SafeGait SG360, Service Manual

Page 1: ...SafeGait 360 Balance and Mobility Trainer Service manual SG360 ISM 004 Rev F ...

Page 2: ...ting Rotary limit switch 24 Actuator Check out Test 26 SafeGait Wiring Diagrams 27 Facility Panel Wiring Diagrams 42 WIFI Ping Test 47 Power Panel Green LED Replacement 49 Version 4 0 1 Software install 51 Data backup 52 CF Card update to Version 3 1 1 53 Kiosk Laptop Tablet V4 0 1 Windows 10 56 Kiosk Laptop Tablet V4 0 1 Windows 8 62 Remote Handheld Android 5 1 68 Remote Handheld Android 6 1 69 R...

Page 3: ...ates at 480 VOLTS Always use caution and wear appropriate PPE Personal Protective Equipment when working near Actuator or Rail when power is applied Failure to comply may result in injury or death WARNING Pinch points areas include the trolley wheels on the rail and the Actuator end stops if installed WARNING when servicing the Actuator after operation the horizontal and vertical drive motors may ...

Page 4: ...rom the kiosk computer exit out of the SafeGait Application by pressing Ctrl Shift Esc This will a launch the Task Manager 2 Click on the file menu and select Run new task 3 In the Create new task window in the open box type explorer exe and press ok ...

Page 5: ...creen at the top Click on the therapist user and a pop up window will appear Select Admin user 5 Enter admin password for kiosk Reference KeePass for site specific password 6 Open VNC viewer on desktop 7 Connect to the service interface using VNC at IP address 10 0 0 2 5900 10 0 0 2 5900 ...

Page 6: ...SG360 ISM 004 REV F 5 8 When prompted for a password enter 123 9 Log in using Service Code 8 followed by the check key ...

Page 7: ...SG360 ISM 004 REV F 6 10 Click on the FACTORY PAGE button 11 To calibrate the load cell click on the LOAD CELL CALIBRATION button ...

Page 8: ... left side The vertical Bias number should change to the Load Raw value and the load in lbs should be 0 zero 14 Re attach the spreader bar and let it hang Wait for any swinging to cease 15 Press the Calibrate Bias button in the HORIZONTAL axis right side The horizontal Bias number should change to the Load Raw value and the load in lbs should be 0 zero ...

Page 9: ...ion is complete the vertical load cell should display a load of 1 2 lbs and the horizontal load cell should display a load of zero Press the HOME PAGE button to complete the recalibration Selecting load cell 1 Login to VNC 2 Click on Factory page ...

Page 10: ...n 4 From select load cell drop down select the load cell that is in the strap management 5 Then press the set button 6 Followed by the reset button 7 Wait for the warm reset to occur then you can login to the VNC and verify the correct load cell has been selected ...

Page 11: ...itched on Any BIOS settings that have been made will remain when the battery is changed with the power turned off stored in nonvolatile EEPROM The date and time must be reset later since this data is lost when the battery is changed The battery should only be replaced by qualified personnel Warning The battery is only permitted to be replaced by a Renata CR2477N battery The use of another battery ...

Page 12: ...wn the unit and follow all lockout tag out procedures 2 Using an insulated screwdriver depress latching tab on inside of covers DANGER Power system down and lock out power panel prior to opening the covers Failure to comply may result in injury or death ...

Page 13: ...ged the latching pins in on either side of the HMI allow HMI to swing down Note starting with Actuator serial number 9101200C 0001 the latching pins are obsolete Loosen and remove the lower screw and nut on both sides of the bracket to allow the HMI to swing down 5 Locate battery on backside of HMI ...

Page 14: ...when inserting the battery Correct Incorrect Insert the new battery with the correct polarity Figure 164 Insert battery Disconnect the power supply to the B R Industrial PC Touch the housing or ground connection in order to discharge any electrostatic charge from your body Remove the cover from the battery compartment and carefully pull out the battery using the removal strip Battery cover Removal...

Page 15: ...360 ISM 004 REV F 14 Replace Trolley Wheel Block Assembly DANGER Power system down and lock out power panel prior to replacing Trolley Wheel Block Assembly Failure to comply may result in injury or death ...

