Otto Bock A200 Operating instructions
3
Table of Contents Page
1.1 Preface ....................................................................................................................5
1.2 Intended Use ..........................................................................................................5
2.1 Explanation of Symbols ..........................................................................................5
2.2 General Safety Instructions ...................................................................................5
2.3 Safety Instructions for the Use of Tools and Aids..................................................6
2.4 Safety Instructions for Service and Maintenance Tasks........................................7
2.5
Safety Instructions for Maintenance Tasks on Electrical Components ................. 8
2.6 Safety Instructions for Disposal .............................................................................9
3.1 Transportation ......................................................................................................10
3.2 Storage ................................................................................................................. 11
6.1 Inspecting the General Condition ........................................................................ 13
6.2 Batteries / Fuses ..................................................................................................13
6.2.1 Battery Charging ...................................................................................................... 13
6.2.2 Battery Replacement ............................................................................................... 15
6.2.3 Fuse Replacement ................................................................................................... 16
6.2.4 Reinstalling the Battery Cable ................................................................................. 16
6.2.5 Contact Strip Replacement ..................................................................................... 17
6.3 Controller Replacement .......................................................................................18
6.4 Side Panels ..........................................................................................................19
6.4.1 Adapting / Replacing the Side Panels ..................................................................... 19
6.4.2 Replacing the Clothing Protector ........................................................................... 21
6.5 Footrests .............................................................................................................. 21
6.5.1 Adapting / Replacing the Footrests ......................................................................... 21
6.5.2 Replacing the footplate ...........................................................................................25
6.6 Wheels ..................................................................................................................25
6.6.1 Inspecting the General Condition ............................................................................25
6.6.2 Replacing the Casing or Inner Tube of Pneumatic Tyres ........................................26
6.6.3 Replacing the Drive Wheel .......................................................................................26
6.6.4 Replacing the Wheel Flange .................................................................................... 27
6.6.5 Replacing the Steering Caster ................................................................................28
6.6.6 Replacing the Caster Fork .......................................................................................29
6.6.7 Replacing the Anti-Tipper Wheels ............................................................................30
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6.7 Control Panel ........................................................................................................30
6.7.1 VR2 Control Panel ....................................................................................................30
6.7.2 Replacing the Control Panel Holder ........................................................................ 31
6.8 Seats ....................................................................................................................32
6.8.1 Replacing the Bearing Plate ....................................................................................32
6.8.2 Standard Seat: Replacing / Adjusting the Back Upholstery ..................................33
6.8.3 Standard Seat: Replacing the Seat Brackets .........................................................33
6.8.4 Standard Seat: Adjusting the Seat Angle ...............................................................34
6.8.5 Standard Seat: Replacing the Seat Plate ...............................................................34
6.8.6 Standard Seat: Replacing the Seat Frame .............................................................35
6.8.7 Standard Seat: Replacing the Seat Angles .............................................................36
6.8.8 Standard Seat: Replacing / Adjusting the Side Panel Attachment Device ............36
6.8.9 Installing the Contour Seat
6.9 Base Frame ..........................................................................................................38
6.9.1 Replacing the Base Frame.......................................................................................38
6.10 Drive Unit ............................................................................................................38
6.10.1 Replacing the Complete Drive Unit ........................................................................38
6.10.2 Replacing the Drive Motor ......................................................................................39
6.11 Accessories .........................................................................................................40
6.11.1 Retrotting the Mechanical Back Angle Adjustment .............................................40
6.11.2 Attaching the Bowden Cable (for Back Angle Adjustment) ................................... 41
6.11.3 Retrotting the Curb Climbing Assist .....................................................................42
6.11.4 Retrotting the Rear View Mirror ............................................................................43
6.11.5 Installing the Headrest Installation Kit
6.11.6 Retrotting the Lap Belt (Option) ...........................................................................44
6.11.7 Retrotting the Swivelling Control Panel Holder (Option) ..........................................44
6.11.8 Additional Lighting ..................................................................................................45
7.1 Diagnostic Steps ...................................................................................................46
7.2 Diagnosis with Battery Capacity LED Indicator ...................................................46
7.3 Diagnosis Using the Handheld Programming Device (s. also Section 8.3).........48
7.4 Other Errors (not displayed) .................................................................................51
8.1 Overview ...............................................................................................................52
8.2 Installation and Wiring..........................................................................................52
8.3 Programming Tools ..............................................................................................53
8.3.1 Handheld Programming Device ...............................................................................53
8.3.2 PC Programming Device .........................................................................................53
8.4 Programmable Parameters ..................................................................................54
8.4.1 Speed Settings ........................................................................................................54
8.4.2 General Parameter Settings ....................................................................................57
8.4.3 Log Functions ..........................................................................................................58
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1.1 Preface
These service instructions describe all regular maintenance tasks as well as repair and replace-
ment tasks for the A200 from Otto Bock. They include all information required by dealers in or-
der to correct functional and mechanical defects in components of the A200.
