Installation manual from P&G
Contents
1. Adjusts the value for turning acceleration of the wheelchair from 0 to 100 in steps of 1 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 to be higher than this limit contact Penny amp Giles 8 2 4 4 Turn Decel n 2 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 8 2 4 5 Forward Speed Adjusts the minimum and maximum values 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 outside thes2. FAULT TYPE D ESCRIPTION 10 High battery voltage Solenoid brake fault Possible controller fault Possible joystick fault Inhibit active Right motor wiring fault Right motor disconnected Left motor wiring fault Left motor disconnected Low battery voltage 8 7 6 5 4 3 2 1 8 3 2 3 Fault Finding Without TruCharge Display If you do not have a controller with a TruCharge display you will need a Penny amp Giles programmer to determine the fault type There are three types of programmer that you may have Pacesetter DP2 or DP1 In all cases you need to plug the programmer into the controller when the lamp is flashing rapidly and a fault message will then be displayed on the programmer The format of the message displayed will vary slightly depending on which type of programmer you are using s an example assume that the wires to the solenoid brake have been disconnected The messages for each programmer type would be as below Pacesetter 15 SOL BRK FAULT DP2 O tu ri DP1 Diagnosis Code 1500 solenoid brake fault check brakes and connections Each message 15 slightly different but the one common factor to each 15 the digits 15 This is known as the fault code and when used in conjunction with the fault tables can be used to determine the fault type 1 to 10 These fault types and their possible sources are described in more detail in Section 3 The fault code may be a 2 or 4 digit code depending
3. Spare Pin 10 Lights Pin 4 Actuator Channel 2 Spare Pin 9 Lights Pin 5 Actuator Channel 3 Seat tilt Pin 8 Left rear indicator Pin 6 Actuator Channel 3 Seat tilt Pin 7 Left rear indicator Pin 7 Actuator Channel 4 Left footrest Pin 6 Left front indicator Pin 8 Actuator Channel 4 Left footrest Pin 5 Left front indicator Pin 9 Actuator Channel 5 Seat height Pin 4 Right rear indicator Pin 10 Actuator Channel 5 Seat height Pin 3 Right rear indicator Pin 11 Actuator Channel 6 Right footrest Pin 2 Right front indicator Pin 12 Actuator Channel 6 Right footrest Pin 1 Right front Indicator Not all channels may be active refer to data sheet for further details 2 The channel to function assignments reflect the Penny amp Giles standard If custom Joystick Modules are used then these assignments may change Note If desired it 15 possible to use just one Indicator connection per side However the connections must be kept separate If an indicator bulb fails the ALM will detect this and flash the remaining bulb for that side at 3Hz as well as sending information to the Joystick Module so that the relevant indicator LED flashes likewise It is possible to use 3 wire lighting indicator clusters with the ALM but the following onditrons must be followed i The negative connection to the cluster must be the Indicator negative not lighting negative ii It is only possible to connect one 3 wire clus
4. inhibit or speed limit function is required on the wheelchair a suitable switch es can be connected to the ALM s speed limit input or if an ALM is not fitted directly to the Power Module via the spare communications connector These inputs have 4 levels set by external resistance which result in a different values of speed limit The table below gives further details The Mid Slow and Inhibit speed limit values can be changed by factory programming contact Penny amp Giles for more details Resistance Inhibit Polarity Low Inhibit Polarity High Inhibit Speed Normal Speed 22 10 Slow Speed Mid Speed 100KQ 10 Mid Speed Slow Speed Normal Speed Inhibit Speed Value of resistance connected between ALM PL2 pins 11 and 12 see ALM Connection Diagram or Power Module communications connector pins 2 and 3 see Power Module Connection Diagram The polarity of the input is programmable see chapter 3 section 5 11 for programming details This feature allows maximum flexibility when configuring fail safe systems The inhibit function is implementing by programming the Inhibit Speed limit to a level of zero When this is done the input can be set to be latching or non latching see chapter 3 section 5 11 for details To ensure the wheelchair is always able to turn on difficult surfaces such as thick carpet the speed limit for turning speed is never less than the programmed minimum Turning Speed see chapter 3 sec
5. If the chair is now driving in full speed there is a fault somewhere in circuit Low battery voltage Charge the I Faw tae as A battery is defect It is possible to turn Seat lift is raised above the resistant and exchange it if ON the chair but it the switch to reduce necessary will not drive or it speed and at the same stops when driving time the 22 kQ resistant over to BK on the ALM is disconnected see the electrical diagram in paragraph The electrical Check the connection and re establish it if connection between necessary power module and ALM is disconnected It is possible to turn The security lock is Insert the key in charger plug and ON the chair but it activated withdraw it again will not drive and the maximum speed indicator will ripple up and down It is possible to turn Fault on brake release Micro switch needs to be adjusted ON the chair but it lever or on the brake The lever is in the wrong position will not drive or it cable The brake cable needs to be adjusted stops when driving 9 see paragraph 6 1 3 flashing fields on the battery indicator indicate a fault It is not possible to turn Possible faults Control method on the chair The automatic fuse 1 Check that the automatic fuse is Wires and plugs pushed in The control box 2 Check that there are approximately 24 The power module over charger positive and charger Th
6. adjustent can be made manually or by programming actual values 8 2 4 9 1 Manual Adjustment When the ENTER key is pressed the current setting for joystick throw in the forward direction will be displayed If the joystick is displaced in the forward direction beyond 25 then the actual joystick position will be displayed Operation of the ENTER key will store the value displayed on the screen This method can therefore be used to interactively set up the joystick throw with the wheelchair user The process is repeated for joystick reverse left and right positions 8 2 4 9 2 Programming Adjustment When the ENTER key is pressed the current setting for joystick throw in the forward direction will be displayed Operation 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 8 2 4 10 Steer Correct 2 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 15 veering to the left you should increase the setting If the chair veers to the right decrease the setting 8 2 4 11 Read Timer The Pilot has a timer which records how long the wheelchair is in use The timer runs whenever the joystick is moved away from
