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Invacare Harrier

1. Invacare Harrier Range Technical Manual CE INTRODUCTION This manual is intended for use by trained and approved Service to repair Invacare UK Limited powered wheelchairs Models covered in this manual are Sufficient trouble shooting information is provided to allow servicing to major component level Brief description of operation and motor construction are included as background information However it is recommended that fault battery charges and motors are returned to Invacare UK Limited for replacement APPLICATION Invacare UK Limited powerchairs enable those who have impaired mobility to lead a full and independent life They are designed to give safe and reliable service when used under normal use as instructed in the wner s Manual Careful use dry storage and regular maintenance will contribute to long and reliable service Prolonged exposure to or operation in harsh weather conditions is not recommended For further application information consult the wner s Manual There are also several adjustments explained in the O wner s Manual SAFETY FEATURES Invacare UK Limited powerchairs have a high level of features designed to increase safety including Electronic dynamic Braking The powerchair will brake the motor and charge the battery automatically when decelerating or going downhill Excessive speed while coasting downhills is therefore prevented and range maximized Fail Safe Solenoid Brakes W
2. 7 bar A joystick Module is fault is indicated Make sure that the joystick is in the rest position before switching on the control system 8 bar A Power Module fault is indicated Make sure that all Power Module connections are secure 9 bar The parking brakes have a bad connection C heck the parking brake and motor connections Make sure the control connections are secure 10 bar An excessive voltage has been applied to the control system This is usually caused by a poor battery connection C heck the battery and Power Module connections If the problem persists after you made the checks described above contact your service agent 19 01 2004 Page 29 of 88 Section harrier Range Technical Manual doc 8 6 Slow or sluggish movement If the wheelchair does not travel at full speed or does not respond quickly enough and the battery condition is good check the maximum speed setting If adjusting the speed setting does not remedy the problem then there may be non hazardous fault 9 0 Battery Gauge The battery gauge is included to let you know how much charge is left in your batteries The best way for you to use the gauge is to learn how it behaves as you drive the wheelchair Like the fuel gauge in a car it is not completely accurate but it will help you avoid running out of fuel The battery gauge works in the following way W hen you switch on the control system the battery gauge shows an estimate of the remaining batter
3. Do not apply lubricant to torsion bush rubber Check for any damage to pins or case Inspect cable and entry into charger C heck fuse rating fitted to plug Samp C heck fuse ratting at rear of charger Inspect plug and lead for damage C heck entry into charger Replace if loose in socket check for contract discolouration Connect the charger plug into the charging socket plug the mains plug into the normally used mains sockets Switch mains supply on and check that the mains or light illuminates The green charging light will come on some Page 71 of 88 Section harrier Range Technical Manual doc second after this Because of the length of time involved in the full charging sequence it is not possible to check the complete charging function Ask the owner whether the charger has been completing its charge programme through to the red charge complete light illuminating 10 Test Run A short test run should now be carried out to test the driving functions of the chair If a kerb climber is fitted this also should be tested Page 72 of 88 19 01 2004 harrier Range T echnical Manual doc DEALER NAME ADDRESS CUSTOMER MR MRS MISS TELNO TYPE OF SERIVCE PERIOD DATE OF SERIVCE PRO DUCT SERIAL NO CO MMENTS RECOMMENDATIONS PARTS REPLACED QTY PART PART NO COST EN GIN EER SERIVCE PROGRAMME 1 UPHLO STERY BACK SEAT ARMPADS SIDE PANELS SAFETY CALF STRAP 2 CONTROL MO
4. Selection this sets all ENGINNER menu parameters to their default values 5 22 Back to root This takes you back to the ROOT menu Page 44 of 88 19 01 2004 harrier Range T echnical Manual doc Section PILOT SERIES POWERCHAIR CONTROLLER 19 01 2004 Page 45 of 88 Section harrier Range Technical Manual doc 1 0 Introduction The operation of the Pilot series of wheelchair controllers is simple and easy to understand The controller incorporates state of the art electronics the result of many years research to provide you with ease of use and a very high level of safety In common with other electronic equipment correct handling and operation of the unit will ensure maximum reliability Please read this user chapter carefully it will help you keep your wheelchair reliable and safe 2 0 General 2 1 Handling Avoid knocking your controller and especially the joystick Be careful not to strike obstacles with the controller or joystick when you drive N ever drop the controller W hen transporting your wheelchair make sure that the controller is well protected Avoid damage to cables 2 2 O perating Conditions Your controller uses industrial grade components throughout ensuring reliable operation in a wide range of conditions However you will improve the reliability of the controller if you keep exposure to extreme conditions to a minimum Do not expose your controller or its components to damp for prolonged periods If
5. Yes Preset Control system Set drive functions to factory preset values Yes Yes Help Mode On line help text Yes Yes Diagnostic Reads fault code from Pilot Yes Yes Soft Reverse Prevents wheels digging in when braking in reverse down a slope Percentage of forward brake rate 25 to 100 1 96 Steps Current Limit Maximum and minimum current outputs 20A to 80A A1 Steps Foldback Temp Reduce current at this temperature 25 C to 70 C then decrease current linearly until shit down temperature is reached 1 C steps Compensation Match motor impedance for precise control 0 to 1 5m Steps Battery Menu Match Tru Charge Display to loom resistance 0 to 25m lm steps Park Brake Trip For Chairs without brakes YES NO Front Drive Select algorithm for front wheel drive YES NO Page 34 of 88 19 01 2004 harrier Range T echnical Manual doc Section Fast Brake Rate Slam braking by pulling 1 Steps joystick in reverse 0 to 100 Soft Stop Controlled braking if YES NO control system switched off whilst driving Inhibit Polarity and latched Low High amp Yes No operation of speed limit input Profiles Set power Module to 12 34 0r 5 operate with drive profiles 1 to 5 Swat Motors Exchanges left and right YES NO motor outputs Brake Voltage Solenoid brake voltage 12 V
6. 2004 harrier Range T echnical Manual doc Section 5 12 Min Turn Accel n 96 Adjusts the minimum value for turn acceleration of the wheelchair It is programmed in increments of 1 96 of the Turn Accel n value This percentage of Trun Accel n value occurs when the controller speed control potentiometer is turned fully anti clockwise For example if Turn Accel n is set at 90 and Min Turn Acceln is set at 50 then when the speed control is turned completely anti clockwise turn acceleration will be 50 x90 45 when the speed control is turned fully clockwise the turn acceleration will be 90 Intermediate positions of the speed control will interpolate linearly between 45 and 90 If Min Turn Accel n is set at 10096 then turn acceleration will not vary as the speed control s setting is changed 5 13 Min Turn Decel n Adjusts the minimum value for turn deceleration of the wheelchair It is programmed in increments of 1 of the Turn D ecel n value This percentage of Turn Decel n value occurs when the controller s speed control potentiometer is turned fully anti clockwise For example if Turn D ecel n is set at 90 an Min Turn Deceln is Set at 50 then when the speed control is turned completely anti clockwise turn deceleration will be 50 x 90245 when the speed control is turned fully clockwise the turn deceleration will be 90 Intermediate positions of the speed control will interpolate linearly between 45 and 90 If min Turn D ecel n set at 10096 t
7. 80 Speed setting 2 3 and 4 will interpolate linearly between 20 and 80 i e turn acceleration values of 35 65 respectively If Min Turn Acc is set at 100 then acceleration will not vary as the speed setting is change Some Power Module may be factory programmed to limit the value of this parameter If you want to set the value outside these limits contact Penny amp Giles 5 18 Min Turn Dec Adjusts the minimum value for turn deceleration of the wheelchair It is programmed in increments of 1 of the Turn D ecel n value This percentage of Turn Decel n value occurs when the joystick Module s Speed setting is at 1 For example if Turn D ecel n is set at 80 and Min Turn Dec is set at 25 then when the speed setting is 1 acceleration will be 25 x80 20 and when the speed setting is 5 the acceleration will be 80 Speed setting 2 3 and 4 will interpolate linearly between 20 and 80 i e turn deceleration values of 35 65 respectively If Min Turn Dec is set at 100 then acceleration will not vary as the speed setting is change 19 01 2004 Page 43 of 88 Section harrier Range Technical Manual doc Some Power Module may be factory programmed to limit the value of this parameter If you want to set the value outside these limits contact Penny amp Giles 5 19 Clear Timer This allows you to reset the timer to 0 hours 5 20 Erase Fault Log This allows you to clear the fault log after a successful repair 5 21 Preset Eng Values
8. Range Technical Manual doc Page 66 of 88 19 01 2004 harrier Range T echnical Manual doc Section 19 01 2004 Page 67 of 88 Section harrier Range Technical Manual doc Page 68 of 88 19 01 2004 harrier Range T echnical Manual doc Section BATTERIES AND BATTERY CHARGING HOW DOES THE CHARGER WORK W hen the battery voltage is low the charger works extra hard to bring up the battery charge As the battery voltage approaches full charge the charger does not work as hard to complete the charging cycle This explains why the charging current drops as it approaches a full charge W hen the battery is fully charged the amperage from the charger is near zero thus when plugged in in charger maintains but not overcharges the battery WHERE DO 1 CHARGE THE BATTERIES Later on in this information there is reference to the way temperature variations can affect the performance of your vehicle when charging the batteries where reasonable practicable ensure that the battery charger is close to the vehicle being charged so that the temperature of the battery charger and batteries are almost compatible For example a vehicle may be outside whilst the battery charger is inside it is possible in this situation that the battery charger will sense the inside temperature whereas the batteries on the vehicle will be at the outside temperature resulting in an overcharged or undercharged situation HOW OFTEN MUST CHARGE THE BATTERIES Many fa
9. The guarantee offered by most battery suppliers cover failures caused by manufacturing defects within a specified period of time The terms of the guarantee do not cover battery premature failures due to high usage rates or misuse It is essential to check that the guarantee period has not expired Sonnenschein batteries are guarantee for 12 months from date of purchase Page 82 of 88 19 01 2004 harrier Range T echnical Manual doc Section 5 Cyclic Life Expectancy of Batteries The number of times that a battery can be charged a discharged before its capacity drops to a specific level is known as its cyclic life C yclic life specifications for batteries are quoted for standard laboratory conditions The actual service life of a battery will depend on many factors such as depth of discharge temperature charging conditions etc etc Battery warranty claims which are found to be a result of cyclic life exhaustion will not be accepted 6 Cyclic Life Factors The most significant factor affecting cyclic life in service is the depth of discharge experienced by the battery The normal limits to battery discharge depth are quoted in the manufacturer s product It is important not to exceed these limits if the best cyclic lifetime is to be achieved To this end it is unwise to allow a battery to continue to discharge when it show signs of being flat D eep discharge of batteries can result from continuing with a discharge after a period of rest w
10. bracket a using four M 5 x 10 pan headed screws Ensure that the screws do not protrude through the upholstery and cause discomfort O ver tightening of these screws will result in damage to the T nit inserts and their purpose becomes ineffective Slot mounting support tube into the bracket adjust to required height and tighten wing screw b Adjust fore and aft position by releasing the horizontal mounting tube using wing screw c and re tightening to the desired position Items 2 and 3 are curved variations of the upholstered pad assembly Refer to recommended instructions on care and maintenance of vinyl materials of the upholstery is showing signs of damage or premature wear Page 14 of 88 19 01 2004 harrier Range T echnical Manual doc Section VINYL UPHOLSTERY CARE AND MAINTENANCE OF VINYL UPHOLSTERY This is the approved recommended care supplied by the material manufacturers To maintain the appearance of PVC coated fabrics they should be cleaned regularly to remove fatty substances in soiling which may reduce their serviceable life A soft cloth and wam soapy water should be used to clean the surface of the material Mild soap flakes are recommended and residual soap removed using cold water The surface should then be dried with clean soft cloth If the dirt is ingrained the surface can be lightly scrubbed with soft brush Solvent cleaners wax polishes strong detergents and patent chemical cleaners should not be use
11. changed Some Power Module may be factory programmed to limit the value of this parameter If you want to set the value outside these limits contact Penny amp Giles 5 16 Min Decel n 96 Adjusts the minimum value for forward and reverse acceleration of the wheelchair It is programmed in increments of 196 of the Deceleration value This percentage of the Deceleration value occurs when the joystick Module speed setting is at 1 For example if Deceleration is set at 80 and Min D ecel n is set at 25 then when speed setting is 1 D eceleration will be 25 X 80220 and when the speed setting is 5 the Deceleration will be 80 Speed settings 2 3 and 4 will interpolate linearly between 20 and 80 i e Deceleration values of 35 50 and 65 respectively If min D ecel n is set at 100 then D eceleration will not vary as the speed setting is changed Some Power Module may be factory programmed to limit the value of this parameter If you want to set the value outside these limits contact Penny amp Giles 5 17 Min Turn Acc 90 Adjusts the minimum value for turn acceleration of the wheelchair It is programmed in increments of 1 of the Turn Accel n value This percentage of Turn Accel n value occurs when the joystick Module s Speed setting is at 1 For example if Turn Accel n is set at 80 and Min Turn Acc is set at 25 then when the speed setting is 1 acceleration will be 25 x80 20 and when the speed setting is 5 the acceleration will be
12. control systems or motors so it should only be used be experts in wheelchair electrical systems 19 01 2004 Page 33 of 88 Section 2 3 PP1 Specifications harrier Range Technical Manual doc FUNCTIONS Acceleration NOTES Vary from 0 or factory set min to 100 or factory set max PPla Un it Steps Unit Steps Deceleration Vary from 0 or factory set min to 100 or factory set max Un it Steps Unit Steps Turn Acceleration Vary from 0 or factory set min to 100 or factory set max Un it Steps Unit Steps Turn Deceleration Vary from 0 or factory set min to 100 or factory set max Un it Steps Unit Steps Forward speed Vary from 0 or factory set min to 100 or factory set max 1 Steps 1 96 Steps Reverse Speed Vary from 0 or factory set min to 100 or factory set max 1 Steps 1 96 Steps Turn Speed Vary from 0 or factory set min to 100 or factory set max 1 96 Steps 1 96 Steps Sleep Timer Period of time before control system goes to sleep 1 to 10 mins 1 min steps 1 min steps Joystick Throw Joystick deflection for full speed 20 to 100 1 96 steps S 96 Steps Steer Correct Veer compensation for mis matched motors 9 to 9 9to 9 Read Timer Displayed hours wheelchair in use Yes Yes Read Fault Log Displayed fault code history Yes