The information in these service instructions is essential in order to work on the A200 correctly
and safely. This is why this document, in particular the section “Safety Instructions”, must be
read carefully by all persons working on the A200. This ensures the functionality of the A200 is
fully utilised.
1.2 Intended Use
The A200 power wheelchair is intended for indoor and outdoor individual self-transportation by
persons with limited mobility. The A200 power wheelchair may only be used by persons who
have the required physical and mental capabilities.
Any other use is considered improper use. The manufacturer is not liable for any personal injury
or damage to property resulting from improper use; in such cases, the user has sole liability.
The A200 power wheelchair may only be used by properly trained persons. Training is one
of the prerequisites in order to protect against personal risks and to operate the A200 power
wheelchair safely and properly.
2.1 Explanation of Symbols
Warnings regarding possible risks of severe accident or injury.
Warnings regarding possible risks of accident or injury.
NOTICE Warnings regarding possible technical damage.
Information regarding operation. Information for service personnel.
2.2 General Safety Instructions
Regular maintenance is important. It increases safety and prolongs the service life of the product.
Packaging materials must be kept out of reach of children.
NOTICE
Service and maintenance tasks may only be completed
by skilled specialists. Only original spare parts may be used for all service and maintenance tasks.
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NOTICE
Otto Bock recommends
having the A200 power wheelchair inspected and maintained for functionality and operational safety
by authorised personnel at least once a year. In case of frequent user changes (growing children or
youths) or users with changing clinical pictures, the wheelchair should be inspected, adjusted and
maintained twice a year.
NOTICE
Knowledge of the
service instructions and the instructions for use is essential for proper service.
The service and maintenance instructions must be read carefully before commencing work. The serv-
ice instructions apply in conjunction with the instructions for use and the spare parts catalogue. All
documents must be used together.
All safety instructions contained in these service instructions and all other applicable documents must be
observed and complied with. They must be available to service and maintenance personnel at all times.
NOTICE
The A200 may only be operated in the temperature
range from -25 °C to +50 °C (-13 °F to 122 °F). It must not be operated at temperatures outside this
range.
NOTICE
The maximum load capacity for the A200 power wheelchair is
100 kg / 220 lbs.
Familiarise yourself with the functions of the product. If you are not familiar with the product, read the
instructions for use prior to inspection. The instructions for use are available from the manufacturer
(see overview of all Otto Bock subsidiaries under “Otto Bock Worldwide”). Additional documentation
can be downloaded from the Otto Bock homepage at www.ottobock.de or www.ottobock.com.
2.3 Safety Instructions for the Use of Tools and Aids
When completing the tasks, only use
tools that are suitable for the conditions at the place of work and for which safety and the protection
of health are assured with proper use.
Verify proper functionality before use. In the use of tools and supplies, also consider the ergonomic
relationships between the place of work, tools and supplies, workplace organisation, workow and
tasks; this is particularly important in regards to posture during the use of tools and supplies.
Ensure legally prescribed pro-
tective work clothing is worn.
7
When repair and maintenance tasks must be completed
under raised parts or equipment, ensure suitable precautions are taken to secure the applicable com-
ponents against falling. Equipment used to raise loads must prevent the load from accidentally shifting
in a dangerous manner, dropping in free fall or being accidentally released.
When using lifting platforms, ensure that the A200 power wheelchair is centred on the platform and
no parts such as the anti-tipper project into the danger area.
Hazardous materials may only be kept at the place of work in quan-
tities required for ongoing tasks. Regularly and safely remove waste and residue. Clean up spilled
substances immediately.
2.4 Safety Instructions for Service and Maintenance Tasks
For design reasons, there are pinch points between the seat and
frame of the A200. Special caution is required during all work on the corresponding components.
Note that there is no braking functionality when the
brake is unlocked. The brake must only be unlocked in hazardous situations and for maintenance or
repairs. The corresponding force required for acceleration and deceleration must come from the per-
son pushing.
Once push mode is no longer needed, the brake release lever must be locked immediately.
NOTICE
• The A200 power wheelchair must be turned off and the fuse must be removed for all maintenance
tasks. This does not apply to functional tests of the electrical components.
• Secure the product to prevent it from tipping over or falling, e.g. off the workbench.