7. away from the Power Module should be provided for the other wheelchair electrical functions 8 1 15 2 Immunity The Pilot control system family has been stringently tested for susceptibility to electromagnetic radiation over the frequency range 26MHz to 1GHz The installations passed the FDA requirements and the proposed requirements of prEN12184 Follow the recommendations in section 15 1 2 to ensure maximum immunity to electromagnetic radiation 8 1 15 3 Electro Static Discharge E S D There are various international standards currently under development for this aspect of the system s performance At present most of the standards are specifying the system to be tested to requirements of IEC1000 4 2 Tests are carried out at SkV air discharge to non conductive surfaces and 6kV contact discharge to conductive surfaces The Pilot family has been tested to these levels If you need advice please contact Penny amp Giles 8 1 16 0 Battery Gauge Refer to Chapter 1 sections 9 0 and 9 1 for how to read the battery gauge The battery gauge typically starts to flash slowly when the battery voltage falls below 23 3V whilst the wheelchair is driving on a level surface For optimum accuracy of the battery gauge the control system should be programmed with the approximate nominal capacity of the wheelchair battery However accuracy 15 not greatly affected if the programmed type and capacity do not closely match the battery The m
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9. connection problem fault code 3B and which the controller has detected five times since the fault log was last re set To leave the fault log menu select the Enter key once more The fault log can be cleared using the Erase Fault Log function of the DP1 but it should be recognised that erasing the fault log will destroy any previous fault history held in the controller Please read Chapter 3 Section 4 for more details on the use of the DPIb 35007 daNddNs G v VS 37870 Wo P RISE iol Bn n HA SMOL O O3NNVIEDOMHS AHOL 4 eae ki E ROLL MOG YES HA BUGGE MOL WHITSSON Mel ME HOLTH MG YH HH a HOUR HL wa TIEN 55558 i hir it i 3 TM PER 08 eui HOLYHEAD MAD muri x d EQHCO3E F sheets ons SERRS EE AOR LY ESI MOL Ort Ake 22 NOLL Vande a i YER Dera a1 S507 APO SAEs BEGAN DNIAFH s s 237 HOL Ode SH Hull FHI Gii EEFE pee Hin uis PEE es p i KAFYG Wa Am am KA dun EU TYSNAGH LW Wwe 4245 Late OG FIHI TEHA LHH xn LENT oa LNG LENT CITAS akka oa Say DTU
10. distance to be as stated in prEN12184 Users with particular disabilities may need very low braking rates However if the control system is programmed with a low braking rate the stopping distance may be more than that specified If this happens the maximum speed must be re programmed so that the stopping distance requirement is satisfied State in the wheelchair user handbook that it is the responsibility of the person programming the control system to make sure that the stopping distance requirement is satisfied If the braking rate is low the forward and reverse maximum speed settings may need to be re programmed To assist the person in this task include a graph in the wheelchair user handbook showing the relationship between the maximum forward reverse speed settings and the forward reverse braking rate which is required to ensure the correct stopping distance It may be possible to program settings which compromise the stability of the wheelchair Perform suitable tests to establish which programming restrictions are needed to prevent instability State any programming restrictions in the wheelchair user handbook State in the wheelchair user handbook that it is the responsibility of the person programming the control system to make sure that the settings are safe and to note any programming changes that they make It is possible for wheelchair manufacturers to limit the values of speeds and accelerations that can be programmed
11. have a means of preventing unauthorized use This function is provided in the Pilot Joystick Modules see chapter I section 3 2 8 1 2 2 Charger Interlock ISO 7176 14 requires you to provide a means of preventing the use of the wheelchair while the batteries are being charged The charger sockets fitted to the Pilot Joystick Modules include an inhibit facility refer to section 5 1 for further details Contact Penny amp Giles if you need advice 8 1 2 3 Sleep Mode The control system can be programmed to go to sleep if the joystick is not operated for a period of time see chapter 3 section 4 8 The sleep state 15 indicated a by short blink of the TruCharge display once every 2 5 seconds To re start switch the control system off and on again 8 1 3 0 Power Module Wiring 8 1 3 1 General Study the data sheet for the Power Module to identify the output current ratings and restrictions Recommendations for the cross sectional area ratings and materials for wiring are given in the table in section 3 2 These depend on the application You are responsible for establishing the suitability of the particular wiring arrangement used on the wheelchair Penny amp Giles can make general recommendations for wiring to Pilot control systems but Penny amp Giles accepts no responsibility for the wiring arrangement used Make sure that the connectors you use are reliable under all operating conditions and correctly wired with no
12. short circuits Do not use unsuitable components it may result in poor wheelchair reliability The power connectors for the Pilot Power Module are specially designed by Penny amp Giles for wheelchair applications The crimps are standard AMP Timer parts but the plastic housings are custom Kits of connectors including the crimps housings and rubber boots can be purchased from Penny amp Giles or directly from the manufacturers Intech Intech will also provide a pre assembled cable service Intech s details are as below Intech Tel 44 0 1522 575535 Fax 44 0 1522 523744 The connector part numbers are Connector P amp G Reference Intech Part No D49712 PG 80B IPG 5202 Motor Brake D49713 PG 80M IPG 5401 Hand tools for crimping and extraction are available from Intech the references are as below Crimp tool for 0 5 1 0mm wire ICT 249 Crimp tool for 2 5 4 0mm wire ICT 531 Crimp tool for 4 0 6 0mm wire ICT 532 Extraction tool for 0 5 1 0mm IET 503 Extraction tool for 2 5 6 0mm IET 552 For details of automatic crimp tools contact Intech The diagram on page 2 18 gives details of the Power Module connections 8 1 3 2 Wire Gauge and Types The table below gives the minimum recommended wire sizes for various Pilot Power Module specifications These recommendations are derived from well proven field experience of various interna tional wheelchair manufacturers Nevertheless it is advised that man
13. the value of this parameter If you want to set the value outside these limits contact Penny amp Giles 8 2 5 16 Min Decel n 2 Adjusts the minimum value for forward and reverse deceleration braking of the wheelchair It is programmed in increments of 1 of the Deceleration value This percent age of the Deceleration value occurs when the Joystick Module s speed setting is at 1 For example if Deceleration is set at 80 and Min Decel n is set at 25 then when the speed setting is 1 deceleration will be 25 x 80 20 and when the speed setting is 5 decelera tion 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 Decel n is set at 100 then deceleration will not vary as the speed setting is changed Some Power Modules may be factory programmed to limit the value of this parameter If vant to set the value outside these limits contact Penny amp Giles 8 2 5 17 Min Turn Acc 2 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 x 80 20 and when the speed setting is 5 the acceleration will be 80 Speed settings
14. 1 Max 15 Max 40 pq Sleep Timer 1 0 _ 0 Steer Correct o 0 Soft Reverse 30 1 90 Current Limit Max 70 Max 70 mmeo Yes Yes Yes Fast Brake Rate 9 Yes Yes Profiles 1 0 _ 0 FWD settings standard P amp G E letrical diagram 93 QATFTEG H Apua 5092 HARAI ans 51066 10 5668 4eA00 11 0959 1938 SI 1938 37000 40 DAYS TWIHHILINSWH OL I3WHWHODSd IIBIHNI non E e ne 1315394405519 W1 MD v9 99 OL akMkRvSO08d 4131 23NND2 WI 80 WV 153W031 LOM W LEIH HIHA IE 19518 154 JH EH AGG vw apga en IEN eO TI L VELIYWIS 1 y punds 487 gs me om E 1HDIM 1431 359 3738 NEJNYN OH 400K 1331 w 0 C 5 amp Dk 3H i i AL u T9 f n Li 1 Du xg m L 439 EU aia ce H s J I E B BET AL j MIS 13538 IT r tel H i 1 6 Dh MM mA J Q 2 Eu AL 314707 DH F Ter se Sy eS am D sheets SPIPTES IM HA