13. diagram It will be necessary to split the wheel rims to replace the FLEXEL puncture proof infill It is of the utmost importance that the five outer bolts and nuts shown as b in the diagram as NOT released until the tyre is fully deflated Repair or replace pneumatic tyres inner tubes by levering the tyre off the wheel rim as on bicycles etc Inflate pneumatic tyres to recommended pressure Min 35psi Max 40psi Min 238 kps Max 272 kpa If the tyre is being inflated with the wheel on the chair ensure the wheels are off the ground during inflation Inflate gradually to ensure even fit around the wheelrim Under inflated tyres will have an effect on the overall range and performance of the vehicle Page 20 of 88 19 01 2004 harrier Range T echnical Manual doc Section 1 0 Introduction The relevant contents of this chapter should be included in the wheelchair operating guide Further copies are available from Penny amp Giles in both written or disk W ord for W indows format Copies should not be made without the express permission of Penny amp Giles The operation of the Pilot wheelchair control system is simple and easy to understand The control system incorporates state of the art electronics the result of many year of research to provide you with ease of use and avery high level of safety In common with other electronic equipment correct handling and operation of the until will ensure maximum reliability 2 0 Gene
14. in your battery properly it will be worth it Remember how long your battery will provide service is quite often a reflection of the care it receives This is how to run in your new battery 1 Fully recharge any new battery prior to your initial use This will bring your battery up to about 88 performance 2 Run your vehicle about the house and garden Do not stray too far until you become accustomed to the controls the feel of the vehicle and break in the batteries 3 Give the batteries another full charge of 8 14 hours and run the vehicle again The batteries will now perform over 90 of their potential 4 After four to five charging cycles the batteries will top off at 100 charge and last for an extended period due to your patience and care in the first few days of operation Page 70 of 88 19 01 2004 harrier Range T echnical Manual doc Section HOW CAN I GET MAXIMUM RANGE OR DISTANCE PER CHARGE Rarely do we have an ideal driving situation such as smooth flat hard terrain with on wind or curves More often we are presented with hills paths cracks uneven and loosely packed surfaces curves and wind All these will affect the distance or running time per battery charge Here are a few suggestions for obtaining the maximum range per charge CO Ui gt 0 Always charge you batteries fully prior to you trip Maintain relevant type pressures as stated in the Technical Specifications Plan your trip in advance to avo
15. ith the control system switched off check that the joystick is not bent or damaged and that it returns to the center when you push and release it If there is a problem do not continue with the safety check and contact your service agent 19 01 2004 Page 27 of 88 Section harrier Range Technical Manual doc 7 2 W eekly Checks Solenoid Parking brake This test should be carried out on a level floor with a least one meter clear space around the wheelchair i Switch on the control system ii Check the battery gauge remains on or flashed slowly after one second iii Push the joystick slowly forwards until you hear the parking brake operate The chair may start to move iv Immediately release the joystick You must be able to hear each parking brake operate within a few seconds v Repeat the test a further three times pushing the joystick slowly backwards left and right Connectors Make sure that all connectors are securely mated Cables Check the condition of all cables and connectors for damage Joystick gaiter C heck the thin rubber gaiter or boot around the base of the joystick shaft for damage or splitting Check visually only do not handle the gaiter Mounting Make sure that all the components of the control system are securely mounted Do not over tighten are securing screws 7 3 Servicing To ensure continued satisfactory service we suggest you have your wheelchair and control system inspected by your s
16. section 3 5 for more details There are two options associated with this function polarity and latching Active low This is the polarity of the input It can be set to yes or no The table below shows the effect of the input on wheelchair speed for the two settings Speed Limit input Inhibit Polarity Low Inhibit Polarity High Resistance active low yes active low no Short circuit Inhibit Speed N ormal Speed 22K 10 Slow Speed Mid Speed 100 10 96 Mid Speed Slow Speed O pen circuit N ormal Speed Inhibit Speed Latched this determines whether the control system trips when an inhibit signal inhibit speed 0 is receive It can be set to yes or no Yes gives atrip condition and the system must be switched off and again to reset No means that drive can be resumed can be resumed as soon as the inhibit signal is removed This setting for inhibit Slow and Mid speed limits are factory programmable if you want to alter these values please contact Penny amp Giles 5 12 Profiles This function can only be used with customer specific joystick Modules which support drive profiles The Pilot generic joystick Modules are not designed to operate with drive profiles Consequently this value should be set to 0 For further information please contract Penny amp Giles 5 13 Swap Motors This swap the motor output connections M1 and M2 on the Power Module N ormally M1 is for the left motor and M2 for the r
17. the ENTER key will store the value displaced on the screen This method can therefore be used to interactively set up the joystick throw the wheelchair user This method can therefore be used to interactively set up the joystick throw with wheelchair user The process is repeated fro joystick reverse left and right positions 4 9 2 Programming Adjustment W hen the ENTER key is pressed the current setting for joystick throw in the forward direction will be displayed O peration of the UP or DOWN keys will change this setting operation of the ENTER key will store the setting The process is repeated for joystick reverse left and right positions 4 10 Steer Correct This factor compensates for any mismatching of motors to ensure that the wheelchair drives directly forward when the control system s joystick is being pushed directly forward It is normally set to zero but may be varied from 9 to 9 in increments of 1 if the chair is veering to the left you should increase the setting if the chair veers to the right decrease the setting If Swap Motors is set this logic will be reversed see section 5 13 4 11 Read Timer The Pilot has a timer which records how long the wheelchair is in use The time runs whenever the joystick is moved away from the center position and stop when the joystick is returned The timer records the number of hours the wheelchair has been in use 4 12 Read Fault Log The Pilot has a fault log faci
18. the control module to see if the manufacturer s seals are intact 3 CASTORS Stem Bearings Check stem bearings for free play and end float Replace upper and lower bearing each side W heel Bearings Rotate wheel and check bearings for excessive play or noise Fork amp Axle Check axle bolts and nuts for tightness Inspect fixing of fork to stem Tyres Inspect for damage or foreign objects Test pressure pneumatic as indicated on tyre wall Replace is excessive wear Page 4 of 88 19 01 2004 harrier Range T echnical Manual doc 4 FRAME Foot Legrests Anti Tip Levers Armests Semi reclining Backs Crossbar C heck Crossbar BATTERIES Batteries Battery Box Junction Box if Fitted Powered actuators Control Main Module Remote MOTORS Mountings Armature Brakes W iring amp Connections Brushes 19 01 2004 Section C heck chrome or paint finish Inspect action of cam lock and fittings Adjust and tighten footrest position C heck hinging of footplates Apply W D40 to moving parts Inspect operation of legrest elevation and calf and movement Check fixings and operation Make sure wheel is in position Replace if missing or damaged Inspect all fittings and scews Ensure arm locates into sockets smoothly Check operation of locking devices Ensure controller moves freely in slide tube C heck for correct position of stop screw Check sidepanels for correct position and wear C heck Fitti
19. the controller becomes contaminated with food or drink clean it off as soon as possible 2 3 Cleaning Clean the controller and joystick with a cloth dampened with washing up liquid mixed with water Be careful when cleaning the joystick N ever use abrasive or spirit based cleaners 3 0 Controls 3 1 Main Power Switch and Power Indicator The main power switch applies power to the controller electronics which in turn supply power to the motors Do not use the main power switch to stop the wheelchair to stop the wheelchair unless there is an emergency If you do you may shorten the life of the wheelchair drive components The battery gauge shows you that the controller is switched on It also indicates the operating status of the wheelchair D etails are given in section 8 Page 46 of 88 19 01 2004 harrier Range T echnical Manual doc Section 19 01 2004 Page 47 of 88 Section harrier Range Technical Manual doc 3 2 Joystick This joystick controls the speed and direction of the wheel chair the further you push the joystick from the rest position The faster your wheelchair will move W hen you release the joystick the brakes are applied auto matically 3 3 Speed Control This control sets the maximum speed the wheelchair Turn the knob clockwise to increase the speed or anti clockwise to decease the speed The speed control is programmable Refer to section 10 for details 4 0 Getting Ready to Drive Check that the spe
20. time the current limit will be allowed to return to the current limit maximum if demanded This reset period is to allow the motor s sufficient time to cool 19 01 2004 Page 59 of 88 Section harrier Range Technical Manual doc 5 6 Compensation This matches the controllers to different motor types in order to achieve optimal performance and control Penny amp Giles recommend that you set thi value to not more than 70 of the resistance of the motor armature and all cables and connectors to it IMPORTANT never set to greater than 70 Motor manufacturer should be able to supply figures for armature resistance and typical cable and connectors would be about 40m 5 7 Battery Menu 5 7 1 Battery Cable This sets the value of cable and connector resistance between the controller and the batteries The value corresponds to the both the positive and negative paths You can set this between and 255 in steps of 1mQ 5 7 2 Guage Cal This allows further fine calibration of the TruC harge battery gauge This is normally set at the factory and should not need adjustment Please contact Penny amp Giles if you are considering altering this factor 5 7 3 Back to E Menu This returns you to the ENGINEER Menu 5 8 Park Brake Trip This tells the controller whether or not to trip if the solenoid brake is disconnected or not fitted You can turn this function on or off IMPROTANT this function should only never
21. up a controller so that it is unsuitable for some users or even some chairs if you need and advice on programming please do not hesitate to contact Penny amp Giles 19 01 2004 Page 55 of 88 Section harrier Range Technical Manual doc 3 0 Using the PP Ib Please read this guide carefully before using the PP1b Programmer Setting parameters to incorrect value could damage controllers and motors and invalidate any warranties In particular Current Limited should never be set to a value than the recommended controller maximum and Park Brake Trip should only be disabled on chairs without brakes 3 1 PP1b Keypad Layout amp Description Page 56 of 88 19 01 2004 harrier Range T echnical Manual doc Section 3 2 Connection The PP1 reacts differently depending on status of the controller when the PP1 in connected i If the controller is on and working simply plug the PP1 into the controller Its ROOT menu will be displayed and the PP1 may be used to change the programming parameters of the controller Provided no engineering functions are altered the chair may be driven with the programmer still attached If any engineering function are altered then the controller will be inhibited from driving until the controller has been turned off and then on ii if the controller is on and a tripped state plug the PP1 in The fault message relating to the trip will automatically be displayed O nce the message has been read you can s
22. 1 is a small hand held unit which can be plugged into your controller to alter the program A PP1 may be included with your wheelchair If a PP1 is not included your wheelchair distributor or service agent or wheelchair manufacture will be able to program your controller for you If you have a PP1 read the PP1 use guide before you use it If you re program your controller make sure that you observe any restrictions given in your wheelchair user manual N ote any changes you make for further reference WANRING Programming should only be conducted by healthcare professional switch in depth knowledge of Penny amp Giles electronic controllers Incorrect programming could result in an unsafe up of a wheelchair for a user Penny amp Giles accept no liability for losses of any kind of the programming of the controller is altered from factory pre set values 11 0 Joystick Knobs The knob fitted to your joystick is suitable for most applications If you would prefer another type there is a range of alternatives please contact your wheelchair distributor or manufactures for advise Do not replace the joystick knob with any unauthorised it may cause hazardous operation 12 0 Servicing All repairs and servicing must be carried out by service personnel O pening or making any unauthorised or modifications to the controllers or its components will invalidate any warranty and may result is hazards to yourself of other people and strictly forbidden
23. BLY ARMREST SUPPO RT ASSEMBLY REPLACEMENT 1 Remove armrest from chair Ref To User Manual 2 Remove panel mounting bracket 1b or 2 by releasing M 8 grub screw 1c 3 End plugs 1d amp 1e may be prised from the tube using a thin blade etc Re assembly is the reverse of the above procedure If suitable gently tap end bungs 1d amp 1e back into position UPHOLSTERED ARMPAD REPLACEMENT ADJUSTMENT The armrest pad can be located on the armrest support assembly to achieve the most sutiable position for the occupant The armrest can also be reversed and crossed over to account for the variations and reductions in width To remove loosen the two M 5 x 35 bolts f fixing the armrest pad to the support tube Tighten to secure Do not overtighten as this will result in the T nut insert becoming ineffective W hen the double panel mounting bracket 2 is fitted to reduce the overall seat width by 40mm crossover the armpads from side to side 19 01 2004 Page 13 of 88 Section harrier Range Technical Manual doc UPHOLSTERED HEADREST ASSEMBLY FITTING Fit the headrest mounting bracket a to the upholstered backrest Locate the four T nut inserts b which are already fitted into the top of the internal plywood former Refer to the above approximate measurements Carefully pierce the vinyl pushing into the T nut insert taking care not to pierce right through the foam into the front of the backrest Attach the mounting
24. N O ID BRAKE LEFT HAND PIN 1 YELLOW PIN 2 MOTOR SU PPLY LIN KED TO PIN 1 PIN 3 RED SMALL SO LEN O ID BRAKE PIN 4 GREEN PIN 5 POSITIVE MOTOR SU PPLY LIN KED TO PIN 4 PIN 6 BLACK SMALL SO LEN O ID BRAKE harrier Range Technical Manual doc BEAU SOCKET CONNECTIONS CONNECTORS WIRE COLOUR CONNECTED TO PIN 1 YELLO W N EGTIVE RIGHT HAND MOTOR PIN 2 GREEN STIVE RIGHT HAND MOTOR PIN 3 BROWN N EGTIVE LEF HAND MOTOR PIN 4 BLUE POSITIVE LEFT HAND MOTOR PIN 5 RED LARGE POSITIVE FROM PIN 6 BATTERY LINKED TO PIN 5 PIN 7 BLACK NEGATIVE FROM PIN 8 BATTERY LINKED TO PIN 7 PIN 9 RED SMALL POSTIVE TO BRAKES PLUG amp SOCKET CONNECTIONS MOTOR AND MAIN CONTORL LOOM Page 76 of 88 19 01 2004 harrier Range T echnical Manual doc Section 19 01 2004 Page 77 of 88 Section harrier Range Technical Manual doc Page 78 of 88 19 01 2004 harrier Range T echnical Manual doc Section MOTORS CARBON BRUSH REPLACEMENT 1 Replace carbon brushes as a pair to both motor when thay are worn down to 8mm or less in length 2 Remove retaining caps a withdraw used brush from retainer inspect motor commutator for condition clear out carbon residue 3 Fit new brush into retainer pushing spring down fit retaining cap and tighten Ensure cap thread is not crossed and correctly s