Page 16: ...he windows Admin using the provided password 2 On the desktop open VNC 3 In VNC server line enter 10 0 0 2 if not already displayed in box then click connect 4 If a warning pops up about unencrypted connection click on the continue button if not skip to step 5 ...

Page 17: ...SG360 ISM 004 REV F 16 5 When prompted for a password enter 123 6 Login screen will pop up click on the service code and a keyboard will pop up ...

Page 18: ...SG360 ISM 004 REV F 17 7 Click on service code box enter service code 8 followed by the check mark 8 Then hit the enter key to login to the HMI ...

Page 19: ... ISM 004 REV F 18 9 On the login screen click on the input output button 10 On the input output page push the force button and then turn E stop 1 and E stop 2 Back on 11 Then hit the Force button once again ...

Page 20: ...ible to the Actuator cover Discard 14 Power unit down and lock out tag out power panel 15 Open covers using instructions listed in this manual 16 NOTE If installing a STRAP ASSEMBLY with a serial number of 0917001 or higher removal and replacement of the Strap Management Assembly is not necessary Skip to step 22 17 NOTE starting with Actuator serial number 9101200C 0001 unplug the load cells from ...

Page 21: ... M3 hex key loosen the three bolts in strap management a Note only turn bolts one or two turns or small springs and bolts will fall loose from strap management unit b For access to bolt on front of strap management remove black plastic cap on outside of unit Use a 12 inch extension to reach bolt ...

Page 22: ... it down the strap out of the unit Place the unit on a work surface 22 Remove Drum cover from drum by pulling screws using the 2 5mm Hex Bit 23 Slide drum cover plate on to flex coupling Pull strap and strap pin from drum Remove the remaining strap and pin from unit and discard ...

Page 23: ... through the Strap Management Assembly per the illustration below If necessary use a flexible plastic shim to help thread the strap assembly through the rollers Note Loop should be facing down Pull the strap through until the reference mark is 3 4 inches above the strap guide Install PIN STRAP ATTACHMENT into the small loop on the end of the strap Re install the Cover Slack Detector Guide tighteni...

Page 24: ...ch with the 3mm Hex Bit Two screws are accessible through the opening in the Fuse Panel and the third screw is accessible from under the Drum When properly tightened mark each screw hole with a paint pen 29 Install the Horizontal and Vertical Load Cell connectors to the matching positions on the Signal Conditioning PCB or the load cell extension cables Actuator serial number 9101200C 001 or higher...

Page 25: ...OTE keep tension on the strap when rotating in the negative direction to actuate the slack limit switch Check the strap mark for 3 4 inches above strap management cover plate If incorrect continue to readjust and recheck the down limit switch until set correctly 37 If an adjustment was made perform a cold re start using the service interface system restart Restart type cold restart restart button ...

Page 26: ... limit switch Click and hold the vertical MANUAL POS button to drive the motor in the positive direction until the switch actuates The edge of stitched flap on the strap should be 3 0 5 inches above the strap management cover plate If incorrect continue to readjust and recheck the up limit switch until set correctly 42 When complete tighten cam locking screw and mark with the paint pen Reinstall t...

Page 27: ...s not drop off Insure that actuator is connected to router C Cycle the unit using the hand held kiosk Jog the unit the length of the track to insure there is no binding If end stops are installed insure that unit stops at end stops Cycle strap all the way out and make sure the white up limit measurement mark is visible outside of the units cover Cycle strap all the way up and make sure approximate...

Page 28: ...9 DC Power Continued 30 Vertical Drive Power 31 Horizontal Drive Power 32 Controls Power 33 Control Communication 34 Status Light Control 35 Vertical Drive Control 36 Strap Vertical Limit 37 Horizontal Drive Control 38 Horizontal Limit 39 X87 Controller 40 WIFI Adaptor 41 ...

Page 29: ...SG360 ISM 004 REV F 28 ...

Page 30: ...SG360 ISM 004 REV F 29 ...

Page 31: ...SG360 ISM 004 REV F 30 ...