15. 2 3 and 4 will interpolate linearly between 20 and 80 1 turn acceleration values of 35 50 and 65 respectively If Min Turn Acc is set at 100 then acceleration will not vary as the speed setting is changed Some Power Modules 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 8 2 5 18 Min Turn Dec Adjusts the minimum value for turn deceleration or braking of the wheelchair It is programmed in increments of 1 of the Turn Decel n value This percentage of Turn Decel n value occurs when the Joystick Module s speed setting is at 1 For example if Turn Decel n is set at 80 and Min Turn Dec 15 set at 25 then when the speed setting 15 1 acceleration will be 25 x 80 20 and when the speed setting 1s 5 the acceleration will be 80 Speed settings 2 3 and 4 will interpolate linearly between 20 and 80 1 turn decelera tion values of 35 50 and 65 respectively If Min Turn Dec is set at 100 then accelera tion will not vary as the speed setting is changed Some Power Modules 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 8 2 5 19 Clear Timer 2 This allows you to reset the timer to 0 hours 8 2 5 20 Erase Fault Log This allows you to clear the fault log after a successful repair 8 2 5 21 Preset Eng Values Selecting th
16. Diagnostics Reads fault code from Solo Yes Soft Reverse Prevents wheels digging in when braking in reverse down a slope 1 steps Percentage of forward brake rate 2596 to 100 Current Limit Maximum and mimimun current outputs 20A to 80A 1A steps Foldback Temp Reduce current at this temperature 25 to 70 then decrease 19C steps current linearly until shut down temperature is reached Timed Foldback Reduce current 2596 to 100 after stall time 5s to 10mins to 196 steps amp 5s steps protect motors Compensation Match motor impedence for precise control 0 to 10 EE Battery Menu Match TruCharge display to loom resistance 0 to 255mQ EE 5mQ steps ImQ steps Yes No Park Brake Trip For chairs without brakes mm Front Drive Select algorithm for front wheel drive Yes No Yes No Low High amp Yes No Min Accel n Vary from 0 to 100 Fast Brake Rate Slam braking by pulling Joystick in reverse 0 to 100 1 steps Soft Stop Controlled braking if control system switched off whilst driving 12 34 or 5 Yes No 12V or 24V 1 steps Min Decel n Vary from 0 to 100 1 steps Min Turn Vary from 0 to 100 1 steps Min Turn Dec Vary from 0 to 100 1 steps Clear Timer Reset elapsed timer Yes No Erase Fault Log Erases fault code history Preset Engineering Values engineering functions to factory preset values 8 2 2 4 Important Note Resetting parame
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18. age or splitting Check visually only do not handle the gaiter Check that the joystick returns to the center position when you push and release it 8 1 14 4 Programmed Settings Make sure that the control system has the correct settings Refer to chapter 3 or the Pro grammer User Guide for detailed instructions Control systems are always supplied with the settings shown on the relevant data sheet 8 1 14 5 Operational Test Drive This test should be carried out on a level floor with at least one metre clear space around the wheelchair i Switch on the control system ii Check that the battery gauge remains on or flashes slowly after one second iii Push the joystick slowly forwards until you hear the solenoid brakes operate The chair may start to move iv Immediately release the joystick You must be able to hear each solenoid brake operate within a few seconds v Repeat the test a further three times pushing the joystick slowly backwards left and right 8 1 14 6 Test Drive Drive the wheelchair and make sure that it operates correctly for all settings of the user controls 8 1 14 7 Soft Stop Test If the control system has the Soft Stop function enabled see data sheet then it must be tested prior to the wheelchair being dispatched To do this drive the wheelchair at full forward speed and switch the control system off The wheelchair must not stop suddenly but should decelerate to standstill In addition e
19. al problems so it is necessary to examine these most vulnerable areas first Most types of are fitted with a 10 bar battery level indicator known as the TruCharge display which also doubles as a comprehensive diagnostic aid If your controller does not have a TruCharge display then you will need to use a Penny amp Giles programmer DPI DP2 in order to read the diagnostic codes listed in this guide 8 3 2 0 Detecting A Fault Has Occurred Detection of a fault is usually signified by a rapid flashing of the TruCharge display Care should be taken because the controllers will give a low battery warning by generating a Slow flash of this indicator This is not a fault just a reminder that you should charge the batteries 8 3 2 1 Using TruCharge Display as a Diagnostic Aid The diagram below shows you how to read the TruCharge display in the event of a fault If you look at the diagram you will see that 10 different types of fault are defined The number of bars flashing on TruCharge display indicates the fault type A brief description for each fault type is also included on the diagram These fault types and their possible sources are described in more detail in Section 3 As an example assume that the wires to the solenoid brake have been disconnected The controller would detect this as a fault so in this instance cause 9 bars to flash on the display corresponding to fault type 9 8 3 2 2 TruCharge Display Diagnostics
20. are being charged for a sufficient time and that they are never deeply discharged See paragraph 9 1 and 9 2 for further advises about batteries Defect in the light Defect bulb circuit or system ALM Defect servo function Defect servo function or ALM 290 mm seat lift will There is an electrical not move down connection to chassis The chair will brake to Cable to brake is a side when driving on ajadjusted too tight Defect engine Check bulbs To locate the fault use a voltmeter to measure if there is a voltage on different locations in the circuits Control method To locate the fault use a voltmeter to measure if there is a voltage on different locations in the circuits If one of servo functions don t work Check the electrical connections and plugs between actuator and ALM If they are all right try to connect one of the other servo functions to the output for the function in question on ALM If this servo function also don t work the ALM is defect and has to be exchanged If the connected servo function works the servo function in question is defect and has to be exchanged Control method Carry out an isolation test between battery and chassis by measuring the voltage between chassis and battery terminal positive and negative Ifa voltage is measured locate the fault by systematically disconnecting the different plug connections from the current supply while still meas
21. cool e g Power Module has current limit of 80A stall time of 15 seconds and foldback of 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 155 758 the current output will return to 80 8 2 5 5 Compensation This matches the control system to different motor types in order to achieve optimal performance and control Penny amp Giles recommend that you set this 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 manufacturers should be able to supply figures for armature resistance and typical cable and connectors would be about 40mW 8 2 5 6 Battery Menu 8 2 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 0mW 255mW in steps of Im W 8 2 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 1f you are considering altering this factor 8 2 5 6 3 Back to E Menu 2 This returns you to the ENGINEER Menu 8 2 5 7 Park Brake Trip This tells the control system whether or not to trip if one or both of the