25. Range T echnical Manual doc Section 3 2 Connection To program you can connect the PP1 to the Pilot via the charging socket on the Joystick Module if the system is either or off You can also drive with PP1 connected Please note for safety reasons accessing some critical parameters will cause the control system to trip This is indicated by the TruC harge display rippling up and down This is intentional and the control system can be simply reset by switching off then on again To use the PP1 to view fault codes and messages connect it to the control system when the control system has tripped N ote if a trip occurs when the PP1 is already connected then no diagnostic information will appear If you wish to program but the PP1 is showing diagnostic information press the EN TER key and the PP1 will go into programming mode IMPORTANT When the PPI is connected to the Pilot the electromagnetic compatibility E M C performance of the wheelchair may be affected Disconnect the PP I as soon as programming is complete and do not use in environments which are E M C sensitive 4 0 Root Menu The ROOT Menu which is included in both the PP1a and PP1b contains all the parameters which set the normal drive characteristics of the wheelchair it is also possible to read the fault log and elapsed time Each parameter is explained in the following paragraphs 4 1 Acceleration Adjusts the value for forward and reverse acceleratio
26. The battery gauge work in the following way W hen you switch on the controller the battery gauge shows and estimate of the remaining battery charge The battery gauge gives you a more accurate reading about a minute after you start driving the wheelchair Note W hen you replace worn out batteries fit the type recommended by the wheelchair manufacturer If you use another type the battery gauge may be inaccurate The amount of charge in your batteries depends on a number of factors Including the way you use your wheelchair The temperature of the batteries their age and the way they are made These factors will affect the distance you can travel in your wheelchair All wheelchair batteries will gradually lose their capacity as they age The most important factor that reduces the life of your batteries is the amount of charge you take from the batteries before you recharge them Battery life is also reduced by the number of times you charge and discharge the batteries To make your batteries last longer do not allow them to become completely flat Always recharge your batteries promptly after they are discharged If your battery gauge reading seems to fall more quickly than usual your batteries may be worn out 10 0 Programming If you find that you cannot find a position of the speed control that suits you the controller can be programmed to meet your needs 19 01 2004 Page 51 of 88 Section harrier Range Technical Manual doc The PP
27. UDLES ON OFF DISPLAY OUTPUT W IRING SPEED CONTROL JOYSTICK MOUNTING WARRANTY SEAL 3 CASTORS STEM BEARIN G W HEEL BEARIN GS FORK amp AXLE TYRES PUN CTURE PROOF 4 FRAME FOOT LEG RESTS ANIT TIP W HEELS ARMRESTS SUPPO RTS FOLDING REC BACK CORSS BRACE 5 BATTERIES BATTERIES TERMIN ALS BATTERY BOX BATTERY LEADS MOTOR SOCKETS OUTPUT LEADS 6 MOTORS MOUNTLINGS ARMATURE BRAKES WIRING amp CONNECTIONS BRUSHES 7 FINAL DRIVE DISEN GAGE MECHAN SIM FREEW HEEL D RIVE SHAFT WHEEL RUNOUT RIM TYRES PN EUMATIC 8 KERB CLIMBER 19 01 2004 Section Page 73 of 88 Section harrier Range Technical Manual doc PLEASE PRINT EN GINEERS SIGNATURE CUSTOMERS SIGNATURE DATE FOR OFFICE USE DATE PARTS COST APPRO VED SERVICE TIME 120 MOUNTLIN GS RETURN POSITION RUBBER FEET 9 CHARGER MAINS PLUG CHARGER PLUG CHARGING FUNCTION 10 FUNCTION RUN TEST RUN Page 74 of 88 19 01 2004 harrier Range T echnical Manual doc Section BATTERY BOX ASSEMBLY REAR BATTERIES LID ACEMENT It is advisable to obtain the battery box lid assembly factory wired for safety and reliability The following instructions apply if this is not practical It is of the utmost importance to pay attention to ensuring all connections are tightened correctly 1 2 3 Remove battery box assembly from the chair following instructions in the User Manual Release th
28. W ARN IN G Penny amp Giles accept no liability for losses of any kind arising from unauthorised opening Adjustment or modifications to the Pilot controller Page 52 of 88 19 01 2004 harrier Range T echnical Manual doc Section PILOT SERIES DEGITAL POWERCHAIR CONTROLLER CHAPTER 2 PROGRAMMING 19 01 2004 Page 53 of 88 Section harrier Range Technical Manual doc 1 0 Programming for Wheelchair Controller The main advantage of using programmable controllers is that they can be easily tailored to the specific needs and capabilities of particular wheelchair user while taking into account the safe performance characteristics of the wheelchair being used This means that powered wheelchair configured with Penny amp Giles Pilot controllers can be readily programmed to be safe under normal driving conditions and also feel secure and comfortable to the use The programmable controller achieves this great flexibility be referring to a seat of internal parameters which govern factors such as the wheelchair s speed These parameters can be changed over a wide span to suit different chairs and users a simple hand held programmer 1 1 Important N ote It is possible to set up acontroller so that is unsuitable for users and possibly even some chairs Take care when programming a controller and if you need any advice in programming or selecting values please do not hesitate to contact Penny amp Giles WARNING Programming should only be cond
29. air cannot be pushed by hand with the controller switched off i e no power to the motors 2 Check each brake connection for good contact at motor plug and socket assembly 3 Check each brake s resistance using an ohm meter across the connection contacts Pin 3 amp 6 with the motor plug disconnected from the motor socket at the battery box The resistance reading is between 58R and 60R at room temperature The solenoid brake test applies to both units fitted to either the EMD motor or the Fracmo motor 4 Remove motor brake cap cover take care to feed supply wires through grommet hole without staining cables 5 Remove two screws holding the brake to the motor 6 Ease the brake from the commutator shaft 7 Test the brakes for freedom of movement listen for clicking noise each time the joystick is moved from the central position 8 Check that the brake disc can be moved when the joystick is activated with power on and the disc becomes tight when the joystick is released returned to the central position If the brake fails this test replace it 19 01 2004 Page 81 of 88 Section harrier Range Technical Manual doc ASSESSMENT OF BATTERIES USED IN CYCLE APPICATIONS Introduction A great number of rechargeable lead acid batteries are used in applications where they are routinely discharged and recharged This type of battery usage of known as cyclic use and is typified by such applications as powered golf trolleys and electr
30. arrier Range T echnical Manual doc Section 5 3 Current Limit This sets the maximum and minimum current output for the controller The current output is dependent on the internal temperature of the controller Graph a below shows the relationship Pilot controllers come in two maximum current families 25A and 40A The table below shows the recommended maximum to minimum relationships Max current limit Min current limit 25A 25A 40A 30A You can set the maximum and minimum current outputs between 20A and the maximum permitted upper value in steps of 1A 5 4 Temp Foldback This is the internal controller temperature at which the current output starts to reduce see Graph A The table below shows the maximum value of temperature for each controller type Max current limit Temp Foldback 25A 55 C 40 55 C IMPORTANT the temperature value should never be set to more than the maximum possible for each controller type Doing so well invalidate the warranty and affect the log term reliability of the controller 5 5 Timed Foldback This function allows measure of protection for motors when they get into a stalled condition You can set a Stall Time of between 5 seconds and 10 minute in 5 increments after which time the maximum current limit is reduced to a percentage of the maximum current This percentage Foldback may be set between 25 and 100 of the current maximum in 1 steps After fixed Reset Period of 5 x Stall
31. assembly outlined on the previous page Follow all these instructions where relevant Additional service requirements are to be carried out as necessary A simple check of the compression spring tension and the tightness of the nuts and bolts is recommended periodically Following re assembly ensure the complete unit fits tightly into the mounting lugs N o ratting or looseness should be evident if so check the tightness of the hand wheel s and replace the compression spring 0 Apply a small amount of W D40 to the telescopic stop tubes and central support bracket a b amp c Page 16 of 88 19 01 2004 harrier Range T echnical Manual doc Section FOOTREST HANGER ASSEMBLY as HANGER TUBE ASSEMBLY RELEASE LEVER REPLACEMENT Release lever i may be removed by dismantling the M 5 screw d and nut h take care not to lose the spacers amp g Note their positions i e the stepped one on top The torsion spring f is handed item Re assembly is the reverse procedure of above taking care to fit the correct handed torsion spring f and locate it correctly Tighten the M 5 self lock nut h sufficiently to allow free movement of the release assembly Fit the assembly to the chair ensuring the footrest assembly locks into place Final adjustment can be achieved by gently tapping the locating hinge c up or down Test until the assembly locks correctly Check that correct locking is not restricted by the t
32. charger Check fuse rating fitted to plug Samp Check fuse rating at rear of charger Inspect plug and lead for damage Check entry into charger Replace if loose in socket check for contact discolouration Connect the charger plug into the charging socket plug the mains plug into the normally used mains socket Switch mains supply on and check that the mains on light illuminates The green charging light will come on some seconds after this Because of the length of time involved in the full charging sequence it is not possible to check the complete charging function Ask the owner whether the charger has been completing its charge programme through to the red charge complete light illuminating A short test run should now be carried out to test the driving functions of the chair If a kerb climber is fitted this also should be tested 19 01 2004 harrier Range T echnical Manual doc Section SIDE FRAME REPLACEMENT 1 Dismantle the chair down to the chassis Remove backrest seat battery box assemblies armrests and motor drive wheel assemblies 2 Remove castor wheel assemblies release castor top nut and withdraw castor fork assemblies from bearings 3 Remove backrests mounting brackets 4 Release and remove nuts and bolts at points a b and c Remove cross brace assemblies Follow the instructions for dis assembly as previously described in guidelines for cross brace replacement 5 Re assemble as reverse proce
33. controller s speed control potentiometer is fully clockwise Its value at other settings of the speed control depends on the setting of the Min turn acceleration parameter see later 4 4 Turn Decel n Adjusts the value of forward and turn deceleration of the wheelchair increments of 1 96 This value occurs when the controller s speed control potentiometer is fully clockwise Its value at other settings of the speed control depends on the setting of the Min Turn Deceleration parameter see later 4 5 Forward Speed Adjusts of the minimum and maximum values for forward speed of the wheelchair in increments of 10 T he maximum value occurs when the controller s speed control potentiometer is fully clockwise and the minimum occurs when the speed control potentiometer is fully anti clockwise 19 01 2004 Page 57 of 88 Section harrier Range Technical Manual doc 4 6 Reverse Speed Adjusts of the values for reverse speed of the wheelchair in increments of 10 The maximum value occurs when the controller s speed control potentiometer is fully clockwise The minimum value is automatically scaled in relationship to the forward speed setting and calculated as below Min rev 2 max reverse x min forward max forward 4 7 Turing Speed Adjusts the minimum and maximum values for turning speed of the wheelchair in increments of 1096 The maximum value occurs when the controller s speed control potentiometer is fully clockwise and the minimu
34. ct wiring and attachment to frames Remove brush cover from sides of motors observe position of brush in holder Re locate in same position Run motors with drive disengaged and observe brush contact with armature Blow out carbon deposits W ith wheels raised from the ground engage and disengage final Drive check for positive re engagement of drive Lubricate Revolve wheel assembly with drive disengaged and check for excessive endfloat and bearing wear Revolve wheels checking for excessive tow in and excessive side movement of rims Check for rim damage Check tyres for damage and foreign objects Test pressure pneumatic as indicated on the tyre wall Check kerb climber on its mounting on the chair and cam lock operation O perate forward and return position Ensure climbing foot is clear of the ground in normal parked position Locate the kerb climber to the locating pins check the locating pin is locking the kerb climber into position Lubricate with W D40 Page 3 of 88 Section harrier Range Technical Manual doc 9 CHARGER Mains Plug Check for any damage to pins or case inspect cable and entry into charger Check correct fuse rating 5 amp Jackplug Inpect plug and lead for damage Check entry into charger Charging Function Connect the jackplug into the charging socket plug the mains plug into the normally used mains socket Switch mains supply on and check that the mains on light illuminate The green char
35. ctors come into pay when deciding how often to charge to batteries You may use your vehicle all day on a daily basis or you may not use it for weeks at a time O ther factors such as driver and baggage weight smooth or rough terrain flat areas or inclines and speed must all be considered W ith these variable you should concern yourself with two questions HOW OFTEN should charge and for HOW LONG The charger was so there is no way to overcharge your batteries on a regular basis If you follow the guidelines below your batteries will provide safe and reliable operation IF YOU USE YOUR VEHICLE AT ALL WHITIN DAY put it on the charger as soon as you have finished using it The charger is fully automatic so it will not overcharge your batteries Y our vehicle will be ready each morning to give you a full day s service It is recommended you charge the batteries for 8 14 hours after daily use 2 IF YOU USE YOUR VEHCILE INFREQUENTLY once a week or less You should charge it at least once per week for 12 14 hours REMEMBCER keep your batteries fully charged and avoid deeply discharging your batteries 3 STRONG BATTERIES Batteries should always be stored FULLY CHARGED Check once a month and recharge fully if needed Sealed batteries can hold their charge for approx 6 months If they are left connected in the chair remember key switches meters and accessories can drain the batteries rapidly It is advisable to disconnect the batteries
36. d The use of these substances is likely to be harmful to PVC coated fabrics and repeated use can result in the removal of the plasticiser from the PVC coating which will result in hardening and subsequent cracking of the material s surface The result of these conditions cannot be covered under the standard terms and conditions of the warranty agreement PVC coated fabrics are resistant to most mild acids alkalis and household stains Some substances such as ball point pen ink lipstick newsprint and food colourings may be absorbed by the vinyl and cause permanent staining This can be minimized by immediate cleaning with a damp soapy cloth or sponge Ultra violet light can also reduce the life of the upholstery coating material this is normal ageing process and cannot be covered under the standard terms and conditions of the warranty agreement N ecessary precautions should be taken to guard against periods of long term exposure to ultra violet light During scheduled service and maintenance checks inspect the condition of the upholstery edging to ensure that due to impact damage etc no sharp edges are protruding which may cause injury 19 01 2004 Page 15 of 88 Section harrier Range Technical Manual doc KERB CLIMBER CENTER MOUNT SERVICE AND TORSION REPLACEMENT Remove the assembly following the recommended procedure in the User Manual Instructions for the replacement of the Torsion Bush are identical to the integral Kerb Climber