• Some components of the power wheelchair, e. g. the batteries, frame, seat and motors, are very
heavy. Hoisting devices of sufcient capacity must be used where applicable.
• Clean / disinfect the product before you start the inspection. Consult the instructions for use regard-
ing product care or product-specic inspection information.
NOTICE
Unsecured screw connections can become
loose while using the product. Secure screws and nuts. The screw connections must be tightened
properly after all installation tasks. Dened torque specications must be followed.
The screws and nuts for many of the screw connections are equipped with thread lock. If you have to
undo such screw connections, the nuts or screws must be replaced with nuts/screws equipped with
new thread lock. If screws or nuts with thread lock are not available, apply a medium-strength liquid
thread lock substance (such as Loctite® 241 or Euro Lock A24.20) to the existing screws.
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NOTICE
During any work on the seat, the padding must be adequately pro-
tected against mechanical and chemical damage. The back rest and seat bottom are ame retardant
but nevertheless ammable. They must not come into contact with open ame or embers.
NOTICE
The A200
may not be cleaned with a jet of water or a pressure washer under any circumstances. A cloth or
sponge may be used for cleaning. Water must not come into direct contact with the motor under any
circumstances.
Check the operating performance of the A200 power wheelchair after cleaning.
The tyres of the A200 power wheelchair contain chemical substances that can react with other chemi-
cal substances (e.g. cleaning agents, acids etc.).
2.5
Safety Instructions for Maintenance Tasks on Electrical Components
Only use a battery charger supplied by Otto Bock which has been tested and approved by Otto Bock
for the respective batteries (observe information on the charger). Failure to do so can result in a bat-
tery explosion and possible impairment of health due to contact with battery acid.
Smoking and open ame are prohibited while working on the battery. Sparks must be avoided.
Explosive gases can develop while the batteries are charging. Observe the safety instructions provided
by the battery manufacturer. Wear protective goggles. Ensure sufcient ventilation when charging the
batteries in an enclosed room.
Drive batteries can supply very large amounts of energy and may arc if they are short-circuited. There-
fore, always disconnect the batteries when working on the motor control or wiring.
NOTICE
• If the driving function is not required, turn off the control unit or jack up the drive wheels in order to
prevent uncontrolled operation through accidental joystick activation.
• Water must not come into direct contact with the electronics or battery during maintenance tasks.
• When attaching plug connections on the controller, ensure the contacts are assigned correctly.
NOTICE
In order to prevent short circuits, always use insulated tools when working
on the batteries.
Prevent deep discharge of the batteries in order to avoid loss of functionality and permanent battery
damage.
Ensure correct polarity is used when connecting the batteries.
NOTICE
Prevent overheating of the charger during the charging proc-
ess. Ensure that the cooling ribs on the back of the device are not covered.
9
The A200 has been tested according to EMC regulations. The following particularities must be ob-
served during operation and communicated to the user:
• The driving characteristics of the A200 can be affected by electromagnetic elds (mobile phones or
other radiating devices). Therefore all mobile devices must be turned off when driving.
• The A200 can generate electromagnetic elds that can cause interference for other devices. There-
fore, turn off the control unit whenever you do not need it.
During extended periods of disuse or shipment of the A200 power wheelchair, remove the fuse from
the battery packs in order to prevent deep discharge of the batteries due to standby consumption.
2.6 Safety Instructions for Disposal
If the power wheelchair is no longer in use, it must be disposed of properly in accordance with national
regulations.
If a wheelchair is to be disposed of, all components and materials of the power wheelchair must be
recycled or disposed of properly.
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Ambient temperature -40 °C to +65 °C (-40 °F to 149 °F)
3.1 Transportation
The A200 power wheelchair must be properly fas-
tened to the transportation vehicle in order to secure it against shifting, e. g. with tensioning straps.
NOTICE
The maximum net weight of the A200 power wheelchair is 66 kg /
145 lbs. Hoisting devices and transportation vehicles used for transportation must have sufcient ca-
pacity.
t is also possible to disassemble the A200 power wheelchair for transportation. To do this, follow the
information given in Section 5.2 of the instructions for use (647G545).
Secure the A200 power wheelchair inside the transportation vehicle, e. g. using tensioning
straps. In order to do so, use the eyebolts at the front and back of the power wheelchair and
the dened mounting points in the transportation vehicle.
Before transporting the power wheelchair, switch off the control unit and engage the brake.
You can reduce the size of the power wheelchair for transportation by folding down the back
rest and removing the side panels and footrests.
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3.2 Storage
If the A200 power wheelchair is not moved for several days, permanent colour changes may occur
where the wheelchair comes into contact with the surface it is standing on. Otto Bock therefore rec-
ommends parking the wheelchair on a suitable surface during extended periods of disuse.