22. e batteries negative on the charger socket see data sheet for control box in paragraph 8 4 3 Check the wire and the plugs between control box and power module 4 Check that the battery plug on power module is properly connected and measure the voltage on the two terminals on the plug 5 If voltage is all right Try to exchange first the control box and if it doesn t help then the power module 6 If voltage is not all right Check batteries and battery circuit The chair have a to Low tire pressure Pump air into the tires short driving distance Battery is defect If possible check battery with a battery tester With a voltmeter check that the difference between the measured voltage on the two batteries do not exceed 1 0 V If the difference exceed 1 0 V both batteries should be exchanged with new ones The difference in voltage on the new batteries must not exceed 0 04 V Charger is defect Check if batteries are showing any sign wrong procedure is that they have been over charged used when charging Normally it is possible to detect that an over charging have occurred if there can be measured an enlarged voltage on the batteries A severely over charging can result in a swollen battery case especially if batteries have also experienced over heating Check charger GI Teamtec GBC02 by using test method described in paragraph 5 under charger By asking the user of the wheelchair secure that batteries
23. e limits contact Penny amp Giles 8 2 4 6 Reverse Speed Adjusts the minimum and maximum values for reverse speed of the wheelchair from 0 to 100 in steps of 1 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 outside these limits contact Penny amp Giles 8 2 4 7 Turning Speed Adjusts the minimum and maximum values for the turning speed of the wheelchair from 0 to 100 in steps of 1 A higher value gives faster speed The minimum value occurs when the Joystick Module has speed setting I 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 outside these limits contact Penny amp Giles 8 2 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 I and 10 minutes in steps of I minute If the time is set to 0 the system will never go to sleep 8 2 4 9 Joystick Throw This allows you to program the control system so that full speed can be reached with a reduced joystcik movement throw This 15 particularyl useful for wheelchair users with limited hand or arm movement The
24. e suitability of the particular wiring arrangement used on the wheelchair Penny amp Giles can make general recommendations for wiring for particular control system types but Penny amp Giles accepts no responsibility for the wiring arrangement used Make sure that the connection methods you use are reliable under all operating conditions and correctly wired with no short circuits Do not use unsuitable components it may result in poor wheelchair reliability 8 1 8 2 Connection to the Power Module The ALM is connected to the Pilot Power Module with a 6 way cable and connector Always ensure the cable is correctly mated by pushing the connector s outer sleeve until it is fully in position 8 1 8 3 Connection to the Lights Actuators and Speed Limit Input These connection are via spring connectors PL1 and PL2 To connect the wires into each terminal release the spring pressure by inserting a 3mm screwdriver and levering downwards then push the wire fully into position Wire gauges of up to 2 5mm can be accommodated in each terminal It is recommended that wires are solder tinned The ALM connection diagram on page 2 22 shows the terminal identification for PL1 and PLZ 8 1 8 4 Lighting Wiring The lighting output is rated at 42W maximum Use suitably rated wire to each bulb The output is self protecting against wiring and bulb faults and will shut off if the maximum power rating is exceeded Likewise if the output becomes too hot
25. have selected 7 In menus help tells DP 7 you what each option does In options it tells you what to do next g SSS Up Yes Button Y This button increases a8 settings or selects No functions ipM Penny tGiles Down No Button gt 2 Enter Button This button decreases This button selects settings or de selects options settings or function states functions 8 2 3 2 Connection To program you can connect the 1 to the Pilot via the charging socket on the Joystick Module if the system is either on or off You can also drive with the PP1 connected Please note for safety reasons accessing some critical parameters will cause the control system to trip This is indicated by the TruCharge 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 to view fault codes and messages connect it to the control system when the control system has tripped Note if a trip occurs when the is already connected then no diagnostic information will appear If you wish to program but the PP1 is showing diagnostic information press the ENTER 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 PP1 as soon as programming is complete and do not use the in envir
26. ibit input if the Inhibit Speed limit value is set to zero see chapter 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 Inhibit Speed Normal Speed 22 10 Slow Speed Mid Speed 100 10 Mid Speed Slow Speed Normal Speed Inhibit Speed latched This determines whether the control system trips when an inhibit signal Inhibit Speed 0 is received It can be set to yes or no Yes gives a trip condition and the system must be switched off and on again to reset No means that drive can be resumed as soon as the Inhibit signal is removed The settings for Inhibit Slow and Mid Speed limits are factory programmable if you want to alter these values please contact Penny amp Giles 8 2 5 12 Profiles 2 This function can only be used with customer specific Modul es which support drive profiles The Pilot generic Joystick Modules are not designed to operate with drive profiles consequently this valiue should be set to 0 For furhter Information please contact Penny amp Giles 8 2 5 13 Swap Motors This swaps the motor output connections 1 and 2 on the Power Module Norma
27. in the field This facility ensures a safe operating envelope for the wheelchair can be maintained These limits are set in the factory by Penny amp Giles and can only be altered by Penny amp Giles WARNING Programming should only be conducted by healthcare professionals with in depth knowledge of Penny amp Giles electronic control systems Incorrect programming could result in an unsafe set up of a wheelchair for the user Penny amp Giles accept no liability for losses of any kind if the programming of the control system is altered from factory preset values Penny amp Giles accept no liability for losses of any kind if the drive or stability characteristics of the wheelchair are altered without prior notification and discussion with Penny amp Giles 8 1 1 3 Soft Stop If the version of Pilot you have has the Soft Stop function enabled see data sheet you must ensure that the emergency stopping distance is 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 prEN12184 8 1 1 4 Other Information You must provide a diagram in the wheelchair user handbook showing the user controls In addition you should include a brief specification of operating supply voltage range and operating temperature range 8 1 2 0 Immobilizing the Wheelchair 8 1 2 1 Prevention of Unauthorized Use TUV Product Service requires that the wheelchair must