Page 32: ...SG360 ISM 004 REV F 31 ...

Page 33: ...SG360 ISM 004 REV F 32 ...

Page 34: ...SG360 ISM 004 REV F 33 ...

Page 35: ...SG360 ISM 004 REV F 34 ...

Page 36: ...SG360 ISM 004 REV F 35 ...

Page 37: ...SG360 ISM 004 REV F 36 ...

Page 38: ...SG360 ISM 004 REV F 37 ...

Page 39: ...SG360 ISM 004 REV F 38 ...

Page 40: ...SG360 ISM 004 REV F 39 ...

Page 41: ...SG360 ISM 004 REV F 40 ...

Page 42: ...SG360 ISM 004 REV F 41 ...

Page 43: ...SG360 ISM 004 REV F 42 Facility Panel Wiring Diagram Primary AC Power 43 Power ON 44 E Stop 45 Bus Power Monitoring 46 ...

Page 44: ...SG360 ISM 004 REV F 43 ...

Page 45: ...SG360 ISM 004 REV F 44 ...

Page 46: ...SG360 ISM 004 REV F 45 ...

Page 47: ...SG360 ISM 004 REV F 46 ...

Page 48: ...SG360 ISM 004 REV F 47 WIFI Ping Test 1 Press the Windows key on the key board to Launch the file explorer 2 Type in CMD to the search field to launch an new command prompt ...

Page 49: ...owed by the IP address you wish to ping followed by t 4 This will continues ping the IP address you have chosen 5 10 0 0 1 for the router 6 10 0 0 2 for the WIFI Adaptor 7 10 0 0 52 for the Actuator 8 10 0 0 4 for the handheld 9 To stop the ping press Ctrl C ...

Page 50: ...el door 4 Remove contactors on both sides of the power on button by placing a small flat head screw driver on top of contactor and lifting up contactor will slide up and out 5 From green light LED remove wire 1431 from top of led and 110n from bottom DANGER Power system down and lock out power panel prior to opening the panel door Failure to comply may result in injury or death ...

Page 51: ...SM 004 REV F 50 6 With a small flat head screwdriver pry up on the plastic tab on the top of the LED light will slide back and up 7 Replace led rewire and reconnected contactors to the back side of the button ...

Page 52: ...run as anticipated Required Service Laptop with Android SDK installed USB stick with all necessary update files Actuator Installation Package V3 1 0 Kiosk UI software installer SafeGaitInstaller 4 0 1 msi Handheld UI software installer SafeGait Debug apk version 4 0 1 KeePass file for all passwords associated with the updated system Ethernet cable Compact Flash Card reader if necessary for optiona...

Page 53: ...cripts Backup and Shift Right Click on Backup_Launcher bat Choose Run as different user option and enter username and password for backup user located in KeePass Verify that a backup file has been created in C Gorbel Medical SafeGait Backup this file should have the format SafeGait_YYYYMMDDHHMMSS BAK Start Acronis Backup and select the SG Database Backup task Right click and select Run Check that ...

Page 54: ...e Horizontal RUN time Vertical ON time Vertical RUN time Navigate to Factory Page Load Cell Calibration Write down or take a picture of the load cell bias and load cell coefficient for both axes Horizontal BIAS Horizontal COEF Vertical BIAS Vertical COEF Exit the service interface by clicking tapping on the HOME PAGE button Connect an Ethernet cable from the HMI to the to the tool laptop Navigate ...

Page 55: ...te CF Card Place the card in the compact flash card reader located in with the tool laptop Run the script Create_CF bat This will format the card and install the new software Alternatively use a pre programmed CF card with V3 0 0 already loaded Replace the card in the HMI and power on the actuator Write CF card values Open folder Configuration Values Run the script Config_Param bat read calibratio...

Page 56: ...es successfully close the window copy the file update_vars txt onto a USB stick for safekeeping Upon return place the update_vars txt into the customer specific network location e g S Quality System RECORDS Device History Records SafeGait 360 Customers XXXX Service Software where XXXX is the customer number ...