37. ds of foldback to 25 This means that if the motors are stalled after 15 seconds the current output of the Power Module will reduce to 25 of 80A 20A After 5 x 15s 75s the current output will return to 80A 5 5 Compensation This matches the control system to different motor types in order to achieve optimal performance and control Penny amp Giles recommended that you set this value to not more than 70 amp of the resistance of the motor armature and all cables and connectors to it IMPORTANT never set to greater than 70 Motor manufacturer should be able to supply figures for armature resistance and typical cable and connectors would be about 40m 5 6 Battery Menu 5 6 1 Battery Cable This sets the value of cable and connector resistance between the control system and the batteries The value corresponds to the total resistance in both the positive and negative paths You can set this between and 255m in steps of 1m 5 6 2 Gauge Cal This allows further fine calibration of the TruCharge battery gauge This is normally set at the factory and should not need adjustment Please contact Penny amp Giles if you are considering altering this factor 5 6 3 Back to E Menu This returns you to the EN GIN EER Menu 5 7 Park Brake Trip This tells the control system whether or not to trip if one or both of the solenoid brakes become disconnected or are not fitted You can turn this function on or off IMPORTANT
38. dure ensure all replacement components are securely tightened paying particular attention to the backrest mounting position and security NB There may be variations in the colour shade due to the characteristics of the lacquered paint finish 19 01 2004 Page 7 of 88 Section harrier Range Technical Manual doc CROSS BRACE ASSEMBLIES REPLACEMENT NB RIGHT AND LEFT SIDE IS DETERMINED BY BEING SEATED IN THE CHAIR THE RIGHT HAND CROSS BRACE S THE ONE WHICH HAS ITS LOWER ATTACHED TO THE RIGHT HAND SIDE FRAME 1 Dismantle the chair down to the chassis Refer to Use Manual Remove backrest seat battery box assemblies armrests and motor drive wheel assemblies 2 Remove the four M 5 x 28 bolts and nuts a from lower rail tubes on both sides of the sideframes 3 Remove bottom inner rail tubes b a large round coarse file wedged into the center of the tube will be required Twist and pull to remove 4 Remove the four M 5 x 28 bolts and nuts c from upper seat rail tubes W ithdraw front d and rear e inner seat rail tubes 5 W ithdraw front f and rear g front slide post tubes Check that these tubes slide freely up and down within the slide frame tubes Replace if these tubes bind in any way Apply a small amount of W D 40 to inner tube 6 Remove cross brace assembly from the chair dismantle center bolt spring and nut h Re assembly is the reverse procedure taking care to ensure the nut on the center bolt ha
39. e Inspect wiring and entry to motor brake up Remove brush covers from sides of motors observe position of brush in holder Re locate in same position Run motors with drive disengaged and Page 5 of 88 Section 7 10 FINAL DRIVE Disengage Mechanism Drive Shaft W heel Runout Tyres KERB CLIMBER peration Mounting CHARGER Mains Plug Charger Plug Charging Function TEST RUN Page 6 of 88 harrier Range Technical Manual doc observe brush contact with armature Blow out carbon deposits replace brushed if less than 8mm in length W ith wheels raised from the ground engage and disengage final drive check for positive re engagement of lever Revolve wheel assembly with drive disengaged and check for excessive endfloat and bearing wear Revolve wheels checking for excessive tow in and excessive side movement of rims Check for rim damage Check tyres for damage and foreign objects Test pressure pneumatic as indicated on the tyre wall Replace if treadless CAUTION Split rim wheel Check kerb climber on its mounting on the chair and cam lock operation Apply W D40 operate forward and return position Replace rubber feet if excessively worn Ensure foot is clear of the ground in normal parked position Locate the kerb climber to the locating pins check the locating pins is locking the kerb climber into position Check for any damage to pins or case Inspect cable and entry into
40. e 88 of 88 19 01 2004 INVA INTERNATIONAL Belgium amp Luxemburg Autobaan 4 B 8210 Loppem Danmark Sdr Ringvej 39 DK 2605 Br ndby Deutschland sterreich Switzerland amp East Europe Dehmer Stra e 66 D 32549 Bad Oeynhausen Espa a c Areny s n Poligon Industrial de Celr E 1 7460 Celr Girona France Les Roches F 37230 Fondettes Italia Via dei Pini 62 1 36016 Thiene VI Nederland Celsiusstraat 46 NL 6716 BZ Ede Norge Grensesvingen 9 N 0603 Oslo Portugal Rua Senhora de Campanhd 105 P 4369 001 Porto Sverige amp Suomi Fagerstagatan 9 Box 66 S 163 91 Sp nga United Kingdom amp Eire South Road Bridgend Industrial Estate Bridgend 3PY UK INVACARE PUE
41. e lid retaining screws both sides open lid sufficiently to gain easy access Dis connect battery terminals taking note of wire connections It is advisable to tie the wire together to ensure correct re assembly DO NOT ALLOW TOOLS OR CABLES TO SHORT OUT ACROSS BATTERY TERMINALS RESULT BOOM CARDIAC ARREST Reconnect replacement batteries in the reverse order ensuring the correct cables are fitted to the correct terminals and fully tightened Refer to the circuit diagram if in doubt Lightly grease all terminals with petroleum jelly Vaseline W iring loom assembly can be replaced as a spare part remove two x m 3 screws and nuts Ensure the reinforcing plate and washers are in place tighten sufficiently to achieve a good connection Do not tighten so as to affect the battery box moulding Check the condition of the circuit breaker d ensuring the button locks positively C heck terminal connections are tight and in good condition Replace only with identical value i e 40 amp etc NOTE Do not use Loctite thread locking compounds or similar as under certain circumstance they may affect the ABS box and lid causing cracking 19 01 2004 Page 75 of 88 Section MOTOR SOCKET CONNECTIONS RIGHGT HAND PIN 1 BROWN PIN 2 PO STIVE MOTOR SU PPLY LINKED TO PIN 1 PIN 3 RED SMALL SO LEN O ID BRAKE PIN 4 BLUE MOTOR PIN 5 BRAKE LIN KED TO PIN 4 PIN 6 BLACK SMALL SO LE
42. eated 4 Run the motor for ashort period approx 20 minutes to bed in brushed SOLENOID BRAKE REPLACEMENT 1 Remove the screws b0 securing the brake cover 2 Remove the two socket head screw and spring washers retaining the solenoid brake to the motor and plate 3 Loosen the small socket grub screw d retaining the drive dog into the end of the commutator shaft and gently prise off 4 Cut brake feed wires routed from the Motor Plug lead 5 Fit replacement brake unit in reverse order W hen refitting the drive dog into the shaft push it down completely then pull it back up the shaft approximately 2m to allow clearance when he drive dog spins at motor speed 6 Use the remaining brake leads to pull the feed wires through the sleeving to the motor plug 7 Re solder to existing connections ensuring a good joint The wires are not polarized and can be connected to either contact 8 If alternate method is more practical strip back insulation from wires routed from the motor plug lead Shorten leads from brake unit 5cm strip back insulation twist together each wire Ensure a good solder connection and using silicone Rubber sleeving head resist cover exposed connection to ensure adequate insulation from motor body DO NOT TWIST WIRES TOGETHER AND APPLY INSULATION TAPE A good solder connection is important 9 Test for function is any excessive heat being generated Replace brake cover 19 01 2004 Page 79 of 88 Section harri
43. echnical Manual doc Section JOYSTICK MODULE DETAILS Joystick Module without Lighting Joystick Module with Lighting Controls ON OFF SWITCH BATTERY GAUGE LIGHTS SWITCH AND LED MAXIMUM SPEED INDICATOR LEFT TURN INDICATOR SWITCH AND LED MODE SWITCH RIGHT TURN INDICATOR SWITCH AND LED HORN SWITCH HAZARD W ARNIG SWITCH AND LED 19 01 2004 Page 23 of 88 Section harrier Range Technical Manual doc 3 3 Joystick The joystick controls the speed and direction of the wheelchair The further you push the joystick from the center position the faster the wheelchair will move W hen you release the joystick the brakes are automatically applied 3 4 Maximum Speed indicator This is a gauge that shows the maximum speed setting of the wheelchair There are five speed settings step 1 is the lowest speed and step 5 is the highest speed For details of how change the maximum speed setting see section 3 5 3 5 Mode Switch The mode switch is used a make maximum speed changes and to change between wheelchair operation modes If the mode switch is operated whilst you are driving the maximum speed setting will be increased by one step Each successive operation of the mode switch will increase the setting when the setting is at 5 the next mode switch operation will put the setting to 1 the diagram below explains this action If the mode switch is operated when the joystick is centered the control system operation mode will be change There a
44. ed is turned to a position which suits you Press the main power switch The battery gauge will blink and then turn on after a second Push the joystick to control the speed and direction of the wheelchair Please note that if you push the joystick after you turn on the controller the battery gauge illumination will ripple up and down and the wheelchair will not be allowed to move You must release the joystick to resume normal operation If you do not release the joystick within five seconds the wheelchair will not be able to move even if you release the joystick and push it again The battery gauge will then flash rapidly You can clear this condition by switching the controller off and of again If you do not push the joystick when you switch on the controller and the battery gauge flashes rapidly then there may be a fault Refer to section 8 for details 5 0 Tips for Using Your Controller 5 1 Driving General Make sure that the controller is mounted securely and the joystick position is correct The hand limb you use to operate the joystick be supported for example by the wheelchair arm pad Do not use the joystick as the sole support for your hand or limb W heelchair movements and bumps could upset your control 5 2 Driving Technique The controller interprets your joystick movements and produces appropriate movement of your wheelchair You will need very little concentration to control the wheelchair which is especially useful
45. elchair manufacturers and engineers the PPI takes full advantage of the complete programmability of the Pilot offering functions not available with less sophisticated control system designs The PPI is a menu driven programmer which plugs directly into the Pilot battery charging socket and is available in two configurations suited to different applications 2 1 Basic PP1 Programmer PP1a The most basic programmer version the PP1a is intended for general purpose use It can set all of the key control system speed acceleration and braking characteristics and allows different settings to be tried out while the programmer is still plugged into the control system A context sensitive help function is available to guide users through the menus and the PP1 and display error message from the Pilot control system allowing any problems with the wheelchair electrical system to be identified and corrected quickly In addition the Pilot fault log and elapsed time indicator can read with the PP1a 2 2 Engineering PP1 Programmer PP1b The engineering version the PP1b offers all of the PP1a a features but also includes a suite of advanced functions for designers such as matching the control system to the motor impedance setting maximum drive current and enabling front or rear wheel drive algorithms Clearly the PP1b is a very powerful tool for prototype design work However users who program parameters incorrectly do run the risk of damaging
46. elect the Enter key to display the ROOT menu and being programming the controller iii If the controller if off Plug the PP1 in and it will display a no connection message If the controller is now turned on the PP1 will enter its ROOT menu IMPORTANT When the PPI is connected to the Pilot the electromagnetic compatibility EMC performance of the wheelchair may be affected Disconnect the PPI as soon as programming is complete and do not use the in environment which are EMC sensitive 4 0 Root Menu The ROOT menu contains all the parameters which set the normal drive characteristics of the wheelchair Each parameter is explained in the following paragraphs 4 1 Acceleration Adjusts the value of forward and reverse acceleration of the wheelchair increments of 1 This value occurs when the controller s speed control potentiometer is fully clockwise Its value at other settings of the speed control depends on the setting of the Min Acceleration parameter see later 4 2 Deceleration Adjusts the value of forward and reverse deceleration of the wheelchair increments of 1 96 This value occurs when the controller s speed control potentiometer is fully clockwise Its value at other settings of the speed control depends on the setting of the Min D eceleration parameter see later 4 3 Turn Accel n Adjusts the value of forward and turn deceleration of the wheelchair increments of 1 96 This value occurs when the
47. ent on the under surface of cases b Bulging of battery cases this is usually a sign of overcharging and will be present on all cell is bulged then this could be a defect C Concave battery cases this is usually a sign that the battery has been overcharged at a relatively high temperature O n cooling the valves of the battery will not allow pressure to equalise and sucking in of the casing may result 3 Battery charging A battery which has been incorrectly charged will not be considered for warranty purpose amp for this reason the charging regime integrity should be established The battery requirements is terms of charging voltage and current are specified in the manufacturer s brochures and these requirements will have been considered by the equipment manufacturer It follows that use of other than specified charging equipment will invalidate warranty claims Periodic checking of charging equipment by the equipment supplier is recommended It should be noted that with many charges the indication of charge complete should not be taken as an instruction to terminate the charging process In most cases this indication means that the bulk of the charge has been completed but the battery should be left to complete the final a few percentage points of recharging W ith chargers that feature a float charge facility it is recommended that batteries are left connected to the energised charger until next needed 4 Guarantee Period
48. ented from moving the wheelchair This indicates that there is fault Please follow this procedure i Switch off the controller ii Make sure that all connectors on the wheelchair and the controller are mated securely iii Check the condition of the battery iv if you can t find the problem try using the self help guide give in section 8 4 v Switch on the controller again and try to drive the wheelchair If the safety circuits operate again switch off and do not try to use the wheelchair Contact your service agent 8 4 Self Help Guide If a fault occurs you can find our what has happened by counting the number of bars on the battery gauge that are flashing Here is a list of self help actions Try to user this list before you contact your service agent Go to the number in the list which matches number of flashing bars and follow the instructions bar The battery needs charging or there is a bad connection to the battery C heck the connections to the battery and the check the controller power connector If the connections are good try charging the battery 2 bar The left hand motor has a bad connection Make sure that the motors is connected properly an the controller connectors are secure 3 bar The left hand motor has a short circuit battery connection Contact your service agent 4 bar The right hand motor has a bad connection Make sure that the motor is connected properly and the controller connectors are secu
49. er Range Technical Manual doc MOTORS MOTOR REPLACEMENT The motor supplied as a spare part will come complete with drive shaft key a and hub nut g Motor mounting plate b is a handed item Removal Disconnect motor plug at battery box unit 1 Remove wheel assembly following the applied instructions carefully 2 Prise of end cap if fitted and release hub nut g Pull off wheel hub W heel assembly attached the hub can be removed complete if required 3 Loosen and release the two M 6 x 10 lower mounting countersunk socket and head screws e 4 Holding the weight of the motor loosen and release the two M 6x4 mounting socket head bolts f Note position of the saddle washers d 5 Remove the four M 8x 16 screws retaining the mounting plate to the motor gearbox These screws have been fitted with Loctite 222 and may require additional pressure to release them Re fit replacement motor in reverse order to above Apply a small quantity of Loctite 222 to the motor mounting plate screws Ensure all fixings are tight and secure It is recommended that the new replacement drive shaft key and hub nut are fitted Plugin motor plug ensure retaining clips is functional and test for correct operation Run the Motor for ashort period approximately 20 minutes to clear manufacturers reside and bed in carbon brushes Page 80 of 88 19 01 2004 harrier Range T echnical Manual doc Section SOLENOID BRAKE TEST 1 Check that the ch
