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decon JWB2 Service Manual

Lithium ion battery, nickel metal hydride battery for electric wheelchair, electric power assist unit for wheelchairs
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For Electric Wheelchair, Electric Power Assist Unit for Wheelchairs
Nickel Metal Hydride Battery JWB2
Nickel Metal Hydride Battery JWB2
Lithium Ion Battery ESB1
Lithium Ion Battery ESB1
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.
2020-06

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Summary of Contents for decon JWB2

  • Page 1 For Electric Wheelchair, Electric Power Assist Unit for Wheelchairs Nickel Metal Hydride Battery JWB2 Nickel Metal Hydride Battery JWB2 Lithium Ion Battery ESB1 Lithium Ion Battery ESB1 SERVICE MANUAL This manual has been created as a guideline for maintenance service to be performed at the dealers before and after the sale.
  • Page 2 Foreword This Service Manual describes the procedures for inspecting, adjusting and as well as how to handle errors of the nickel metal hydride battery, lithium ion battery and battery chargers for the electric wheelchair and the electric power assist unit for wheelchair manufactured by Yamaha Motor.

  • Page 3: Table Of Contents

    CONTENTS Nickel Metal Hydride Battery ....4 1.1. Names of Parts and Circuits ..... . . 4 1.2.

  • Page 4: Nickel Metal Hydride Battery

    Nickel Metal Hydride Battery 1.1. Names of Parts and Circuits Indicator switch Capacity indicator lamp Screw Release button Battery fuse (20A blade type) Contacts TX RX Blue Narrow Black White Narrow 20A fuse Narrow Backup battery fuse Protective cap Battery management system Battery management controller Thermistor Black...

  • Page 5: Function Of The Battery

    1.2. Function of the Battery The battery management system, which is built-in the battery, provides the following three major functions: “residual capacity management”, “battery information communication”, and “service”. (1) Residual Capacity Management Capacity guide The battery management system uses an “amperage (new state) integration system”...
  • Page 6 If the battery will not be used for a long time, store it in a dry area, at a temperature between 0 and 30°C. In addition, charge at least once every three CAUTION months. (2) Battery Information Communication The battery management system is equipped with a function to display and communicate various information about the battery.
  • Page 7 (3) Simple Diagnosis of the Battery (Service Mode) On the battery, the battery management system has a service mode. This mode enables you to perform a simple diagnosis on the battery as follows. Push and hold the indicator switch for 10 seconds The capacity indication will turn OFF in 5 seconds Keep on pushing the switch The capacity indication will turn ON again...
  • Page 8 Simple Diagnosis List Blinking Simple Battery Diagnosis Table Top LED is ON The battery is normal. Center LED is ON Refresh charge has not been performed, or the capacity learn failed. Bottom LED is ON Advise the customer to be sure to perform Tester diagnosis is required.
  • Page 9 (4) Troubleshooting the Battery Management System If the battery management system cannot show the capacity or is unable to charge, diagnose the system by referring to the flowchart below. Start diagnosis Eliminate cause of the blown fuse, Is the battery fuse blown? then replace the fuse. Has the battery voltage Charge the battery.

  • Page 10: Lithium Ion Battery

    Lithium Ion Battery 2.1. Names of Parts and Circuits Gripping handle Indicator switch Capacity indicator lamp Connector cover Contacts Connector for charger TX RX Manufactured date (underside) Protective cap Battery management system Battery management controller...

  • Page 11: Function Of The Battery

    2.2. Function of the Battery The battery management system, which is built-in the battery, provides the following three major functions: “residual capacity management”, “battery information communication”, and “service”. (1) Residual Capacity Management The battery management system uses an “amperage Residual capacity integration system”...
  • Page 12 (3) Simple Diagnosis of the Battery (Service Mode) On the battery, the battery management system has a service mode. This mode enables you to perform a simple diagnosis on the battery as follows. Push and hold the indicator switch for 10 seconds The capacity indication will turn OFF in 5 seconds Keep on pushing the switch The capacity indication will turn ON again...
  • Page 13 Simple Diagnosis List Simple Battery Diagnosis Table : OFF : ON : blinking (2 second interval) Normal Charge Thermistor High Battery Measurement current error temperature voltage mismatch temperature error error error error regenerative overcharge Deterioration Level This indicates the deteriorated state of the battery in terms of the ratio Indication to the capacity of a new battery.
  • Page 14 (4) Troubleshooting the Battery Management System If the battery management system cannot show the capacity or is unable to charge, diagnose the system by referring to the flowchart below. Start diagnosis Has the battery voltage Charge the battery. dropped below 20V? The battery management system may have failed. Contact a person in charge of service.