28. is not actually a fault but incorrect use of the programmer To program you must connect the programmer before the controller is turned on 8 3 4 7 Possible Joystick Fault This occurs when the controller detects a fault in the joystick or the connections to it The course of action will differ depending on whether you have an integral joystick In main box or remote separate joystick module system Integral the fault is in the joystick or connections to it As the joystick is within the main box then the controller must be assumed defective and repaired by an authorised person Remote the fault 15 in the joystick or connections to it The fault could be in the joystick module or the cable to it which is attached to the controller If you have a spare working joystick module connect it and see if it cures the problem if it does the original joystick module must be assumed defective and repaired by an authorised person If the fault is still present with the spare joystick module then the controller must be assumed defective and repaired by an authorised person 8 3 4 8 Possible Controller Fault This occurs when the controller detects a fault within itself The controller must be assumed defective and repaired by an authorised person 8 3 4 9 Solenoid Brake Fault This occurs when the controller detects a fault in the solenoid brake or the connections to it Check these connections and the solenoid brake 8 3 4 10 High Battery Fa
29. is sets all ENGINEER menu parameters to their default values 8 2 5 22 Back to root 2 This takes you back to the ROOT menu Penny amp Giles Drives Technology Penny amp Giles Drives Technology Division of Autronics Corporation 1 Airspeed Road 1580 South Sinclair Street Christchurch Anaheim Dorset CA 92806 5933 U S A BH23 4HD U K Tel 714 712 7911 Tel 01425 271444 Fax 714 978 9512 Fax 01425 272655 ault key 8 3 Fault finding This paragraph contains hints to faultfinding on the wheelchair There are also two paragraphs paragraph 4 3 and 4 4 in the wheelchair manual that might be helpful Use a programmer unit to read Pilot fault log Fault key Symptoms Control method and or solution The wheelchair cant Fault in the electrical Control method drive and a number of system Use the faultfinding guide from P amp G or fields on the battery use a programmer unit to read Pilot fault indicator flashes log The chair is not driving Unlike tire pressures Check the tire pressures and adjust if strait necessary The castor wheels are Block up the castor wheels from the floor wrongly adjusted or the and check in accordions with paragraph locking ability doesn t 6 1 5 work properly Defect engine Control method The chair is turning to one side when attempting to drive strait and to the other side when braking Maybe try to exchange the two wires from engines in power module with one and a
30. it will shut off to prevent permanent damage to itself TUV stipulate that to comply with the StVZO German Road Traffic Regulations each rear light must be separately fused You should therefore split the wiring from the ALM output so that each rear light is supplied via a different fuse It is recommended that an 800mA quick blow fuse is used for the left hand front and rear lights and that an identical fuse is used for the right hand front and rear lights 8 1 8 5 Indicator Wiring The left and right indicator outputs are split inside the ALM into front and rear this is to enable detection of an individual bulb failure All currents referred to hereon in this section are the total of front and rear Each indicator output is rated at 42W maximum Use suitably rated wire to each bulb The s are self protecting against wiring and bulb faults and will shut off if the maximum power rating is exceeded Likewise if either output becomes too hot it will shut off to prevent permanent damage to itself ALM Connection Diagram __ COMMUNICATIONS CONNECTOR 12 X TO POWER MODULE WW 9 PL1 PL2 t 12 1 PLI PL2 Pin I Actuator Channel 1 Backrest Pin 12 Speed Limit Input Pin 2 Actuator Channel 1 Backrest Pin 11 Speed Limit Input Pin 3 Actuator Channel 2
31. lly 1 is for the left motor and M2 for the right motor You can select between yes and no If set to yes 1 will be for the right motor and M2 for the left motor If set to no the normal condition will apply Note 1 you swap the motor connections the TruCharge motor diagnostic information will need to be interpreted differently see chapter 1 section 8 5 8 2 5 14 Brake Voltage This sets the voltage output from the Power Module to the solenoid brakes You can select either 12V or 24V WARNING 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 the drive performance of the wheelchair may be affected 8 2 5 15 Min Accel n 2 Adjusts the minimum value for forward and reverse acceleration of the wheelchair It is programmed in increments of 1 of the Acceleration value This percentage of the Acceleration value occurs when the Joystick Module s speed setting is at 1 For example if Acceleration is set at 80 and Min Accel n is set at 25 then when the speed setting 15 1 acceleration will be 25 x 80 20 and when the speed setting 15 5 the acceleration will be 80 Speed settings 2 3 and 4 will interpolate linearly between 20 and 80 1 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 changed Some Power Modules may be factory programmed to limit
32. may not be compatible with actuators which have their own over current detection electronics Actuator assemblies with slipping clutches may also be unsuitable as the motors will never stall therefore not allowing the ALM to detect the end stop Please contact Penny amp Giles if you are unsure 8 1 11 0 Power Module Mounting 8 1 11 1 General Fix the Power Module to the wheelchair chassis using suitable 5 or equivalent hardware 8 1 11 2 Orientation minimize the effect of water and dust fix the control system with the connectors as the underside The Power Module has an IP54 dust and water resistance rating 8 1 11 3 Position The Power Module must be mounted in a position where it is not exposed to water or dust or subject to excessive shock or vibration The Power Module has excellent thermal performance but to improve this further it may be secured against a metal part of the wheelchair chassis To provide even better thermal performance a non silicone thermally conductive paste or pad may be applied between the Power Module and the wheelchair chassis Contact Penny amp Giles if you need further advice 8 1 11 4 Cables The cables to the Power Module must be routed and secured in such a way as to prevent damage to them for example by cutting or crushing 8 1 12 0 Joystick Module Mounting 8 1 12 1 General The Joystick Module should be fitted to a bracket made from 25x3mm or 1 x1 8 stock bar and secured
33. motor cable and connector resistance Failure to match the control system with the motors may result in poor control characteristics in particular speed stability on gradients may be affected If you have any doubts about the suitability of a particular motor type or you need advice on measuring motor impedance contact Penny amp Giles 8 1 7 0 Solenoid Brakes The solenoid brakes can be either 12V or 24V types however the control system must be programmed for the correct voltage Refer to data sheet for the programming details of the control system Refer to chapter 3 section 5 15 for information on programming If the current to either brake is less than 100mA or greater than 1A a brake fault will be detected WARNING 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 the drive performance of the wheelchair may be affected 8 1 8 0 Actuator and Lighting Module ALM Wiring This section is applicable if the wheelchair is fitted with lights or actuators controlled from the Joystick Module 8 1 8 1 General Study the data sheet for the ALM to identify 1 the output current ratings and restrictions il the connector pin assignments Refer also to the ALM connection diagram on page 2 22 Recommendations for the cross sectional area ratings and materials for wiring will depend on the application You are responsible for establishing th