50. ervice agent after a period of 1 year from commencement of service Contact your service agent for details when the inspection is due 8 0 Status indication The battery gauge will indicate the status of the control system Please not that a number of supposedly faulty control system returned to us are subsequently found to operate correctly This indicates that many faults are due to the wheelchair problems rather than the control system 8 1 Battery G auge Steady This indicates that all is well 8 2 Battery Gauge flashes slowly The control system is function correctly but you should charge the battery as soon as possible 8 3 Battery Gauge Blinks O nce Every 2 5 Seconds The control system has gone to sleep because the joystick has not been operated for a period of time This time period depends on the programming of the system To re start switch the system off and on again 8 4 Battery Gauge Flashes Rapidly even with the joystick released The control system safety circuits have operated and the control system has been prevented from moving the wheelchair This indicates that there in not fault Please follow this procedure Page 28 of 88 19 01 2004 harrier Range T echnical Manual doc Section i Switch off the control system ii Make sure that all connectors on the wheelchair and the control system are mated securely iii Check the condition of the battery iv If you can t find the problem try using the self help
51. ever be turned off if there are no solenoid brakes fitted to this function on or off 5 9 Front Drive This selects special front wheel drive control software You can turn this on or off 5 10 Min Accel n Adjusts the minimum value for forward and reverse acceleration of the wheelchair It is programmed in increments of 1 of the Accel n value This percentage of Accel n value occurs when the controller s speed control potentiometer is turned fully anti clockwise For example if Accel n is set at 90 and Min Accel n is set at 50 x 90 45 when the control is turned fully clockwise the acceleration will be 90 Intermediate positions of the speed control will interpolate linearly between 45 and 90 if Min Accel n set at 100 then acceleration will not vary as the speed control s setting is changed 5 11 Min Decel n Adjusts the minimum value for forward and reverse deceleration of the wheelchair It is programmed in increments of 1 of the D ecel n value This percentage of Decel n value occurs when the controller s speed control potentiometer is turned fully anti clockwise For example if D ecel n is set at 90 and Min Accel n is set at 50 x 90245 when the control is turned fully clockwise the deceleration will be 90 Intermediate positions of the speed control will interpolate linearly between 45 and 90 if Min D ecel n set at 10096 then deceleration will not vary as the speed control s setting is changed Page 60 of 88 19 01
52. everse down a slop Percentage of forward brake rate 25 to 40A Set Current Limit Maximum and minimum Yes Yes current outputs 20A to 40A Set Foldback Temp Reduce current at this Yes Yes temperature 25 C to 70 C then decrease current linearly until shut down temperature is reached Set Foldback Time Reduce current 25 to 1 Steps 100 after stall time 5s to 10mins to protect motors Set Compensation Match motor impendence A1 Steps for precise control 0 to 1 Set Battery Menu Match TruC harge display 1 C steps to loom resistance 0 to 255m Set Brake Triple Disablea For chair without brakes 5m Steps Set Front W heel Drive Vary from 0 to 100 lm steps Min Acceleration Vary from 0 to 100 YES NO Min Deceleration Vary from 0 to 100 YES NO Min Turn Acceleration Vary from 0 to 100 1 96 Steps Min Turn D eceleration Vary from 0 to 100 YES NO Erase Fault Log Erase fault code history Low High amp Yes No Preset Engineering Values Set engineering functions 12 34 or 5 to factory preset values 2 4 Important N ote 1 Resetting these parameters to non compatible values could damage controllers and motors and invalidate any warranties Currant Limit should never be set t a value greater than the recommended controller maximum and Brake amp Trip should only be disabled on those chairs without brakes Contact Penny amp Giles if there is the slightest doubt O n a more general note is possible to set
53. for prolonged storage HOW CAN I ENSURE THE MAXIMUM BATTERY LIFE Simply put a fully charged battery is a happy battery A fully charged deep cycle battery will provide reliable performance and extended battery life So keep you batteries fully charged whenever possible Please be warned batteries that are regularly deeply discharged infrequently charged or stored without a full charge may be permanently damaged providing unreliable operation and limited life 19 01 2004 Page 69 of 88 Section harrier Range Technical Manual doc HANDLING BATTERIES Extra care must be taken when handling batteries if you decide to dismantle the vehicle for transportation etc Dropped batteries even from a very small height can lead to these plates and plates touching causing a cell failure Do not leave the charger lead connected to the batteries without the mains supply switched on indicated by only the green LED illuminated on the battery charger In this condition the batteries will slowly discharge Used batteries must not be disposed of by means of a Domestic Refuse Disposal U nit Dustbin etc Please contact your dealer to dispose of used batteries BATTERY WARRANTEIS The batteries fitted to your vehicle are guaranteed against a manufacturing or material defect for 12 months Any battery fault due to a defect in manufacture or mis handling will be obvious within a few weeks of use The batteries are not guaranteed to perform to full capaci
54. ge T echnical Manual doc 5 BATTERIES Battery Box Batteries Junction Box if fitted Powered actuators Control Main Module Remote MOTORS Mountings Armature Brakes W iring amp Connections Brushes FINAL DRIVE D isengage Mechanism Drive Shaft W heel Runout Tyres KERB CLIMBER peration Mounting 19 01 2004 Section hand unit Check backpost mounting brackets for tightness Ensure both sides are in same position Inspect battery box and lid ensure lid is secure Check battery terminals are tight clean and apply silicon grease or petroleum jelly Check mounting of junction box to battery box Inspect wiring harness form junction box to actuator module Inspect drive plug for function and fit Check operation of circuit breaker Check motor socket fittings Check mounting of controller output module to battery box tray Check multi pin connector for fit Make visual inspection of main module for damage Inspect warranty seal Check rear battery tray fittings ensure secure mountings Isnpect motor mountings and fittings Check function of detach facility and securing of release knob Lift rear of chair and mount on blocks W ith the drive engaged run motors return control lever to the central position and O bserve operation of brakes Blow out dust from brake lining Check connections to battery box make sure the latches are holding the sockets and plugs in position inspe
55. ging light will come on some seconds after this Because of the length of time involved in the full charging sequence it is not possible to check the complete charging function As the owner whether the charger has been completing its charge programme through to the red charge complete light illuminating 10 TEST RUN A short test run should now be carried out to test the driving functions of the chair If a kerb climber is fitted this also should be tested RECOMMENDED SERVICE PROCEDURE At 12 18 month period The following schedule should be used in conjunction with the Service Programme Sheet and Technical Manual 1 Upholstery Check seat fittings and screw fasteners on back seat and armpad assemblies and for upholstery wear 2 Control Module O n O ff Switch Press switch down and up several times making sure the display is illuminated and switch is operating smoothly O utput W iring Check the output socket is located into the control module and is secure Visually check output cable for damage or incorrect route through framework Speed Control Inspect speed control knob and fixing O perate speed control making sure output speed of motors is proportional to switch position Joystick Control Visually inspect the control lever knob Shroud and gaiter O perate the joystick through all the driving modes Mounting Make sure module is correctly fitted to armrest C heck position of joystick to customer requirements W arranty Seal Inspect
56. guide given is section 8 5 v Switch on the control system again and try to drive the wheelchair If the safety circuits operate again switch off and do not try to use the wheelchair Contact your service agent 8 5 Self Help Guide If a fault occurs you can find out what has happened by counting the number of bars on the battery gauge that are flashing Here is a list of self help actions Try to use this list before you contact your service agent Go to the number in the list which matches the number of flashing bars and follow the instructions l bar The battery needs charging or there is bad connection to the battery Check the connections to the battery and the check the Power Module battery connector this is the 2 pole connector situate between the two motor connectors If the connections are good try charging the battery 2 bar The left hand motor has a bad connection Make sure that the motor is connected properly and the Power Module connector M1 is secure 3 bar The left hand motor has short circuit to a battery connection Contact your service agent 4 bar The right hand motor has a bad connection Make sure that the motor is connected properly and the Power Module connector M2 is secure 5 bar The right hand motor has a short circuit to a battery connection Contact your service agent 6 bar The battery charger is preventing the control system from driving the wheelchair D isconnect the charger from the wheelchair
57. hen turn deceleration will not vary as the speed control s setting is changed 5 14 Erase Fault Log This allows you to clear the fault log after a successful repair 5 15 Preset Eng Values Selection this seta all EN GIN EERIN G menu parameters to their default values 5 16 Back to root This takes you back to the RO OT menu 19 01 2004 Page 61 of 88 Section harrier Range Technical Manual doc CONTROLLER INTERFACE UNITS SERVICE VARIATIONS These may be fitted to appropriate mounting brackets using two M 5 x10 pan head screws on items 1 2 and 3 Use three M 5x10 pan head screws on item 4 and 2 two M 5x14 countersunk head on item 5 The nine pin Beau plug and socket of item 5 and the Pilot controller will benefit from a light application of an anti seize fluid or compound To ensure good electrical contact prevent corrosion and ease operation when dis mantling etc Check that all plug and socket connections are 100 efficient and that no wires are exposed and showing outside the connector Check joystick gaiter for condition replace if split or damaged Refer to instructions on programming and fault diagnosis and ensure that the power chair is safe to use Page 62 of 88 19 01 2004 harrier Range T echnical Manual doc Section 19 01 2004 Page 63 of 88 Section harrier Range Technical Manual doc Page 64 of 88 19 01 2004 harrier Range T echnical Manual doc Section 19 01 2004 Page 65 of 88 Section harrier
58. hen that battery has apparently recovered or using equipment such as an electric gold trolley as a crutch to assist its user up a slope for instance In hot temperature conditions a battery will be capable of providing significantly more duration time than normal If the battery is allowed to deliver this extra energy then it will driven into deep discharge with consequent cyclic life reduction Batteries are often forced into extremely deep discharge by leaving them connected to electrical consumer circuits when they have been normally discharged Typically the circuits may be indicators or control circuits taking a very small current of a few milliamps Under these conditions it is not unusual for a battery to delivery more than 15096 of its rated capacity with consequent deep discharge penalty Other good examples of over discharging are trying to achieve too many holes or rounds of golf in a day or allowing too few hours for recharging between uses 7 Pre test check W hen assessing batteries returned under guarantee claim by user the supplier should carry out checks on each battery before conducing performance test The physical checks described in 2 should be made and also it should be confirmed that the battery was actually supplied by the organisation i e proof of purchase should be established Purchase date should be within the period of guarantee 8 Voltage tests The open circuit voltage of each battery should be measured u
59. henever the powerchair is stationary or switched off the brakes are automatically applied They operate promptly when the joystick is released and returned to the central position They will reduce roll back on ramps and hills to a minimum The Penny and Giles controller has additional safety features which monitor the electrical function of the powerchair Refer to the section in this manual relevant to theh controller operation WARRANTY W arranty terms and conditions and recommended procedures are outlined in the Technical Service Manual Individually applied warranties are included in the U ser Manual Section harrier Range Technical Manual doc RECOMMENDED SERVICE PROCEDURE At 6 month period The following schedule should be used in conjunction with Service Programme Sheet 1 Upholstery Check seat fittings and screw fasteners on back seat and armpad assemblies and for upholstery wear Control Module O n O ff Switch O utput W iring Speed Control Joystick Control Mounting W arranty Seal CASTORS Stem Bearings W heel Bearings Fork amp Axle Tyres FRAME Foot Legrests Anti Tip Levers Armrests Semi reclining Backs Page 2 of 88 Press switch down and up several times making sure the display is illuminated and switch is operating smoothly C heck the output socket is located into the control module and is secure Visually check output cable for damage or incorrect route through fra
60. ic wheelchairs etc W here a user perceives a reduced performance from the application then it is necessary to determine the reasons for the reduction and where this is found to the battery to assess feasibility of a possible warranty claim This document has been prepared to help manufactures and distributors with the process of assessment of the battery condition 1 Is the batter defective Poor performance may be due to the equipment the battery the battery charger or abusive use and it is necessary to determine which of these is the cause of the problem Bear is mind also that a combination of contributory factors may exist In the absence of special test equipment it may be possible to eliminate some factors by substitution as an example a user of an electric gold caddie experiencing poor performance could consider asking another user to test a support battery with equipment and in this way the caddie itself could be eliminated or confirmed defective A similar method can be used to check the charging equipment 2 Physical Inspection of batteries A battery being considered for possible reduced performance should be inspected for physical damage which could lead to rejection of the claim Points to consider are as follows a Damaged cases any cracking of the casing which allows air into the battery will cause premature failure Such damage is not readily obvious with batteries having non spillable electrolyte and damage could be pres