  • Page 15: Specifications

    3. Specifications 3.1. Nickel Metal Hydride Battery Charger (JWC-2) The names and functions of the Nickel Metal Hydride Battery Charger (JWC-2) are explained below. AC cable (releasable) Exhaust vent Contacts (4 locations) Charge lamp Battery insertion opening Refresh lamp Gripping handle Refresh switch Intake vent Intake vent...
  • Page 16 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. NOTE Refresh charging a fully charged battery takes approximately 13 to 15 hours. Therefore, recommend that the user refresh charge a battery from a state of low residual capacity, whenever possible.
  • Page 17 (6) Indication Function (List of Lamp Indications) State Green Lamp Yellow Lamp Pre-charging or temperature Blinking standby Quick charging Charging completed Refresh charging notice Blinking Refresh charging Malfunction indication Various types of blinking patterns (refer to the Malfunction Diagnosis Function) (7) Malfunction Diagnosis Function Malfunction Location State of Indicator Lamp...
  • Page 18 (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 below. Start diagnosis Battery itself can Is the amperage fuse indicate its capacity blown? Eliminate the cause, and then replace the fuse Contact points are Clean or repair deformed or have foreign...
  • Page 19 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 nickel metal hydride batteries manufactured before 3/13/2008 (manufactured lot: JWB2-83D).

  • Page 20: Charger For Lithium Ion (Esc1)

    3.2. Charger for Lithium Ion (ESC1) The names and functions of the Lithium Ion Battery Charger (ESC1) are explained below. Charger plug Gripping handle Indicator lamp AC cable (releasable) The model (ESC1) is shown on the label on reverse side. (1) Charging System Pre-Charging ...
  • Page 21 (2) Battery Protection Function The temperature of the battery during charging significantly affects the life of 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.
  • Page 22 Pre-charging a battery that has been excessively discharged.  During a pre-charge, such as when you started to charge an excessively discharged battery, the green lamp blinks slowly. If the battery voltage is low (below 18.2V) at the start of charging, the charger will automatically charge at low amperage.
  • Page 23 Inspection or LED Color Indication ON or Blinking Cause of Malfunction Replacement Location Battery overheat, BMC malfunction, thermistor malfunction, voltage malfunction, short, or Battery (continuously) battery malfunction (overvoltage protection board) Green Blinking slowly (continuously) Slow blinking/ 1 blink per sec ON for 5 sec Battery Malfunction Battery...
  • Page 24 Inspection or LED Color Indication ON or Blinking Cause of Malfunction Replacement Location Communication disabled due to a contact point Fast blinking 0.1 sec Blinking failure or excessive Charging cords, plug, quickly discharge, damaged or battery (continuously) insulation on charging cord plug, or damaged 0.1 sec charger...
  • Page 25 (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. Start diagnosis Battery itself can indicate its capacity Contact points are Clean or repair deformed or have foreign matter on them Battery management Charger is able to...

  • Page 26: Charger For Lithium Ion And Nickel Metal Hydride

    3.3. Charger for Lithium Ion and Nickel Metal Hydride Battery (ESC3) The names and functions of the Lithium Ion Battery Charger (ESC1) are explained below. Contacts for Nickel Metal Charger plug for Lithium Ion Battery Power cord Hydride Battery (4 locations) Power plug Battery insertion slot for Nickel Metal Hydride Battery...
  • Page 27 If you notice an abnormality during charging, immediately abort charging, WARNING unplug the AC cable, and pull out the charger plug from the battery. (3) Battery Protection Function The temperature of the battery during charging significantly affects the life of the battery. Therefore, the charger controls the charging based on the battery temperature data that is sent by the battery management system.
  • Page 28 Battery capacity Charger lamp indication Description indicator lamps Charge lamp (green) is on Indicates normal charging. The charge lamp will turn off after charging is completed. Turn on succes- sively Charge lamp (green) Charge lamp (green) is flashing Indicates charge standby. (once per second) • When the temperature of the battery is not within the charge- able range 32 to 104°F (0 to 40°C), the charger enters a stand- by state and the charge lamp (green) starts flashing.
  • Page 29 Battery capacity Charger lamp indication Description indicator lamps Refresh lamp (orange) is on Indicates refresh charging. The remaining electricity is being discharged as part of the refresh charging process. When the discharge Turn off has completed, normal charging will start. succes- sively Refresh lamp (orange) (5) Diagnosing Charger Communication Malfunction...

  • Page 30: Specifications

    ESC1 Charging method Automatic Charging controlled by the microprocessor Rated output during charging 29 V · 2.6 A 29.4 V · 4.5 A Chargeable battery JWB2 * ESB1 * Battery Charger Time for normal 2.5–3.5 hr Approx. 4.5 hr 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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Esb1

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