34. nications fault between programmer and controller 8 3 4 0 Fault Types and Their Possible Causes 8 3 4 1 Low Battery Fault This occurs when the controller detects that the battery voltage has fallen below 13 5v Check the condition of the batteries 8 3 4 2 Left Motor Disconnected This occurs when the controller detects that the left motor has become disconnected Check the left motor motor connectors and wiring 8 3 4 3 Left Motor Wiring Fault This occurs when the controller detects a fault in the wiring to the left motor in particular a motor connection has short circuited to a battery connection Check the left motor connectors and wiring 8 3 4 4 Right Motor Disconnected This occurs when the controller detects that the right motor has become disconnected Check the right motor motor connectors and wiring 8 3 4 5 Right Motor Wiring Fault This occurs when the controller detects a fault in the wiring to the right motor in particular a motor connection has short circuited to a battery connection Check the right motor connectors and wiring 8 3 4 6 Inhibit Active This occurs when the controller detects that the inhibit input is connected The most common use for the inhibit input is for disabling the drive when the charger is connected Check that battery charger is disconnected from wheelchair Please note this fault occurs you connect a programmer to a working controller when it is turned on This
35. nother If the chair is now turning to the opposite side the engine Is proven defect Wrong parameter The parameter Steer Correct has to be setting adjusted Try with different settings see One engine is more paragraph 8 2 worn than the other one The wheelchair is weak O verheating of power Avoid situations with risk of overheating module of the power module E g driving in a hilly or soft terrain for a long time Fault in battery f possible check the battery with a battery tester With a voltmeter check that the difference between the measured voltages on the two batteries don t exceed 1 0 V I the difference 15 bigger both batteries should be exchanged with new ones On new batteries the difference in voltage between the batteries must not exceed 0 04 V Parameter setting The parameter Current Limit is set to low See the standard settings in paragraph 8 5 Battery connections Poor contact between terminals and wires Clean and grease with acid free Vaseline The chair doesn t drive Maximum speed Seat lift positioned to high with maximum speed adjusted to low Seat lift positioned to Lower the seat lift till under the switch high Defect switch or Control method disrupted electrical Check the electrical circuit by short circuit for low speed circuits the outputs for reduced speed GY to BK at the actuator light module ALM see the electrical diagram in paragraph 8 6
36. nstallation manual from P amp G 8 1 Installation manual from P amp G Penny amp Giles 8 1 1 1 Pilot Operation Study Chapter 1 Operation It is important that the information in Chapter 1 is supplied with the wheelchair either as part of the wheelchair user handbook or as a separate document This chapter sets out the installation conditions that must be complied with in order to meet the safety requirements of Product Service Germany IS07176 14 and prEN12184 If a wheelchair manufacturer s label is placed over the Pilot identification label then to maintain the control system s TUV approval Penny amp Giles must be informed Penny amp Giles will then inform TUV Product Service 8 1 1 2 Program Settings All programmable values are stored within the Power Module therefore if you change a Joystick Module or ALM there is no need to re program the system You must supply the Power Module programmed with the manufacturer s preset settings Power Modules are always supplied by Penny amp Giles with the preset settings shown on the relevant data sheet The preset settings are chosen with the wheelchair manufacturer to ensure safe operation and compliance with relevant legal requirements over the whole of the operating range of the joystick and speed control The wheelchair must stop within the maximum distance specified for the country in which the wheelchair will be used TUV Product Service Germany specify the
37. nsure that the requirements in section 1 3 of this chapter are satisfied WARNING This test should be conducted in an open space and a restraining device such as a seat belt should always be used 8 1 14 8 Lights Indicators and Hazard Lamps Test If lights are fitted visually check each bulb for correct illumination If indicators are fitted check each bulb for correct illumination and that the flashrate is 1 5Hz 0 5Hz Disconnect each bulb in turn and check that the remaining bulb for that side flashes at 3Hz 0 5Hz If hazard lamps are fitted check each bulb for correct illumination and that the flashrate 15 1 5Hz 0 5Hz 8 1 14 9 Actuator Test If actuators are fitted check each motor for correct direction of movement Ensure the mechanical end stops are secure and that they stall the actuator motors thus operating the ALM s automatic end stop detection 8 1 14 10 Speed Limit Input Test If this input is connected check for correct operation at all speed levels 8 1 15 0 Electromagnetic Compatibility E M C The Pilot family has been tested for compliance with EC directive 89 336 EEC and the E M C requirements of prEN12184 the FDA and the FCC The guidelines in this section will help you to make sure that your wheelchair installation will easily meet these requirements You should consider E M C and perform relevant tests as early as possible in the design phase 8 1 15 1 Emissions A typical wheelchair and Pilot in
38. ntrol system achieves this great flexibility by referring to a set of Internal parameters which 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 or ALM there is no need to re program the system 8 2 1 1 Important Note It is possible to set up a control system so that it Is unsuitable for some users and possibly even some wheelchairs Take care when programming a control system 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 conducted by healthcare professionals with in depth knowledge of Penny amp Giles electronic control systems Incorrect programming could result in an unsafe set up of a wheelchair for a user Penny amp Giles accept no liability for losses of any kind if the programming of the control system is altered from factory pre set values 8 2 2 0 PP1 Programmer The is the handheld programmer that Penny amp Gile
39. on which type of programmer you are using However the important digits are the first two Once you have established the fault code you can determine the fault type then you can read the explanation for each fault type and take the suggested action The table that follows relates each fault code to a specific fault type which should enable you to swiftly determine the problem area 3 0 Fault Tables First Two Fault Code Digits Fault Type Description Possible Joystick fault amp Possible controller fault amp Possible controller fault amp Possible controller fault amp Possible controller fault 9 Solenoid brake fault High battery voltage amp Possible controller fault gt jm ON wiol al gt EE mm 23 1 08 90 9b oF REN 38 md NO Hj First Two Fault Code Digits Fault Type Description s Possible controller fault Sd 8 Possible controller fault 33 O s Possible controller fault 5 Possible controller fault 38 8 Possible controller fault 36 8 Possible controller fault Possible controller fault 38 5 Possible controller fault 5 Possible controller fault 8 Possible controller fault FY s Possible controller fault rp Gre 40 or above Commu
