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D-Box G3 Installation, Use And Care Manual

Haptic system
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G3 HAPTIC SYSTEM
INSTALLATION, USER AND
TROUBLESHOOTING GUIDE
209-914-0002-EN12
FEBRUARY 2024

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  • Page 1 G3 HAPTIC SYSTEM INSTALLATION, USER AND TROUBLESHOOTING GUIDE 209-914-0002-EN12 FEBRUARY 2024...

  • Page 2: Table Of Contents

    D-BOX System Configurator and Actuator Positioning ................9 Communication Module - KCU-1P ..............9 KCU-1P Power up ........................... 10 Actuator Control Module (ACM) ............... 11 ACM G3 families and compatibility ......................11 ACM Connections ........................... 12 Haptic Actuator ....................15 Maximum axial load ..........................15 Weight Distribution ..........................
  • Page 3 Haptic System Operation .................. 19 Power up ..............................19 During Operation ........................... 19 Shut down/Stand Still ..........................20 Troubleshooting your G3 Haptic System ............21 Reinitiate the haptic settings to default ....................21 Initial Troubleshooting Steps ......................... 22 Update Software and Firmware ......................24 Troubleshooting with KCU-1P LED Status ....................

  • Page 4: Important Safety Instructions

    IMPORTANT SAFETY INSTRUCTIONS Read and follow these instructions step-by-step. Keep them for future reference. Install in accordance with the manufacturer's instructions and heed all warnings. Do not use this apparatus near water. Only clean with a dry cloth. Do not block any ventilation openings. Do not install near any heat sources such as radiators, heat registers, stoves, or other apparatus (including amplifiers) that produce heat.
  • Page 5 Thank you for purchasing a D-BOX haptic system, the most immersive experience for the simulation and game markets. We strongly advise that you read these guidelines before assembling and using your haptic system. Do not hesitate to contact us if you have questions.

  • Page 6: Introduction

    D-BOX haptic systems are evolutive and scalable. Integrated into a seat, platform, or simulator, they are designed to simulate a range of textures and scalable axes of movement. Whatever you require, D-BOX can help you select the best arrangement of haptic actuators.

  • Page 7: Software Integration Phase

    D-BOX Coded Movies. Access the D-BOX Connect website here. Haptic Code Integration Phase D-BOX Haptic Code is readily compatible with many contents (2D, 3D, linear, interactive). Contact us for more information. The following section applies only if you need to code a linear content.

  • Page 8: Operating Conditions

    The D-BOX System Configurator is a free software tool used to update and configure your haptic system. The D-BOX System Configurator is compatible with Microsoft Windows 7, 8, 10 & 11 - 64 bits. Download D-BOX System Configurator here. Take note that the User Guide is located into the Windows Start menu/D-BOX folder.
  • Page 9 You may have a configuration requirement different from the factory configuration. If this is the case, you need to change it using the D-BOX System Configurator to modify the configuration BEFORE you install your haptic system. The D-BOX System Configurator application attributes a specific ACM port to each actuator position.

  • Page 10: D-Box System Configurator And Actuator Positioning

    KCU-1P is connected to the computer, it requires driver files to complete the installation process. CAUTION: The KCU-1P works with a D-BOX G2 or G3 ACM. Never connect the KCU-1P to an ACM-I (G1). The KCU-1P comes with an installation bracket and a power supply. It has 2 ports and a power input jack.

  • Page 11: Kcu-1P Power Up

    Connected to the PC USB port, drivers are installed. The unit is ready to operate. ● GREEN: Active Motion. ● For more information on the LED status, refer to the Troubleshooting section. NOTE: One KCU-1P can provide the haptic signal for a maximum of 20 daisy-chained ACM G3.

  • Page 12: Actuator Control Module (Acm)

    4. A (ACM) CTUATOR ONTROL ODULE 4.1 ACM G3 families and compatibility There exists multiple ACM in the G3 architecture. The following table outlines the ACM G3 compatibility with different actuator models. MAX NUMBER OF ACM G3 TRAVEL MODEL ACTUATORS PER ACM...

  • Page 13: Acm Connections

    4.2 ACM Connections Depending on the ACM position in the system, it is programmed either as: MAIN: first ACM in a haptic system ● SECONDARY: all following ACMs ● The last MAIN and SECONDARY ACM(s) in the chain must always be terminated using a 1-foot shielded CAT5e cable, connecting from OUT to END ports of ACM.
  • Page 14 The following example shows 3 D-BOX haptic systems using 2 ACMs each.
  • Page 15 If you are connecting a G2 SECONDARY ACM to a G3 haptic system, please refer to the diagram below and note the following: • You will be able to use the D-BOX System Configurator to change the configuration however, you will not be able to change the actuator type or reorder the ACMs.