Page 57: ...s using the administrator admin account Click on the Windows button and type services msc to launch Windows local services Search for SafeGait Admin Service and press Stop the service Do not close the services window Click on the Windows button and type Control Panel to access the control panel ...

Page 58: ...M 004 REV F 57 Under Adjust your computer settings Click on Administrative Tools Under Administrative Tools Click on Internet Information Services IIS Click on the Windows button and type Add or Remove Programs ...

Page 59: ...SG360 ISM 004 REV F 58 Type app name SAFEGAIT 360 BALANCE AND MOBILITY TRAINER ...

Page 60: ...ton on the pop up message that appears Copy the latest Kiosk installer SafeGaitInstaller 4 0 1 msi to the disk and run it Navigate to C Gorbel Medical SafeGait webapi and edit the file Web config Under the connectionStrings node modify the SQL password to match the one in KeePass ...

Page 61: ...ss Navigate to C Gorbel Medical SafeGait bin and open an administrator command prompt Type install bat and press Enter When prompted for credentials username SAFEGAIT PC password Windows login password for the administrator admin account from Keepass You may get an error warning message in the prompt window but this is normal for updates Go back to the main IIS window and re start the server ...

Page 62: ...avigating to https localhost safegait using the kiosk laptop the page should load without error Go back to the services window and re start the SafeGait Admin Service Check that the Windows system time and date are current Clear any unwanted icons off the desktop start screen etc for the therapist user ...

Page 63: ...ing the administrator admin account Click on the Windows button and type services msc to launch Windows local services Search for SafeGait Admin Service and press Stop the service Do not close the services window Click on the Windows button and type IIS to start Internet Information Service ...

Page 64: ...d Features Double click on the SAFEGAIT 360 BALANCE AND MOBILITY TRAINER to remove it Copy the latest Kiosk installer SafeGaitInstaller 4 0 1 msi to the disk anywhere and run it Navigate to C Gorbel Medical SafeGait webapi and edit the file Web config Under the connectionStrings node modify the SQL password to match the one in KeePass ...

Page 65: ...er When prompted for credentials username SAFEGAIT PC password Windows login password for the administrator admin account from Keepass You may get an error warning message in the prompt window but this is normal for updates Go back to the main IIS window and re start the server Verify the SafeGait WebApi has been installed properly by opening Chrome and navigating to https localhost safegait using...

Page 66: ...and type Schedule Tasks in Windows Launch Task Scheduler Under Microsoft Windows Windows Update verify that all tasks are disabled If they are enabled disable them Under Lenovo Verify that all Lenovo scheduled tasks are disabled If they are enabled disable them Check that the Windows system time and date are current ...

Page 67: ...ttom of the screen Open windows explorer and navigate to the folder C Gorbel Medical SafeGait Backup Check if user has access to this folder Navigate to the folder C SafeGait Scripts Check if user has access to this folder If this folder does not exist the scripts folder may also be located in C Temp Scripts If therapist user does not have access to these folders skip the rest of this section and ...

Page 68: ...ght click on the Scripts folder and select Properties Select the Security tab and click Advanced On the next screen click Change Permissions Uncheck Include inheritable permissions from this object s parents On the popup dialog click Add Check replace all child object permissions with inheritable permissions from this object Click Add On the next screen in the box type backup then click on Check N...

Page 69: ...up Connect device to a PC with Android SDK installed via USB cable On PC open Command Prompt and enter the following command adb install path to the SafeGait apk Check to see whether SafeGait application gets installed on the handheld The command prompt should also say Success Click on main screen Click on app drawer Drag SafeGait app on to main screen Turn off Developer Options Go to Settings Dev...

Page 70: ...to a PC with Android SDK installed via USB cable On PC open Command Prompt and enter the following command adb install path to the SafeGait apk Check to see whether SafeGait application gets installed on the handheld The command prompt should also say Success Click on main screen Click on app drawer Drag SafeGait app on to main screen Go to Settings Appplications Applications manager scroll right ...

Page 71: ...Router Firmware update Open a web browser on the kiosk and navigate to 10 0 0 1 Log into Router using the administrator admin account using the passwords found in Keepass On the Netgear genie login page select the advanced tap ...