61. ich govern factors such as the wheelchair s speed acceleration and braking These parameters can be changed over a wide span to suit different wheelchairs and users using a simple hand held programmer Minimum and maximum limits can be applied to these parameters thereby ensuring the wheelchair can only be programmed within a certain operating envelope These limits can only be altered with the agreement of the wheelchair manufacturer and Penny amp Giles All programmable values are stored within the Power Module therefore if you change a Joystick Module of ALM there is not need to re program the system 1 1 Important N ote It is possible to set up a control system so that is unsuitable for some users and possibly even some wheelchairs Take care when programming a control system and if you need and advice is programming or selecting values please do not hesitate to contact Penny amp Giles WARNING Programming should only be conducted by healthcare professionals with in depth knowledge of Penny amp Giles electronic control system Incorrect programming could result in an unsafe set up a wheelchair for a user Penny amp Giles accept no liability for losses for any kind if the programming of the control system is altered from pre set values 2 0 PPI Programmer The PP1 is the handheld programmer that Penny amp Giles supply for their Pilot control systems Primarily intended for the specialized design and test requirements of whe
62. id hills cracks and broken or soft surfaces Limit your baggage weight to essential items Try to maintain an even speed to avoid stop and go driving Ensure recommended routine servicing of the vehicles components i e motors brakes electrical connections etc is carried out 7 Final Drive Disengage Mechanism Drive Shaft Wheel Runout Tyres 8 Kerb Climber Operation Mounting 9 Charger Mains Plug Charger Plug Charging Function 19 01 2004 W ith wheels raised from the ground engage and disengage final drive check for positive re engagement of lever Lubricate mechanism Revolve wheel assembly with drive disengaged and check for excessive endfloat and bearing wear Check hub locating screw is secure Revolve wheels checking for excessive tow in and excessive side movement of rims C heck for rim damage C heck hub cap security Check tyres for damage and foreign objects Test pressure pneumatics as indicated on the tyre wall Replace if treadles CAUTION Split rim wheel C heck kerb climber on its mounting on the chair and cam lock operation Apply W D 40 perate forward and parked position C heck torsion bush retains tension and rubber feet clear swivelling castors Replace rubber feet Locate the kerb climber to the locating pins check the spring loaded latches are locking the kerb climber into position Apply Molyslip C opper Eze to swivel point metal casing of torsion bush
63. if you are inexperienced O ne popular technique is to simply point the joystick in the direction you want to go The wheelchair will home in on the direction you push the joystick The further you push joystick away from the rest position the faster the wheelchair will go The intelligent speed control system minimises the effect of the slopes and different types of terrain 6 0 Precautions for Use Note In the event of the wheelchair moving in an unexpected way release the joystick This action will stop the wheelchair under any circumstances Page 48 of 88 19 01 2004 harrier Range T echnical Manual doc Section 6 1 Hazards Do not drive the wheelchair i Beyond restrictions indicated in your wheelchair user manual for example maximum inclines curb height etc ii In places or on surface where a loss of wheel grip could be hazardous for example on wet grassy slopes iii If you know that the controller or other crucial components require repair WARNING Although the Pilot controller is designed to be extremely reliable and each unit is rigorously tested during manufacture the possibility of a system malfunction always exists however small the probability Under some conditions of system malfunction the controller must for safety reasons stop the chair instantaneously If there is any possibility of the user falling out of the chair as a result of a sudden braking action it is imperative that a restraining device such a
64. ight motor You can select between yes and no If set to yes M1 will be for the right motor and M2 for the left motor if set to no the normal condition will apply Page 42 of 88 19 01 2004 harrier Range T echnical Manual doc Section Note if you swap the motor connections the truC harge motor diagnostic information will need to be interpreted differently see chapter 1 section 8 5 The function of Steel Correct will also be reversed See section 4 10 5 14 Brake Voltage This sets the voltage output from the Power Module to the Solenoid brakes you can select either 12V or 24v W ARN ING It is essential that the control system is programmed for the correct brake voltage If it is not damage may occur to the brakes or drive performance of the wheelchair may be affected 5 15 Min Accel n Adjusts the minimum value for forward and reverse acceleration of the wheelchair It is programmed in increments of 196 of the Acceleration value This percentage of the Acceleration value occurs when the joystick Module speed setting is at 1 For example if Acceleration is set at 80 and Min Accel n is set at 25 then when speed setting is 1 acceleration will be 25 X 80220 and when the speed setting is 5 the acceleration will be 80 Speed settings 2 3 and 4 will interpolate linearly between 20 and 80 i e acceleration values of 35 50 and 65 respectively If min Accel n is set at 100 then acceleration will not vary as the speed setting is
65. lchair on and the battery gauge flashes rapidly then there may be a fault Refer to section 8 4 for details 5 0 Tips for Using Control System 5 1 Driving General Make sure that the control system is mounted securely ad the joystick position is correct The hand or limb you use to operate the joystick should be supported for example by the wheelchair arm pad Do not use the joystick as the sole support for your hand or limb wheelchair movements and bumps could upset your control Page 26 of 88 19 01 2004 harrier Range T echnical Manual doc Section 5 2 Driving Technique The control system interprets your joystick movements and produces appropriate movements of Your wheelchair You will need very little concentration to control the wheelchair which is especially useful if you are inexperienced O ne popular technique is to simply point the joystick in the direction you want to go The wheelchair will home in on the direction you push the joystick The further you push the joystick away from the rest position the faster the wheelchair will go The intelligent speed control system minimizes the effects of slopes and different types of terrain 6 0 Precautions for Use N ote In the event of the wheelchair moving in an unexpected way release the joystick This action will stop the wheelchair under any circumstances 6 1 Hazards Do not drive the wheel chair i Beyond restrictions indicated in your wheelchair user ma
66. lity which store the number of occurrence of the last eight faults This allows you to view the contents The display format is as below 1 Code 2C 00 1 2 Code 3C 00 3 N o more entries This reads line by line as Line 1 fault code 2C00 has occurred once Line 2 fault code 3CC has occurred three times Only two faults types recorded To clear the fault log refer to section 5 21 4 13 Preset Unit Selecting this sets all RO O T menu parameters to their default values These default values are decided between Penny amp Giles and the wheelchair manufacturer 19 01 2004 Page 39 of 88 Section harrier Range Technical Manual doc 5 0 Engineer Menu Selection of this enters the engineering menu and allows you to adjust the technical performance parameters or functions of the control system Each parameter or function is described below 5 1Soft Reverse This sets the reverse braking rate Reverse braking is normally 70 of forward braking to prevent the chair s tendency to topple when stopping in reverse on a gradient You can set the reverse braking between 25 and 100 of forward braking 5 2 Current Limit This sets the maximum and minimum current output for the control system The current output is dependent on the internal temperature of the Power Module Graph A below show the relationship Pilot Power Modules are available two power ratings 50 and 80A The table below shows the recommended maximum t
67. m occurs when the speed control potentiometer is fully anti clockwise 4 8 Read Fault Log The pilot has a fault log facility which stores the number of occurrences of the last eight faults This allows you to view the contents The display format is a below 1 Code 2C00 1 2 Code 3C00 3 No more entries This reads line by line as Line 1 fault code 2 00 has occurred once Line 2 fault code 3C 00 has occurred three times O nly two fault types recorded 4 9 Preset Unit Selecting this sets all ROOT menu parameters to their default values 5 0 Engineering Menu Selection of this enters the engineering menu and allows you to adjust the technical performance parameters of function of the controller Each parameter of function is described below 5 1 Steer Correct This factor compensates for any mismatching of motors to ensure that the wheelchair drives directly forward when controller s joystick is being pushed directly forward It is normally set to zero but may be varied from 9 to 9 in increments of 1 If the chair is veering to the left you should increase the setting of the chair veers to the right decrease the setting 5 2 Soft Reverse This sets the reverse braking rate Reverse braking is normally 70 of forward braking to prevent the chair s tendency to topple when stopping in reverse on a gradient You can set the reverse braking between 25 and 100 of forward braking Page 58 of 88 19 01 2004 h
68. mework Inspect speed control knob and fixing O perate speed control making sure output speed of motors is proportional to switch position Visually inspect the joystick control knob shroud and gaiter O perate the joystick through all the driving modes Make sure control module is correctly fitted to armrest Check position of joystick to customer requirements Inspect the control module to see if the manufacturer s seals are intact C heck stem bearings for free play and end float adjust as necessary Rotate wheel and check bearings for excessive play or noise Check axle bolts and nuts for tightness Inspect fixing of fork to stem Inspect for damage or foreign objects Test pressure pneumatic as indicated or tyre wall C heck chrome or paint finish Inspect action of cam lock and fittings Adjust and tighten footrest position Check hinging of footplates Apply W D40 inspect operation of legrest elevation and calf pad movement C heck fixing and operation Make sure wheel is in position on stop bar Apply W D40 Inspect all fittings and screws Ensure arm locates into sockets smoothly Check operation of locking devices Ensure controller moves freely in slide tube Check for correct position of stop screw Check sidepanels for correct position and wear check fittings and forward folding detachable operation O n powered reclining backs check function and mounting of actuator Inspect cable and 19 01 2004 harrier Ran
69. mit the value of this parameter If you want to set the value to be higher than this limit contact Penny amp Giles 4 7 Turning Speed Adjusts the minimum and maximum value for turning speed of the wheelchair from 0 to 100 in steps of 1 A higher value gives a faster speed The minimum value occurs when the Joystick Module has speed setting 1 selected and the maximum value occurs at speed setting 5 Some Power Modules may be factory programmed to limit the value of this parameter If you want to set the value to be higher than this limit contact Penny amp Giles 4 8 Sleep Timer Sets the period of time before the control system will go to sleep if the joystick is not operated The time can be set between 1 and 10 minutes in steps of 1 minute If the time is set to 0 the system will never go to sleep 4 9 Joystick Throw This allows you to program the control system so that full speed can be reached with a reduced joystick movement throw This is particularly useful for wheelchair user with limti4ed hand or arm movement The adjustment can be made manually or by programming actual values Page 38 of 88 19 01 2004 harrier Range T echnical Manual doc Section 4 9 1 Manual Adjustment when the ENTER key is pressed the current setting for joystick in the forward direction will be Displayed If the joystick in displaced in the forward direction beyond 25 then the actual joystick position will be displaced O peration of
70. n of the wheelchair form 0 to 100 in steps of 1 4 higher value gives faster acceleration This programmed value of acceleration occurs when the Joystick Module has speed setting 5 selected Its value at other settings depends on the value of the Min Accel n parameter see section 5 15 Some Power Modules may be factory programmed to limit the value of this parameter If you want to set the value to be higher than this limit contact Penny amp Giles 4 2 Deceleration Adjusts the value for forward and reverse deceleration or braking of the wheelchair from 0 to 100 in steps of higher value gives faster deceleration This programmed value of deceleration occurs when the Joystick Module has speed setting 5 selected Its value at other settings depends on the value of the Min Decel n parameter see section 5 16 Some Power Modules may be factory programmed to limit the value of this parameter If you want to set the value to be higher than this limit contact Penny amp Giles 4 3 Turn Accel n Adjusts the value for turning acceleration of the wheelchair from 0 to 100 in steps of 1 A higher value gives faster acceleration This programmed value of acceleration occurs when the Joystick Module has speed setting 5 selected Its value at other settings depends on the value of the Min Turn Acc parameter see section 5 17 Some Power Modules may be factory programmed to limit the value of this parameter If you want to set the value
71. nal rate This means that a battery having a nominal capacity of 25 Ah at the C20 rate will only give a 30 Ah if discharged over 100 hours or some 15 Ah if discharged at 1 hour rate This means that the manufacturer s discharge table must be used for evaluating tests 10 Interpretation of test results The rest obtained for each battery may be expressed as a percentage of the specified duration W hen valuating the results is necessary to consider what performance level constitute an acceptable performance It is important to differentiate between acceptable performances based on normal battery again factors and what is expected by the specific users application To illustrate this point consider an electric gold cart application which is particularly demanding A very hilly course for instance It may well be the case that almost 100 amp of the battery capacity is needed for a typical gold round As the battery ages its capacity will gradually reduce and the user may well experience problems when the battery still has 9596 of its nominal capacity available This illustration describes an application where a larger battery would be a better solution Page 84 of 88 19 01 2004 harrier Range T echnical Manual doc Section 19 01 2004 Page 85 of 88 Section harrier Range Technical Manual doc Page 86 of 88 19 01 2004 harrier Range T echnical Manual doc Section 19 01 2004 Page 87 of 88 Section harrier Range Technical Manual doc Pag
72. ngs and forward folding detachable operation O n powered reclining backs check function and mounting actuator inspect cable and hand unit Check backpost mounting brackets for tightness Ensure both sides are in same position Centre fixing is not overtightened Lubricate at hinge points to sideframe using W D40 Check batteries for capacity Replace if below specification Check battery terminals are tight Apply silicon grease or petroleum jelly to terminals Inspect battery box and lid Ensure lid is secure Check mounting of junction box to battery box Inspect wiring harness from junction box to actuator module C heck operation of circuit breaker C heck motor socket fittings Check Mounting of Controller output module to battery box tray Check multi pin connector for fit Make visual inspection of main module for damage Inspect warranty seal Check battery tray fittings ensure secure mountings C heck programme is correct Inspect motor mountings and fittings C heck funtion of detach facility and securing of knob Lubricate sliding contact Life rear of chair and mount on blocks W ith drive engaged run motors return control lever to the central position and observe operation of brakes Blow out dust from brake lining Check connections to battery box make sure the latches are holding the sockets and plugs in position C heck for discolouration and burning of contacts evidence of poor contact replace if burning excessiv