  • Page 16: Haptic Actuator

    Each haptic actuator has an individual maximal payload as previously mentioned. When integrating the haptic system on a platform, D-BOX recommends balancing the center of gravity (CG) of the platform to ensure each actuator supports an equal load. The following figures show equal distribution of weight with 2, 3 or 4 actuators.

  • Page 17: Haptic Actuator Acceleration

    5.3 Haptic Actuator Acceleration The D-BOX haptic system can produce a 1G acceleration or greater. However, to avoid risks of injury for the user or damage to the equipment, D-BOX recommends calibrating the haptic system to produce a maximum of 1G, using the control panel - see information on Motion Core.

  • Page 18: Haptic Actuator Alignment

    alignment Haptic actuator When using 3 actuators, install them per an isosceles triangle pattern, avoid other patterns – e.g. scalene triangle: When using 4 actuators, install them per a square or rectangular pattern. Avoid other patterns - e.g. trapezoid: 5.6 Haptic actuator straightness During installation, the haptic actuators should always remain straight to limit radial loading.

  • Page 19: Level Surface

    As D-BOX is not providing an external step-down transformer, you will need to assure power conversion by your own means if needed. To select your converter, please follow the power requirement listed in the spec sheets for...

  • Page 20: Pivot

    6.2 Pivot When using a 2-actuator haptic system, D-BOX provides a pivot as a third attachment point to ensure proper actuator movement. D-BOX suggests locating the pivot near the center of gravity, to support most weight and allow equal weight distribution on the actuators.

  • Page 21: Shut Down/Stand Still

    7.3 Shut down/Stand Still D-BOX does not offer a built in shutting off for its haptic systems. There is a way to settle the actuator to the ground with software. However, if the shut off must be physical, the best way is to cut the power to the ACM or the USB Controller.

  • Page 22: Troubleshooting Your G3 Haptic System

    Step 2: Reset the specific haptic code settings for the game you are using. If using D-BOX with a software available from the game center, right click on the game line and choose Motion Code settings. In the new...

  • Page 23: Initial Troubleshooting Steps

    Step 3: Verify that the haptic system, KCU-1P and computer are powered on. If you see an orange or red light on the equipment, refer to the LED status tables. Step 4: The G3 ACM does not have a universal voltage input. haptic systems can be ordered 120V or 220V. Make sure your haptic system suits country voltage.
  • Page 24 NOTE: If the actuators move up and down continuously, there might be a cable or a foreign object preventing the actuators from functioning properly. Step 11: Proceed with a motion & communication test using the D-BOX Control Panel application. Select your KCU device (on the left) then press the ‘’Test’’ button: If the haptic system is moving following the preprogramed pattern, it means the computer can communicate with the haptic system correctly.

  • Page 25: Update Software And Firmware

    8.3 Update Software and Firmware Step 12: Make sure you have the latest version of the D-BOX Motion Core installed on your computer. You can verify which version is currently installed on your computer: Windows Control Panel > Programs >Programs and Features Find an item called “D-BOX Motion Core”...

  • Page 26: Troubleshooting With Kcu-1P Led Status

    The device is operational and receiving haptic data (or silence data). NOTE: One (1) KCU-1P can provide the haptic signal for a maximum of twenty (20) daisy-chained ACM G3 If the LED stays off or red, contact D-BOX Customer Support.

  • Page 27: Troubleshooting With Acm Led Status

    8.5 Troubleshooting with ACM LED Status This section covers the status LEDs located on your ACM. There are two LED sections. Power LED ACM Mode Actuator Status Actuator Fault Signal LED KC Command POWER STATUS SOLUTION STATUS ACM not powered Make sure your ACM fits your country voltage.
  • Page 28 Green No fault Actuator fault. The unit will reinitialize by itself Make sure there is no foreign objects Actuator after a few minutes. blocking the actuators. Orange Fault A delay of 30 sec before the system tries to recover See System Monitor for more details. Actuator fault.

  • Page 29: Troubleshooting With D-Box System Monitor

    8.6 Troubleshooting with D-BOX System Monitor The D-BOX System Monitor software gives you the ability to test and diagnostic your haptic system. The software is accessible from your Windows program menu under the D-BOX software: Taking screenshot will help support with resolving your issues.
  • Page 30 Connections Tab: Displays the status for each component of your haptic system. All dots should be green. A red indicator means faulty component. Go to the Detail Tab to investigate further. Dots shows the status of the D-BOX equipment. Red dots indicate a failure.