The A200 power wheelchair must be stored in an enclosed area. Remove the fuse; otherwise,
there is a risk of deep discharge.
The storage location must be dry and have sufcient air circulation. There must not be any build-
up of humidity. The A200 power wheelchair must not be subjected to any damaging exterior
inuences, e. g. rain, snow, or strong solar radiation during storage.
Otto Bock recommends storing the A200 power wheelchair with slightly elevated tyre pressure
and using assembly stands or wooden blocks in order to raise the tyres (completely) off the ground
in order to protect them from frost. Regularly rotating the wheels helps to prevent at spots.
Suitable tools and aids for the completion of service tasks are listed below:
❒Suitable tools and aids for the completion of service tasks are listed below:
❒Screwdrivers, blade widths: 2.5 / 3.5 / 5.5 mm
❒Phillips head screwdriver, 2 mm
❒Ring or open-end wrenches, 8 – 24 mm
❒Allen wrenches, 2 – 8 mm
❒Torque wrench
❒Reversible ratchet handle wrench and sockets, 8 – 20 mm
❒Puller
❒Pin punch, Ø 3 mm
❒Hammer, approx. 300 g
❒Plastic hammer
❒Drill bit, 4 / 5 mm + hand drill
❒Plastic tyre mounting lever
❒Inner tube repair kit
❒Side cutting pliers
❒Water pump pliers, gripping width up to 32 mm
❒Liquid thread lock “medium strength”
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Please see Section 7 “Error Diagnosis” for information on the display of error messages using the bat-
tery capacity LED indicator or the handheld programming device / PC software.
The wheelchair functions are displayed on the LED display elds of the control panel:
The LEDs show the battery capacity
(see instructions for use, 647G545).
The LEDs show the currently selected speed level
(from 1 to 5).
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6.1 Inspecting the General Condition
❒Check all safety-related components for corrosion, repair if required and reapply corrosion
protection.
❒Check weld seams.
❒Check tightness of screw connections; replace thread-locking compound if required; ob-
serve dened torque specications; replace defective screws (e.g. in case of corrosion).
❒Check cables for ruptures, signs of wear and proper attachment; replace defective com-
ponents according to the cable layout plan.
❒Check cable connections and plug connections.
6.2 Batteries / Fuses
Smoking and open ame are prohibited while working on the battery. Sparks must be avoided.
Explosive gases can develop while the batteries are charging. Observe the safety instructions provided
by the battery manufacturer. Wear protective goggles. Ensure sufcient ventilation when charging the
batteries in an enclosed room.
Drive batteries can supply very large amounts of energy and may arc if they are short-circuited. There-
fore, always disconnect the batteries when working on the motor control or wiring.
NOTICE
In order to prevent short circuits, always use insulated tools when working
on the batteries.
Prevent deep discharge of the batteries in order to avoid loss of functionality and permanent battery
damage.
Ensure correct polarity is used when connecting the batteries and battery capacity meter.
The A200 power wheelchair comes factory-equipped with two maintenance-free 32 Ah/ 12 V
GEL batteries.
NOTICE
Please note the following when handling the bat-
teries:
• Charge the batteries immediately if only 2 segments of the battery capacity LED indicator are lit.
• During extended periods of disuse, charge the batteries of the A600 power wheelchair weekly.
• Otto Bock assumes no liability for damage caused by deep discharge.
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NOTICE
Please
note the following when using the charger:
• Only use a battery charger supplied by Otto Bock which has been tested and approved by Otto
Bock for the respective batteries (observe information on the charger). Failure to do so can result in
a battery explosion.
• The information on the nameplate of the charger must match the country-specic voltage of the re-
spective power supply network.
• Only use the battery charger within the specied ranges of temperature and humidity.
• Place the rubber feet of the battery charger on a level surface.
• When setting the charger up close to a window, protect it against direct sunlight.
•
Keep the charger from overheating. The vent openings on the back of the charger must not be covered.
• Turn off the control unit during the charging process so that the entire charging current ows to the
battery.
• Avoid dust and dirt. Only clean with a dry cloth.
The remaining battery capacity determines the range of the A200 power wheelchair. The fol-
lowing factors affect the battery capacity:
❒Ambient temperature
❒Age of the batteries
❒Amount of use
❒Charging process
Driving for an extended period of time in the lower range of the battery indicator will result in
deep discharge and therefore battery damage. In addition, there is the risk that the A200 power
wheelchair may stop due to zero battery capacity and put the user in a dangerous situation.
❒Charger intended for use by Otto Bock
1. Turn off the control unit on the power wheelchair.
2. Connect the plug of the battery charger to the charging receptacle on the underside of the
control panel.