73. nual for example maximum inclines curb height etc ii In places or on surfaces where a loss of wheel grip could be hazardous for exampled on wet grassy slopes iii If you know that the control system or other crucial components require repair W ARNING Although the Pilot control system is designed to be extremely reliable and each unit is rigorously tested during manufacture the possibility of a system malfunction always exists however small the probability Under some condition of system malfunction the control system must for safety reasons stop the chair instantaneously If there is any possibility of the user falling out of the chair as a result of a sudden braking action it is imperative that a restraining device such as seat belt is supplied with the wheelchair and that is in use at all times when the wheelchair is in motion Penny amp Giles accept to no liability for losses of any kind arising from the unexpected stopping the wheelchair or arising from the improper use of the wheelchair or control system 7 0 Safety Checks The electronic circuits in your control system have been designed to be extremely safe and reliable The on board microcomputer carries out safety checks at up 100 times per second To supplement this safety monitoring you should carry out of the following periodic checks If the control system fails any these checks do not use the wheelchair and contact your service agent 7 1 Daily Checks Joystick W
74. o minimum relationship Max Current Limit Min Current Limit 50A 40A 80A 60A You can set the maximum and minimum current outputs between 20A and the maximum permitted upper value in steps of 1A 5 3 Temp Foldback This is the internal Power Module temperature at which the current starts to reduce see Graph A The table below shows the maximum value of temperature for each Power Module type Max Current Limit Temp Foldback 50A 55 80 55 IMPORTAN the temperature value should never be set to than the maximum possible for each control system type Doing so will invalidate the warranty and affect the long term reliability of the control system Page 40 of 88 19 01 2004 harrier Range T echnical Manual doc Section 5 4 Timed Foldback This function allows a measure of protection for motors when they get into a stalled condition You can seta Stall Time of between 5 seconds and 10 minutes in 4 second increments after which time the maximum current limit is reduced to a percentage of the maximum current This percentage Foldback may be set between 25 and 100 of the current limit maximum in 1 steps After a fixed Reset Period of 5 x Stall Time the current limit will be allowed to return to the current limit maximum if demanded This reset period is to allow the motor s sufficient time to cool e g Power Module has current limit of 80A stall time of 15 secon
75. or 24V 12 24v Min Accel n 96 Vary from 0 to 100 1 96 Steps Min Decel n 96 Vary from 0 to 100 1 96 Steps Min Turn Acc Vary from 0 to 100 1 96 Steps Min Turn D ec 96 Vary from 0 to 100 1 Steps Clear Timer Reset elapsed timer Yes No Erase Fault Log Erases fault code history Yes Preset Engineering Values Set engineering to factory Yes preset values 2 4 Important N ote Resetting parameters to non compatible values could damage control systems and motors and invalidate any warranties Current Limit should never be set to a value greater than the values recommended for the Power Module you have and Park Brake Trip should only be disabled on those chairs without solenoid brakes Contact Penny amp Giles if there is the slightest doubt n a more general note is possible to set up a control system so that is unsuitable for some users or even some wheelchairs if you need any advice on programming please do not hesitate to contact Penny amp Giles 3 0 Using the Please read this guide carefully before using the PP1 Programmer Setting parameters to incorrect values could damage control systems and motors and invalidate any warranties In particular C urrent Limit should never be set to a value great than the recommended control system maximum 19 01 2004 Page 35 of 88 Section harrier Range Technical Manual doc 3 1 PP1b Keypad Layout amp Description Page 36 of 88 19 01 2004 harrier
76. pe you fitted to your wheelchair Most of the controls are common to both modules however the lighting turn indicator and hazard warning controls are only included on the Joystick Module with lighting control Each of the controls is explained below 3 1 0 n O ff Switch and Battery G auge The on off switch applies power to the control system electronics which in turn supply power to the wheelchair s motors Do not use the on off power switch to stop the wheelchair unless there is an emergency if you do you may shorten the life of the wheelchair drive components The battery gauge shows you that the wheelchair is switched on It also indicates the operating status of the wheelchair D etails are given in section 8 0 W hen the wheelchair is switched on each of the LEDs on the joystick Module will briefly illuminate if any of the LEDs is not illuminate contact your service agent 3 2 Security Key The security key can be used to lock the wheelchair to prevent unauthorized use To lock the wheelchair it must be switched on the key should then be inserted into and withdrawn from the battery charging socket the wheelchair will not be locked To unlock the wheelchair firstly switch it on the maximum speed indicator will ripple up and down but driving will not be possible the key should now be inserted into and withdrawn from the battery charging socket the wheelchair can no be driven Page 22 of 88 19 01 2004 harrier Range T
77. plug 1b should be fitted with Loctite Screwlock and securely tightened into the cross pin 19 01 2004 Page 11 of 88 Section harrier Range Technical Manual doc ARMREST SUPPORT HEIGHT AND WIDTH ADJUSTMENT HEIGHT ADJUSTMENT The armrest can be pre set for height Select suitable position and fix the self tapping screw f in one of the holes in the vertical support tube Do this for both sides as required The upholstered side panel can also be set to the required height Loosen the slotted grub screw d located in the mounting bracket re tighten at selected position Re locate complete assembly onto the chair and check with occupant for correct position and comfort TRAN SVERSE WIDTH ADJUSTMENT W ith armrest assembly in place release locking lever g and slide the transverse mounting bracket in or out to achieve the desired seat width To remove transverse mounting bracket depress button lock f and withdraw the unit sideways Depending on the width of the chair if may be necessary to carry out this operation to remove the front battery box assembly NOTE Ensure the spring button lock f located on the inside of the horizontal mounting tube of the side frame and locked in position facing upwards Item 3 reduces the width between the side panels by 20mm each side This will reduce the overall sear width by approximately 40mm Page 12 of 88 19 01 2004 harrier Range T echnical Manual doc Section ARMREST SUPPORT ASSEM
78. ps to overcome resistance of retaining pips on the thread which prevents accidental removal 3 Remove M 8 x 30 pan head screw by slackening lock nut and unscrewing from bracket 4 W hen fitting the hand wheel b should be screwed into the lower of the mounting bracket and three indentations punched into the end two threads to prevent complete withdrawal and possible loss 5 The two M 6 x 35 bolts c must be securely tightened when the mounting bracket is assembled to the side frame NOTE It is advisable to fit the complete backrest assembly and check alignment clearances prior to final tightening Page 10 of 88 19 01 2004 harrier Range T echnical Manual doc Section BACKREST SUPPORT ASSEMBLY SINGLE AND COMBINED BACKREST SU PPO RT STANDARD AND SWAN NECK VARIATIONS The backrest support can be folded down or detached for improved portability Refer to the User Manual for this procedure REPLACEMENT Replacement backrest assemblies are supplied complete with handgrips and locating components If the handgrips require replacement cut through with a sharp blade and peel off The replacement handgrip must be secured with a recommended adhesive e g hot glue contact Invacare for guidance If the locating components require replacement follow this procedure Loosen grub screw 1d and tap out locating Cross pin the reinforcing plug can now be removed Replacement re assembly is the reverse procedure Insert reinforcing
79. ral A Pilot control systems comprises of two or three modules Joystick Module Power Module and Actuator and Lighting Module ALM The ALM is only required if the wheelchair if fitted with lights or seat adjustment actuators The diagram below shows the modules and the connections between them 19 01 2004 Page 21 of 88 Section harrier Range Technical Manual doc 21 Handling Avoid knocking your control system and especially the joystick Be careful not to strike obstacle with the control system or joystick when you drive N ever drop the control system W hen transporting your wheelchair make sure that the control system is well protected Avoid damage to cables 2 2 Operating Conditions Your control system uses industrial grade components throughout ensuring reliable operation in a wide range of conditions However you will improve the reliability of the control system if you keep exposure to extreme conditions to a minimum Do not expose your control system or its components to damp for prolonged periods if the control system becomes contaminated with food or drink clean it off as soon as possible 2 3 Cleaning Clean the control system and the joystick with a cloth dampened with diluted detergent Be careful when cleaning the joystick N ever use abrasive or spirit based cleaners 3 0 Controls The Pilot system has two versions of Joystick Module W ith and without lighting control refer to page 1 4 see which ty
80. re Page 50 of 88 19 01 2004 harrier Range T echnical Manual doc Section 5 bar The right hand motor has a short circuit to a battery connection Contact your service agent 6 bar The battery charger is preventing the controller from driving the wheelchair Disconnect the charger from the wheelchair 7 bar A joystick is indicated Make sure that the joystick is in the rest position before switching on the controller 8 bar A controller fault is indicated Make sure the controller connections are secure 9 bar The parking brakes have a bad connection Check the parking brake and motor connections Make sure the controller connections are secure 10 bar An excessive voltage has been applied to the controller This is usually caused by a poor battery connection Check the battery and controller connections 8 5 Slow or Sluggish Movement If the wheelchair does not travel at full speed or does not respond quickly enough and the battery condition is good check the position of the speed control If adjusting the speed control does not remedy the problem then there may be a non hazardous fault Contact your service agent 9 0 Battery Gauge The battery gauge is included to let you know how much charge is left in your batteries The best way for you to use the gauge is to learn how it behaves as you drive the wheelchair Like the fuel gauge in a car it is not completely accurate but it will help you avoid running out of fuel
81. re three modes drive speed adjustment and actuator adjustment The diagram below explains this action Page 24 of 88 19 01 2004 harrier Range T echnical Manual doc Section 3 5 1 Speed adjustment mode when the control system is in this mode the maximum speed indicator will flash The maximum speed can be adjusted by left or right movements of the joystick Left will decrease the speed setting right will increase it Forward or reverse movements of the joystick will take you back into drive mode O perating the mode switch will put the control system back into drive mode or if seat adjustment actuators are fitted actuator adjustment mode 3 5 2 Actuator Adjustment Mode W hen the control system is in this mode the actuator indicator will be illuminated The section of the wheelchair symbol that is illuminated shows the actuator that is selected for adjustment to change the selected actuator move the joystick left or right The make an actuator adjustment move the joystick forwards or backwards O perating the mode switch will put the control system back into drive mode 19 01 2004 Page 25 of 88 Section harrier Range Technical Manual doc 3 6 Horn Switch The horn will sound whilst this switch is depressed 3 7 Lights Switch and LED To turn on the wheelchair s lights operate this switch the associated LED will illuminate 3 8 Right Turn indicator switch and LED To turn on the wheelchair right turn indicator operate thi
82. ring Version PP1b offers all the PP1a features but also includes a suite of advanced functions for designers such a matching the controller to motor impedance setting maximum drive current and enabling front or rear wheel drive algorithms Clearly the PP1b is a very powerful tool for prototype design work However users who program parameters incorrectly do run the risk damaging controllers or motors so is should be used by experts in wheelchair electrical systems Page 54 of 88 19 01 2004 harrier Range T echnical Manual doc 2 3 PP1 Specifications Section FUNCTIONS NOTES PPla Set Acceleration Vary from 0 to 100 Unit Steps Unit Steps Set Deceleration Vary from 0 to 100 Unit Steps Unit Steps Set Turn Acceleration Vary from 0 to 100 Unit Steps Unit Steps Set Turn D eceleration Vary from 0 to 100 Unit Steps Unit Steps Set Forward speed Vary from 0 to 100 1 96 Steps 1 96 Steps Set Reverse Speed Vary from 0 to 100 1 96 Steps 1 96 Steps Set Turn Speed Vary from 0 to 100 1 96 Steps 1 96 Steps Read Fault Log Display fault code history 1 min steps 1 min steps Preset Controller Set drive functions to 1 steps S Steps factory preset values Help Mode On line help test 9 to 9 9to 9 Diagnostics Reads fault code from Pilot Yes Yes Steer Correction Compensate fro Yes Yes mismatched motors Set Soft Reverse Prevents wheels diggingin Yes Yes when braking in r
83. rings if slight adjust locknut a sufficiently to take up free play spin assembly check that it rotates freely Remove dirt and grit etc Follow this procedure Remove nut cap b Hold fork and unscrew the self locking nut a retain W ithdraw assembly downwards from the bearings inspect the fork stem of excessive wear and tightness of fork to stem locking nut d Replace if either is evident Remove bearings h from housing with suitable tool fit replacement bearings by pressing in or gently taping into place Take care not to damage bearings casing Replace fork assembly and fully tighten locking nut a to seat top and bottom bearings Adjust nut a to allow fork assembly to swivel smoothly without free play W heel may be removed from fork by prising off plastic caps e and unscrewing nut from axle bolt withdraw bolt taking care to retain any washers and re fitting as per removal Pneumatic tyres tubes and puncture proof infills can be replaced by dismantling the five nuts and bolts g and separating the two halves of the hub NOTE PNEUMATIC TYRES MUST BE DEFLATED BEFORE FOLLOWING THIS PROCEDURE 19 01 2004 Page 19 of 88 Section harrier Range Technical Manual doc DRIVE WHEEL REMOVAL PROCEDURE FOR FLEXEL PUNCTURE PROOF REPLACEMENT AND PUNCTURE REPAIR CAUTION W HEEL IS SPLIT RIM FOLLOW CAREFULLY RECOMMENDED GUIDELINES Pull off the plastic wheel cover release the five M8 x 20 inner bolts shown as a in the
84. s a seat belt is supplied with the wheelchair and that it is use at all times when the wheelchair is in motion Penny amp Giles accept no liability for losses of any kind arising from the unexpected stopping of the wheelchair or arising from the improper use of the wheelchair or controller 7 0 Safety Checks The electronic circuits in your controller have been designed to be extremely safe and reliable This no board microcomputer carries out safety at up to 100 times per second To supplement this safety monitoring you should carry out the following periodic checks If the control system fails any of these checks do not use the wheelchair and contact your service agent 7 1 Daily Checks Joystick with the controller switched off check that the joystick is not bent of damaged and that is returns to the centre when you push and release it If there is a problem do not continue with the safety check and contact your service agent 7 2 W eekly Checks Parking brake This test should be carried out on level floor with at least one meter clear space around the wheelchair i Switch on the Controller ii Check that the battery gauge remains on or flashes slowly after one second iii Push the joystick slowly forwards until you hear the parking brakes operate The chair may start to move iv Immediately release the joystick You must be able to hear each parking brake operate within a few seconds v Repeat the test a further three
