If both

the battery wire harness have full voltage and correct polar-

ity, then proceed to circuit breaker test. If the voltage is ab-

sent proceed to battery fuse test. If the polarity is reversed

correct battery wiring. A1.6.1

If polarity is reversed correct battery wiring.

Check that the battery fuse is in good condition. Inspect

the fuse to see if the fuse is blown. Set the meter to ohms

and measure the resistance across the fuse. Measure the

negative terminal of the battery box and the positive termi-

nal of the battery harness. Measure the positive terminal

of the battery box and the negative terminal of the battery

harness (figureA1.7.1). If the meter reads more than one

ohm, change the harness, or else proceed to the next step.

1.7 Battery Fuse

A1.7.1

If the meter reads more than one ohm, change the Battery harness.

1.8 Circuit Breaker Test

To check the circuit breaker set the meter to ohms and

measure the resistance across the circuit breaker as shown

in (figureA1.8.1). If the meter reads more than 1 ohm,

then change the circuit breaker, otherwise proceed to next

step.

A1.8.1

If the meter reads more than 1 ohm, then change the circuit breaker.

If the above steps did not correct the problem, change the

main harness.

1.9 Main Harness

A1.7.2

Troubleshooting: No Power (cont.)

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