  • Page 31: Faults And Corrective Actions

    Make sure to follow these safety rules in the case you need to open the ACM for troubleshooting or to replace an actuator or an ACM: You must ask D-BOX Support authorization prior opening the main cover of an AMC. Opening the main cover of an ACM without formal authorization voids the warranty.
  • Page 32 Command Overrun command was not completed. Fault From System Monitor, check if there is any other fault and This should not be a permanent fault follow the solution recommended. and should clear after a while. If error persists, contact D-BOX Support.
  • Page 33 FAULT CAUSE CORRECTIVE ACTION Do a visual inspection to make sure nothing is blocking the actuator travel. This is a Hard fault; the faulty Power off the haptic system, support the platform to gain actuator is immediately access to the actuator piston and pull it out of its body deactivated to prevent damage Critical Actuator Fault slowly until the entire piston is out of the body and than...
  • Page 34 FAULT CAUSE CORRECTIVE ACTION Too high voltage detected. Make sure your system matches your country voltage. High Voltage Rail Overvoltage Fault Make sure you are not connected to a GFI breaker. Voltage from the wall outlet is too high for the haptic system Check the power coming out of the outlet and make sure it respects the specified operating conditions.
  • Page 35 Motor Hall Sensor Will not occur for G3 system. Fault When the position of the Verify that you are running a D-BOX certified haptic code. actuator is over its limits. Should Call D-BOX for validation if necessary. never occur in normal operation Out of bounds Fault conditions.
  • Page 36 Let the system cool down for a while and see if overheated, or the sensor is Temperature High the temperature cools within normal limits. defective. If error persists, contact D-BOX Support This fault is always accompanied Soft Actuator Fault with another fault (called ‘’main Check solution for the main fault.

  • Page 37: Troubleshooting Software Issues (Game Center)

    (on the left) then press the ‘’Test’’ button: Step 3: If you are using a game (not your own simulation software), open D-BOX Game Center and make sure the game is well installed. If the game is not found (as shown below), the default path used by the Game...
  • Page 38 Step 4: Reinstall the motion code or update to the latest version. If the game is on the Game Center, you can check the version of the motion code directly on the Game Center If the game is not on the Game Center, you can check the version here: Go to C:\ProgramData\D- BOX\Gaming\LiveMotion\[GAME NAME]\dbxlive32-64.dll.
  • Page 39 Haptic Code not working / No There was a problem during the and exit. movement installation Install the latest version of the D-BOX Motion Core available on the D-BOX website (Download section). The Haptic Code of the game should be installed where the installer is suggesting.
  • Page 40 Exporting haptic system Logs If the haptic system is still not working properly after updating the firmware and the D-BOX Motion Core software, proceed by exporting the logs of your haptic system. The log file can be exported directly from the D-BOX System Monitor software.

  • Page 41: Removal/Installation Procedures

    9. R EMOVAL NSTALLATION PROCEDURES Please follow instructions below if you need to replace an actuator and/or an ACM. WARNING: USE CAUTION WHEN HANDLING ACTUATOR CABLES AND CONNECTIONS INSIDE THE ACM. THESE EQUIPMENT OPERATE UNDER EXTREMELY HIGH VOLTAGE. SERIOUS INJURY OR DEATH COULD OCCUR IF HANDLED WHILE OPERATING. Make sure to disconnect all ACM power cables and the Cat.5E cable coming from the KCU-1P Controller.
  • Page 42 Align holes on H-plate (2) with holes on housing (1) and align holes on stop (3) with holes on H-plate (2), and then secure with lock washer (4) and bolt (5). Torque bolt (5) to 98 lbf.in. 2. Align holes on end piston adapter with holes on piston end and secure end piston adapter (6) with bolt (7). Torque bolt (7) to 40 lbf.in.
  • Page 43 Installation Place the H-bracket (3) on the end of the piston body (1) with the screw holes aligned. 2. Apply Loctite 243 (blue) thread locker in the four blind holes (2) on the piston body. NOTE: Apply the thread locker just before the bottom of the blind holes. 3.