3.
Connect the battery charger to a wall socket. The batteries will start charging automatically,
and the current charge status is indicated on the LEDs of the battery charger (see Table 2).
4. When the charging process is complete, disconnect the battery charger from the wall outlet
and from the control panel.
5. Turn on the control unit; the power wheelchair is now ready for operation.
The battery charger indicates the following states:
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All LEDs light up for a moment Once the connection to the mains supply has been established
Yellow LED is lit Battery is charging
Yellow LED ashes Battery is charged to 90 %
Green LED is lit Battery is fully charged; battery charger has changed to trickle
charge
Red LED is lit Incorrect polarity (immediately unplug the battery charger from
the wall outlet and reconnect the cables with correct polarity)
Red LED ashes Error in the course of the characteristic curve; charging time has
been exceeded
The battery charger features a programmed recharging phase. Once a discharged battery is
completely charged (after approximately 8 hours), the battery charger can remain connected
with no risk of overcharging or damaging the battery.
The batteries are to be replaced as complete units (battery packs). Except for battery charging,
they do not require servicing.
1. Undo the lock, hold the battery packs by the handle and pull up to remove them (Fig. 4).
2.
Place the new battery packs back into the drive unit sustainer. Make sure that the red arrows
on the battery packs point in driving direction and that the plug contacts (Fig. 5, item A)
engage with the battery contacts.
3. The locking mechanism should be reengaged to prevent the battery packs from falling out.
16
A
B
The two 60 A fuses are located in the fuse holders on the bottom side of the battery packs
(Fig. 5, item B).
❒Remove the battery pack (see Section 6.2.2).
1. Pull out the fuse on the bottom side.
2. Insert the new fuse into the holder between the contacts on the bottom side of the batter-
ies. Make sure that the fuse is pressed into the centre of the spring contacts and that it is
not at an angle.
NOTICE
Ensure correct polarity is used when connecting the batteries.
❒Side cutting pliers
1. Disconnect the old main battery cable from the contact strip (Fig. 6).
2. Disconnect the old main battery cable from the controller (for connections on the controller,
see Figure 7).
3. Cut the cable ties with side-cutting pliers (Fig. 7, item A).
4. Connect the new battery main cable to the controller and to the contact strip.
5. Apply and tighten new cable ties around the cable and cut off the protruding ends.
Properly reassemble all components upon completion of the work.
17
42
A
31
1 Control device connector
2 Motor 1 connector
3 Motor 2 connector
4 Battery cable connector
The contact strip is used to establish the connection between the battery packs and the main
battery cable. The contact strip needs to be exchanged only for replacement.
❒Separate the frame from the drive unit sustainer (see instructions for use 647G545, Sec-
tion 5.2).
❒Remove the battery packs (see Section 6.2.2).
❒Allen wrench, 6 mm
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6. Disconnect the old main battery cable from the contact strip (Fig. 6).
7. Remove the contact strip and replace, if necessary (Fig. 8).
Properly reassemble all components upon completion of the work.
6.3 Controller Replacement
Ensure correct polarity is used when connecting the cables.
❒Separate the frame from the drive unit sustainer (see instructions for use 647G545, Sec-
tion 5.2).
❒Remove the battery packs (see Section 6.2.2
).
❒Allen wrench, 3 mm
1. Remove the protective cover (Fig. 9, item A).
2. Remove all connectors on the controller.
3. Loosen the two Allen head screws, remove the controller and replace if required.
Properly reassemble all components upon completion of the work.
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42 31A
A
1 Control device connector
2 Motor 1 connector
3 Motor 2 connector
4 Battery connector
6.4 Side Panels
For adjusting the side panel attachment devices (width setting), refer to Section 6.8.7.
A side panel attachment device is located on the left and right sides of the seat frame. The side
panels with arm rests are inserted into these attachment devices. The height and position of the
side panels can be individually adapted to the arm length of the wheelchair user.
❒Allen wrench, 2 mm
1. Loosen the two Allen head screws (Fig. 10, item A).
2. Change the position of the arm rests by moving them forward or backward, or remove and
replace them if required.
1. Loosen the sliding nuts in the C-prole (Fig. 10, item B).
2. Adjust / replace the arm rest and tighten the sliding nuts.
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A
A A B
1. Loosen the set screw at the top of the side panel attachment device.
2. Move the arm rest to the required height.
3. Tighten the set screw.
1. Loosen the wing nut laterally at the bottom of the side panel attachment device.
2. Pull the side panel up and out, and replace if required.
Properly reassemble all components upon completion of the work.
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5
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