40. onments which are E M C sensitive 8 2 4 0 Root Menu The ROOT menu which is included in both the PPla 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 timer Each parameter is explained in the following paragraphs 8 2 4 1 Acceleration Adjusts the value for forward and reverse 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 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 8 2 4 2 Deceleration Adjusts the value for forward and reverse deceleration or braking of the wheelchair from O 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 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 2 8 2 4 3 Turn Accel n 2
41. ost important factor affecting the accuracy of the battery gauge is the resistance of the cable and connections between the battery and the Power Module The control system must be matched approximately to the cable resistance of your wheelchair to make the battery gauge accurate see chapter 3 section 5 6 1 As a guide 2 5mm wire has resistance of about 8 milliohms per metre 4 0mm wire has about 5 milliohms per metre and 6 0mm has about 3 3 milliohms per metre Circuit breakers and connectors usually account for about 15 milliohms These values will be chosen at the time the control system is being specified by the wheelchair manufacturer Like the preset rates once the values for the battery are decided they are programmed into control systems during manufacture and should never need changing If you need advice contact Penny amp Giles rogramming manual from P amp G 8 2 Programming manual from P amp G 8 2 1 0 Programming For Wheelchair Control systems The main advantage of using programmable control systems 15 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 program med to be safe under normal driving conditions and also feel secure and comfortable to the user The programmable co
42. rature of the Power Module Graph A below shows the relationship current limit fold 70 Pilot Power Modules below shows recommended mayimum to myanun relations Ips 40A You can set the maximum and minimum current outputs between 20 and the maximum permitted upper value in steps of 1 8 2 5 3 Temp Foldback This is the internal Power Module temperature at which the current output 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 SOA IMPORTANT the temperature value should never be set to more 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 8 2 5 4 Timed Foldback 2 This function allows a measure of protection for motors when they get into a stalled condition You can set a Stall Time of between 5 seconds and 10 minutes in 5 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
43. rcuit breaker operates You must therefore fit a circuit breaker with an auxiliary switch which disconnects the solenoid brake from the Power Module Power Module Connection Diagram WIV HO J1NAON MDILSAOP OL YOLDAINNOD SNOILVO2INnWWOOS 4 AVZ AZL YOLOW k X r1 r1 r1 r1 x ZN elg iN gt T LINDUID H C IMVHYG 1H95IH HO ITNAON MDILSAOP OL HYOLOANNOD SNOLLVIINNNNOD 4371081NOD OL Q3aXi4 HOLO3NNOO dO SNid HOLO3NNOO SNOI LVOINDnININOO 4 HOLON 1 1 AAILVSAN HOLOIN JAILISOd HOLOW JAILVDAIN 3MVHE JAILISOd JAVA HATTOHLNOD dO NOLLOY LV SNIMOO1 ONY LIN S IIVL3d NOILO3NNOO HOLON IMVHYG CIN LIN GI gt j G ECE JINAON YIMOd 1331 id 1 1 1 JAILVSAN AHILLVE JAILISOd AYALLVE HITTOHLNOO 40 WOLLOG LY ONINOOT 51191349 NOILOJ3NNOO AHILLVE 8 1 3 5 Inhibit or Speed Limit Connections If
44. s supply for their Pilot control systems Primarily intended for the specialized design and test requirements of wheelchair manufacturers and engineers the PP takes full advantage of the complete programmability of the Pilot offering functions not available with less sophisticated control system designs The is a menu driven programmer which plugs directly into the Pilott battery charging socket and is available in two configurations suited to different applications 8 2 2 1 Basic PP1 Programmer 1 The most basic programmer version the PPla 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 can also display error messages 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 be read with the PPla 8 2 2 2 Engineering PP1 Programmer PP1b The engineering version the PPlb offers all of the PPla 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 algori
45. solenoid brakes become disconnected or are not fitted You can turn this function on or off IMPORTANT this function should only ever be turned off if there are no solenoid brakes fitted to the wheelchair 8 2 5 8 Front Drive 2 This selects special front wheel drive control software You can turn this on or off It is possible for wheelchair manufacturers in conjunction with Penny amp Giles to change the driving characteristics of the front wheel drive software please contact Penny amp Giles for further details 8 2 5 9 Fast Brake Rate This sets the deceleration rate for fast braking Fast braking is when the joystick 15 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 be used 8 2 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 is 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 prEN 12184 8 2 5 11 Set Inhibit This sets the operation of the speed limit input This input can also be used as an inh
46. stallation have been type tested and have passed the requirements of CISPR 22 and FCC CFR47 part 15 Observe the following recommendations to minimize radio frequency emissions 8 1 15 1 1 Motor Suppression For the drive motors solder a suitable suppression capacitor between the brush holders inside the motor cases Keep the capacitor s lead length as short as possible We recommend a value of 4n7F 250V AC ceramic The maximum value you should use is 10nF A typical type is Roderstein WY0472MCMCFOK The above should also be applied to actuator motors if fitted If it is not possible to fit these capacitors inside the actuator motors then contact the motor manufacturers for further advice Alternatively placing the capacitor externally but as close as possible to the motor may have the same effect 8 1 15 1 2 Cables You do not need to use screened battery and motor looms but i Keep the length of all wiring to a minimum ii Make sure the loop area of the wiring is minimized Route the positive and negative wires to each motor together Route the battery positive and negative wires together Where possible route the battery and motor looms together If fitted route the lighting indicator and actuator wires together iii Secure all looms to the wheelchairs chassis over as much of their length as is practical iv Do not use the control system connectors as junction points for the battery connections Separate junction points
47. sus dj ucseap yoce 22 POL eq suomnseuuns mempu uyeg e SEL Apos ej JBYSjeGYE SUL pub uo pimp sq PERU w jnpeu mod 10711 p uomsanBuuos uo spuedep ugode ajae Gul pards imajo L pubs xe pubu AQ i pub xo pub a j ws PUDH jeune pub mujdas pub AO AERE een pubis uae puus puni jeug Pupu AZ LIDE IA Je qun Lu wm tor oo 47 13205 JO LNOHJ MIN l L Vid og 36 apia 5 56 PR uwi 9 tandard settings 8 5 Standard setting The underneath diagram contains the chair setting programmed from the factory If settings are altered the new values shall be saved The wheelchair manual contains a diagram to save the new settings concerning the driving properties Standard settings for Moover 95 Flex with PILOT Some parameters have limited values for safety reasons motors and battery protection These are shown as fence values PARAMETER Moover 90 95 Moover 90 95 Fence values 895 985 RWD FWD gt DECELERATION 80 75 Min 30 Max 65 Max 65 FORWARD SPEED Max 100 Max 85 O REVERSE SPEED Max 40 Max 40 Max 50 wr _ TURN SPEED Max 2