  • Page 44: Captive Ending

    9.2 Captive ending Some platforms may require the use of an actuator ending that binds the actuator to the floor or a frame. The D-BOX captive ending (ball joint) allows proper actuator movements. The D-BOX captive ending is a 2 components assembly:...
  • Page 45 The thread of the captive endings for each actuator is as follow: Spacer retainer The spacer-retainer allows specific movements of the ball joint on both x and y axes, thus eliminating any constraints during the movement of the platform. There are 3 models of spacer retainer. All spacer retainers can be fitted on any model of ball joint.
  • Page 46 Here are some spacer retainer configurations. 2 actuators and pivot 3 actuators 4 actuators To help with positioning, the spacer retainer is marked OUTWARD on its top surface.
  • Page 47 There is no flat spot for AC218, AC10, AC360. 1.5-inch actuator - AC218 Here are installation instructions for the D-BOX ball joints. Make sure all the parts are clean before installation. CAUTION: Never operate the AC218 actuator without the pivot installed. Operating the AC218...
  • Page 48 Removal Pull the piston out of its body until you can access the flats on both side of the shaft. Position the wrench around the flat spot to hold the piston while performing next step and prevent rotation. Unscrew bolt (4) with the ½ hex key and remove washer (3) and pivot (2) from the actuator (1).
  • Page 49 Apply Threadlocker Loctite 263 to the threaded section of bolts (3) and ball joint (4). Install pivot (2) on actuator (1) with bolts (3). Torque bolts to 50 lbf in. Screw the threaded section of ball joint (4) in the actuator (3).
  • Page 50 Align the holes in the retainers with the holes in the spacer. Use 5/16 bolts to tighten the spacer and retainers to the floor. NOTE: the way the ball joint is anchored to the floor is the same for all actuators – 1.5”, 3”, and 6”. 3-inch actuator –...
  • Page 51 3-inch actuator – AC231 Add Threadlocker Loctite 263 to the threaded section. Screw the threaded section in the actuator (1). Use a torque wrench with a 5/8 crow foot socket to tighten the ball joint assembly (2) in the actuator. Torque to 170 lbf in.
  • Page 52 3-inch actuator – AC231 6-inch actuator - AC360 Pull the piston out of its body until you can access the flats on both side of the shaft. Position the wrench around the flat spot to hold the piston while performing next step and prevent rotation.
  • Page 53 3-inch actuator – AC231 Place spacer (3) at its required location. Make sure the holes in the spacer are aligned with the holes in the floor and place the actuator and ball joint assembly in spacer (3). Slide retainers (4) on spacer (3) and in the slot on the ball joint.

  • Page 54: Actuator Installation/Removal From Acm

    9.3 Actuator Installation/Removal from ACM Removal Remove the screws holding the center ACM cover. Then remove the remaining screws from the actuator cover and gently pull the actuator cover from the ACM. Each actuator is identified by a letter. Each actuator has two cables: a power cable and an signal cable.
  • Page 55 Installation Plug both power and signal cables in the ACM. Install the actuator cover with screw. Install the center ACM cover with screw.

  • Page 56: Mechanic/Motor Replacement

    9.4 Mechanic/Motor replacement This procedure is written for a AC231 (3in) actuator but is valid for all of our actuator family. The following tool will be needed: Hexagonal screwdriver • 3mm (for AC218, AC231) • 4mm (for AC231-Moons', AC360) • 9/64 (for AC7, AC211, AC10) Note: T-handle will ease the procedure Torque wrench Removal of the old mechanic...
  • Page 57 2) Split motor from mechanic. NOTE: Keep the yellow spider on the coupling of the motor. Installation of the new mechanic Install new motor on the mechanic and align the yellow spider correctly. NOTE: Hold anchor with your finger to prevent ballscrew from turning while mating the motor to the housing;...

  • Page 58: Swap Actuator At Acm Port (For Troubleshooting Purposes)

    9.5 Swap actuator at ACM port (for troubleshooting purposes) Remove the screws holding the center ACM cover. Then remove the remaining screws from the actuator cover and gently pull the actuator cover from the ACM. Each actuator is identified by a letter. Each actuator has two cables: a power cable and a signal cable.
  • Page 59 Swap power connectors from A to B and vice-versa. Swap signal connector from A to B and vice-versa. This procedure is meant to isolate an issue with either an ACM or an actuator. Perform the requested tests. Once the test is finalized, depending on the next recommended step, you might need to connect the actuator and close the ACM.
  • Page 60 Risk Assessment Criteria for product certification Risks Description Probability Severity Risk Mitigation Action Internal Risks The weight on an actuator exceeds the limit of the motor (Limit in the Overweight The design should take in consideration the worst model Firmware of the ACM). When an Overweight Fault occurs, the Moderate Minor Fault on a n...

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