85. s switch the associated LED will flash at the same rate If the LED Flashes rapidly one of the left turn indicator bulbs is defective contact your service agent 3 9 Right Turn Indicator switch and LED To turn on the wheelchair s right turn indicator operate this switch the associated LED will flash at the same rate If the LED flashes rapidly one the right turn indicator bulbs is defective contact your service agent 3 10 Hazard W arning Switch and LED To turn on the wheelchair s hazard warning lamps operate this switch the associated LED will flash at the same rate The left and right turn indicator LED s will also flash 4 0 Getting Ready to Drive perate the on off switch The battery gauge will blink then turn on after a second Check that the maximum speed control is set to a level which suits you Push the joystick to control the speed and direction of the wheelchair Please note that if you push the joystick before or just after you switch the control system on the battery gauge will ripple up and down and the wheelchair will be allowed to move You must release the joystick to resume normal operation If you do not release the joystick within five seconds the wheelchair will not be able to move even if you release the joystick and push it again The battery gauge will then flash rapidly You can reset this condition by switching the control system off and on again If you do not push the joystick as you switch the whee
86. s two clear threads only showing through the nut Do not fully tighten as the articulation between the cross bars is important Page 8 of 88 19 01 2004 harrier Range T echnical Manual doc Section SEAT DEPTH BACK ANGLE ADJUSTMENT SEAT DEPTH ADJUSTMENT Can be adjusted by 35mm Tools required 2 x 10 mm spanners 1 Unscrew and remove bolts and nuts a from the backrest mounting brackets 2 Move the backrest to the extended position Replace the bolts and nuts intothe mounting bracket and sideframe and tighten securely BACKREST ANGLE ADJUSTMENT Can be adjusted from 90deg Rearwards through 12deg Tools required 1 x 13mm spanner medium cross head screw driver 1 Release lock nut b located on the cross headed screw 2 Screw the handwheel c partially out under normal hand pressure 3 Screw the cross headed screw in or out to give the required back angle position Adjust the position of the handwheel as necessary 4 Position the locknut up to the mounting bracket and fully tighten 5 Re adjust the handwheel c fully ensuring the backrest assembly is secure NOTE Each backrest tube must be positioned in the same plane as each other or the backrest wil be twisted 19 01 2004 Page 9 of 88 Section harrier Range Technical Manual doc BACKREST MOUNTING BACKREST MOUNTING BRACKET REPLACEMENT 1 Remove the two M 6 x 35 hex head screws and nuts c holding bracket to side frame 2 Remove hand wheel b using gri
87. sing a DC voltmeter of at least 10 000 ohms per volt sensitivity Batteries having a voltage of less than 1 65 volts per cell 9 9 v for a 12V battery of 4 95 V for a 6V battery should be rejected as being deeply discharged Batteries having more than 2 25 volts per cell 13 5V for a 12V battery or 6 75V for a 6V battery may well have overcharged particularly if case bulging is also apparent these batteries should also be rejected 9 Discharge test Before carrying out discharge performance tests the batteries must be fully charged to ensure full charge state O vernight charging is recommended The nature of the discharge test will depend on what test equipment is available Equipment may consist of simple improvised loads such as lamps and resistors or more sophisticated equipment having constant current or constant power discharge capability 19 01 2004 Page 83 of 88 Section harrier Range Technical Manual doc By reference to the product brochures it may be ascertained how long a specific battery will support a particular load level until a designated voltage level is reached The actual achieved test duration time can be divided by the specification duration time to establish the available capacity as proportion of its specified capacity at the particular discharge rate It should be noted that the actual capacity achieved on test will only be comparable with nominal battery capacity if the discharge rate is the same as the nomi
88. this function should only ever be turned off if there are no solenoid brakes fitted to the wheelchair 5 8 Front Drive This selects special front wheel drive control software You can turn this on or off It is possible for wheelchair manufacturer in conjunction with Penny amp Giles to change toe driving characteristics of the front wheel drive software please contact Penny amp Giles for further details 19 01 2004 Page 41 of 88 Section harrier Range Technical Manual doc 5 9 Fast Brake Rate This sets the declaration for fast braking Fast braking is when the joystick is pulled to the reverse position to effect a faster stop You can set the fast brake rate between 0 and 100 If this value is set lower than the normal Deceleration rate then the latter rate will used 5 10 Soft Stop This selects whether the soft stop facility is enabled Soft stop means that if you switch the control system off whilst driving the wheelchair will steadily decelerate to standstill You can turn this function on or off IMPORTANT if this function is on you must ensure that the emergency stopping distance within the distance specified for the country in which the wheelchair will be used TUV Product Service Germany specify the distance to be as stated in prENI2184 5 11 Set Inhibit This set the operation of the speed limit input This input can also be used an inhibit input the inhibit speed limited Value is set to zero see chapter
89. times pushing the joystick slowly backwards left and right Connectors Make sure that all cable and connectors for damage Cables Check the condition of all cables and connectors for damage Joystick gaiter C heck the thin rubber or boot around the base of the joystick shaft for damage of splitting C heck visually only do not handle the gaiter 19 01 2004 Page 49 of 88 Section harrier Range Technical Manual doc Mounting Make sure that all the components of the control system are securely mounted Do not over tighten any securing screws 7 3 Servicing To ensure continued satisfactory service we suggest you have your wheelchair and control system inspected by your service agent after a period of 1 year from commencement of service Contact your service agent for details when the inspection is due 8 0 Status Indication The battery gauge will indicate the status of the controller Please note that a number of supposedly faulty controllers returned to us are subsequently found to operate correctly This indicates that many faults are due to the wheelchair problems rather than the controller 8 1 Battery Gauge Steady This indicate that all is well 8 2 Battery Gauge Flashes Slowly The Controller is functioning correctly but you should charge the battery as soon as possible 8 3 Battery Gauge Flashes Rapidly even with the joystick released This controller safety circuits have operated and the controllers has been prev
90. to be higher than this limit contact Penny amp Giles 19 01 2004 Page 37 of 88 Section harrier Range Technical Manual doc 4 4 Turn Decel n Adjusts the value for turning deceleration or braking of the wheelchair from 0 to 100 in steps of 1 A higher value gives faster deceleration This programmed value of deceleration occurs when the Joystick Module has speed setting 5 selected Its value at other settings depends on the value of the Min Turn Dec parameter see section 5 18 Some Power Modules may be factory programmed to limit the value of this parameter If you want to set the value to be higher than this limit contact Penny amp Giles 4 5 Forward Speed Adjusts the minimum and maximum value for forward speed of the wheelchair from 0 to 100 in steps of 1 A higher value gives a faster speed The minimum value occurs when the Joystick Module has speed setting 1 selected and the maximum value occurs at speed setting 5 Some Power Modules may be factory programmed to limit the value of this parameter If you want to set the value to be higher than this limit contact Penny amp Giles 4 6 Reverse Speed Adjusts the minimum and maximum value for reverse speed of the wheelchair from 0 to 100 in steps of 1 A higher value gives a faster speed The minimum value occurs when the Joystick Module has speed setting 1 selected and the maximum value occurs at speed setting 5 Some Power Modules may be factory programmed to li
91. ty for 12 months This will ff course be dependent on the actual use of the vehicle and how often the batteries are cycled ie discharged and charged The gradual deterioration in performance and lack of range is normally associated with fair wear and tear mis use or accidental damage U nder these circumstances the warranty will not apply WHY DO MY NEW BATTEREIS SEEM WEAK Deep cycle batteries employ a much different chemical technology than used in car batteries nickel cadmium N I Cads or other common battery types They are specifically designed to provide power discharge down and then accept a relatively quick recharge W e work closely with our battery manufacturer to provide a battery that best suits the vehicle s specific demands Fresh batteries arrive regularly and are promptly delivered with a full charge D uring delivery they can encounter temperature extremes that may influence their initial performance Heat will rob the charge from the battery cold will slow the power available and extend the time needed to recharge just like a car battery Simply a brand new battery can often act a little stubborn it might take a few days for the temperature to stabilise and adjust to your room temperature More importantly it will take a few charging cycles a partial drain then full recharge to establish the critical chemical balance that is essential t the battery s peak performance and long life If you take the time to run
92. ube end bung j tap right home 19 01 2004 Page 17 of 88 Section harrier Range Technical Manual doc FOOTREST EXTENSION ASSEMBLY FOOTREST EXTENSION ADJUSTMENT 1 Loosen clamp bolt and nut a amp b on the hanger tube assembly using a 13mm spanner Using a twisting action adjust the footrest up or down to the required length Ensure the bolt located into the notch and domed head is on the inside of the chair Tighten the clamp bolt sufficiently so that the footplate will not swivel when weight is applied CAUTION The lowest position of the footplate must be at least from the ground for clearance FOOTPLATE REPLACEMENT The footplate d can be removed from the extension tube c by removing the end bungs or bumper rollers collars and the self tapping screw which secure these components The footplate can now be twisted and pulled off the tube NOTE the leaf spring and its positioning Re assembly of the footplate to the extension tube will be much easier if a mild steel tapered service tool is available This is placed in the end of the short length of the extension tube c and the footplate complete with the correctly positioned leaf spring is fed down over the service tool Page 18 of 88 19 01 2004 harrier Range T echnical Manual doc Section CASTOR FORK ASSEMBLIES SERVICE REPLACEMENT 1 Raise front of wheelchair off the ground rock assembly to and from to check for free play of top and bottom stem bea
93. ucted by healthcare professional switch in depth knowledge of Penny amp Giles electronic controllers Incorrect programming could result in an unsafe up of a wheelchair for a user Penny amp Giles accept no liability for losses of any kind of the programming of the controller is altered from factory pre set values 2 0 PP I Pilot Programmer The PP1 is the handheld programmer that Penny amp Giles supply for their Pilot series of wheelchair controllers Primarily intended for the specialised design and test requirements of wheelchair manufacturers an engineers the PP1 takes full advantage of the compete programmability of the Pilot offering functions not available with less sophisticated controllers designs The PP1 is a menu driven programmer which plugs directly into controller and is available in two configurations suited to different applications 2 1 Basic PP1 Programmer The most basic programmer version the 1 is intended for purpose use It can set upper and lower limits for all of the key controller speed and acceleration characteristics and allows different settings to be tried out while the programmer is still plugged into the controller A context sensitive help function is available to guide users through the menus and the PP1 can also display error message from the Pilot controller allowing any problems with the wheelchair electrical system to be identified and corrected quickly 2 2 Engineering Version The enginee
94. vailable Please contact your wheelchair distributor or manufacturer for advice Do not replace the joystick knob with any unauthorized item it may cause hazardous operation 13 0 Servicing All repairs and servicing must be carried out by authorized service personnel O pening or making any unauthorized adjustments or modifications to the control system or its components will invalidate any warranty and may result is hazards to yourself or other people and is strictly forbidden WARNING Penny and Giles accept no liability for losses of any kind arising from unauthorized opening adjustment or modifications to the Pilott control system 19 01 2004 Page 31 of 88 Section harrier Range Technical Manual doc PILOT DIGITAL POWERCHAIR CONTROL SYSTEM CHAPTER PROGRAMMING Page 32 of 88 19 01 2004 harrier Range T echnical Manual doc Section 1 0 Programming for Wheelchair Control System The main advantage of using programmable control system is that they can be easily tailored to the specific needs and capabilities of a particular wheelchair user while taking into account the safe performance characteristics of the wheelchair being used This means that wheelchairs fitted with a Penny amp Giles Pilot control system can be readily programmed to be safe under normal driving conditions and also feel secure and comfortable to the user The programmable control system achieves this great flexibility be referring to aset internal parameters wh
95. when the charger is connected WARNING Use only the battery charger that has been supplied with your wheelchair The use of incorrect chargers could damage the batteries wheelchair or charge itself 11 0 Programming If you find that you cannot find a maximum speed control setting that suits you the control system can be programmed to meet your needs The PP1 is a small hand held unit which can be plugged into your control system to alter the program A PP1 may be included with wheelchair If a PP1 is not included your wheelchair distributor or service agent or wheelchair manufacture will be able to program your control system for you If you have a PP1 read the PP1 user guide before you use it Page 30 of 88 19 01 2004 harrier Range T echnical Manual doc Section If you re program your control system Make sure that you observe any restrictions given in your wheelchair user manual N ote any changes you make for future reference WARNING Programming should only be conducted by healthcare professionals with in depth knowledge of Penny amp Giles electronic systems Incorrect programming could result in an unsafe set up of a wheelchair for user Penny amp Giles accept no liability for losses of any kind if the programming of the control system is from factory pre set values 12 0 Joystick Knobs The knob fitted to your joystick is suitable for most applications If you would prefer another type there is a range of alternative a
96. y charge The battery gauge gives you a more accurate reading about a minute after you start driving the wheelchair Note W hen you replace worn out batteries fit the type recommended by the wheelchair manufacturer If you use another type the battery gauge may be inaccurate The amount of charge in your batteries depends on a number of factors including the way you use your wheelchair the temperature of the batteries their age and the way they are made These factors will affect the distance you can travel in your wheelchair All wheelchair batteries will gradually their capacity as they age The most important factor that reduces the life of your batteries is the amount of charge you take from the batteries before you recharge them Battery life is also reduced by the number of times you charge and discharge the batteries To make battery gauge reading seems to fall more quickly than usual You batteries may be worn out 9 1 How to Read a TruCharge Battery G auge If the battery gauge shows red yellow and green the batteries are charged If the battery gauges show just red and yellow then you should charge the batteries as soon as you can If the battery gauge shows just either steady or flashing slowly then you should charge the batteries immediately 10 0 Battery Charging To charge the wheelchair batteries connect the charger plug into the battery charging socket on the Joystick Module You will not be able to drive wheelchair

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