Page 72: ...n the Administration tab in the left hand column then click on Router Update Click on the Browse and go to Software upgrade Removable disk usb and under Netgear router firmware select V1 0 4 8_10 0 77 chk Click on the upload button ...

Page 73: ...rmware is updated Once the firmware is updated the router will reset you will have to log back in using the admin user and keepass password for the router Once logged in verify that the firmware version has been up dated to V1 0 4 8_10 0 77 in the upper right hand corner ...

Page 74: ... on Use the following IP address to change the laptop s IP address to 10 0 0 200 with subnet 255 255 255 0 Click OK Click Close Click No for Local Network restart box Open the web browser on the Tool Laptop and navigate to the following address http 10 0 0 52 Note the web browser must be Google Chrome v10 or later Mozilla Firefox V3 6 or later or Internet Explorer v9 or later If using Google Chrom...

Page 75: ...SG360 ISM 004 REV F 74 After the device reboots login with the Keepass username and password and insure that the firmware now reflects the latest build ...

Page 76: ...ate Open a web browser and navigate to 10 0 0 152 Log into NAS using the administrator admin account using the passwords found in Keepass Click on control panel on the left side of the screen Click on Update Restore under the control panel menu ...

Page 77: ...SG360 ISM 004 REV F 76 ...

Page 78: ...SG360 ISM 004 REV F 77 Click on Manual DSM update Click the browse button on the pop up window Navigate to the SafeGait thumb drive NAS firmware DSM_RS214_15047 ...

Page 79: ...ng the Actuator from the rail 2 Remove M6x80 screws from horizontal drive 3 Slide pressure drive wheel carriage off of linear bearing 4 Remove springs and washers from assembly 5 Remove 2 DRIVE SPRING BLOCK one on each side of the Friction Wheel Pull 8 LOCKWASHER M5 HIGH COLLAR and 8 SHCS M5X30 ...

Page 80: ...L UPPER ASSEMBLY one on each Drive Guide Block Remove 4 SPRING WHEEL SPACER one on each side of each Guide Wheel Take 2 SHOULDER BOLT 6MM X 12MM and apply 1 drop of Vibra Tite VC 3 threadlocker to each Drag the drop of threadlocker along the length of the thread Set aside and allow to dry a minimum of 10 minutes before using in the assembly 8 Remove 8 SHCS M3X20 and 8 LOCK WASHER HIGH COLLAR M3 ZI...

Page 81: ...Take 1 HORIZONTAL DRIVE CORE ASSEMBLY and place it on the two Drive Linear Carriages closest to the operator Secure with 8 SHCS M3X20 and 8 LOCK WASHER HIGH COLLAR M3 ZINC PLATE Do not fully tighten Slide the Drive Core Assembly up against the edge of the Plate cutout to align the assembly to the previously aligned rails While in this position tighten screws securely using the 2 5mm Hex Bit Slide ...

Page 82: ...and one into the Drive Guide Block Install 1 DIE SPRING 2 LG into the drive spring block Slide the Guide Block towards the Spring Block to trap the Die Spring Repeat the above steps for other side using 3 WASHER LARGE DIAMETER 8 and 1 DIE SPRING 2 LG Do not thread the M6x80 screws into Guide Blocks at this time 14 Install 2 TROLLEY GUIDE WHEEL UPPER ASSEMBLY one into each Drive Guide Block When as...

Page 83: ... of rail 3 Replace clip and tighten M4x6 with M3 Allen key 4 Replace conductor bars WARNING Arc flash is possible during power up after service if the conductor shoes are not installed in the correct conductor bars DANGER Power system down and lock out power panel prior to working on conductor bars or clips Failure to comply may result in injury or death ...

Page 84: ...to remove conductor shoe assembly from bracket 3 Install new shoe assembly on bracket and secure with previously removed screws 4 Install power cables on the back of the shoe NOTE install L1 on the top shoe L2 on the second shoe L3 on the third shoe and GND to the bottom green shoe WARNING Arc flash is possible during power up after service if the conductor shoes are not installed in the correct c...