48. ter per side 1 only the front or rear lights indicators may be connected in 3 wire configuration Hi It is possible to connect to connect all lights indicators in 3 wire configuration but 4 external diodes need to be fitted Please contact Penny amp Giles for further details 8 1 8 6 Actuator Wiring Each actuator channel is rated at 10 maximum however when both footrests are operated simultaneously the rating is SA per footrest If the maximum current is required the wire gauge should be at least 1mm Each actuator output will shut off if the current from it is greater than 10 If the wheelchair is fitted with solid mechanical end stops at the end of the actuator travel it is not necessary to fit limit switches as the ALM will detect when the actuator motor has stopped and will cut off the power to it 8 1 8 7 Speed Limit Input Wiring Pins 11 and 12 of PL2 can be used as a speed limit or inhibit input refer to section 3 5 for more details This input requires only a very small current so wire gauge of 0 2201 is suitable 8 1 9 0 Bulbs The ALM 15 designed to operate with 12V bulbs The ALM will supply a constant power to the bulbs so that the brightness is not affected by variations in battery voltage The lighting output can supply a total power of 42W Each Indicator output can supply 42W 8 1 10 0 Actuator Motors The ALM 15 designed to be connected directly to permanent magnet DC motors Please note the ALM
49. ters to non compatible values could damage control systems and motors and invalidate any warranties Current Limit should never be set to a value greater the values recommened 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 On a more general note it is possible to set up a control system so that it 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 PP1 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 Current Limit should never be set to a value greater than the recommended control system maximum 3 1 Keypad Layout amp Description Help Button Pressing this button displays information regarding the function you
50. the centre position and stops when the joystick is returned The timer records the number of hours the wheelchair has been in use To reset the timer see section 5 19 8 2 4 12 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 as below 1 Code 2 00 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 3C00 has occurred three times Only two fault types recorded To clear the fault log refer to section 5 21 8 2 4 13 Preset Unit Selecting this sets all ROOT menu parameters to their default values These default values are decided between Penny amp Giles and the wheelchair manufacturer 8 2 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 15 described below 8 2 5 1 Soft Reverse 2 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 8 2 5 2 Current Limit 2 This sets the maximum and minimum current output for the control system The current output Is dependent on the Internal tempe
51. thms Clearly the PP1b is a very powerful tool for prototype design work However users who program parameters incorrectly do run the risk of damaging control systems or motors so it should only be used by experts in wheelchair electrical systems 2 3 PP1 Specifications Functions Notes PP1a PP1b Acceleration Vary from 0 or factory set min to 100 or factory set max Unit steps Unit steps Deceleration Vary from 0 or factory set min to 100 or factory set max Unit steps Tun Acceleration Vary from 0 or factory set min to 100 or factory set max Unit steps Turn Deceleration Vary from 0 or factory set min to 100 or factory set max Unit steps Forward Speed Vary from 0 or factory set min to 100 or factory set max 1 steps 1 steps Reverse Speed Vary from 0 or factory set min to 100 or factory set max 1 steps 1 steps Turn Speed Vary from 0 or factory set min to 100 or factory set max 1 steps 1 steps Sleep Timer Period of time before control system goes to sleep 1 to 10 mins I min steps I min steps Joystick Throw Joystick deflection for full speed 25 to 100 1 steps Steer Correct Veer compensation for mis matched motors Read Timer Displays hours wheelchair in use Yes 9 to 9 Read Fault Log Displays fault code history Preset Control system Set drive functions to factory preset values Help Mode On line help text Ye Ye un un Yes Yes Yes Yes es
52. tion 4 7 This input requires only a very small current so a wire size of 0 22mm is suitable 8 1 4 0 Joystick Module Wiring The Joystick Module is connected to the Power Module with a 6 way cable assembly Always ensure the cable is correctly mated at both ends by pushing the connectors outer sleeves until they are fully in position Route and secure the cable in such a way as to prevent damage for example by crushing or cutting 8 1 5 0 Batteries The control system is designed for operation with 24V lead acid batteries The batteries may be wet or gel electrolyte types Contact Penny amp Giles if you need advice on battery selection 8 1 5 1 Battery Charging The battery charging socket is mounted on the Joystick Module The charging socket 15 Neutrik 3 pin type NC3FPP or equivalent and the maximum charging current is 12A RMS The pin connections of the socket are as below Pin Connection Charge Inhibit To prevent the wheelchair from driving whilst the charger is connected pin 3 must be linked to pin 2 inside the charger s plug 8 1 6 0 Drive Motors The control system is designed to be connected to permanent magnet DC motor fitted with a suitable gearbox and solenoid brake In order to optimize the performance of the wheelchair the control system must be matched to the motor terminal impedance see chapter 3 section 5 5 The data sheet may define a motor compensation value normally 70 of the total
53. ufacturers confirm them by carrying out suitable tests Keep wire lengths as short as possible Pilot Power Module Battery Wires Motor Wires Brake Wires 50A 30A Note Battery and motor wires should have 105 C rated PVC insulation 8 1 3 3 Battery Connections The control system incorporates sophisticated current limiting circuitry as protection for the circuits in the control system ISO 7176 14 requires you to provide protection against short circuits in the battery wiring and the power loom or the extremely unlikely event of a short circuit in the control system Place a suitable circuit breaker in series with the battery supply for example in the link between two 12V batteries If your batteries are held in separate enclosures you must provide a circuit breaker with each of them The rating of the circuit breaker must match the capacity of the wiring specified in section 3 2 For Pilot 50A Power Modules the circuit breaker rating should not exceed a 50A maximum rating For Pilot 80A Power Modules the circuit breaker rating should not exceed 70A These ratings refer to the MP16 series of circuit breakers manufactured by Mechanical Products Inc ISO 7176 14 states that the minimum operating time for the circuit breaker when the wheelchair is stalled is 15 seconds 8 1 3 4 Motor Connections If a circuit breaker is fitted in series with a motor it is essential that the wheelchair assumes a safe condition the moment the ci
54. ult This occurs when the controller detects that the battery voltage has risen above 35v Check the batteries and the connections to them 8 3 5 0 Advanced Diagnostics With The DP1b The special engineering version of the DP1 advanced programmer has the facility to read a fault log which resides inside the PG8 controller The PG8 s fault log keeps a record of the last 8 different fault codes detected by the controller and also keeps a count of the number of occurrences of each of these fault codes up to a maximum of 31 times This is a very powerful tool for diagnosing problems particularly if there is a suspected intermittent problem with the wheelchair electrical system However the data needs to be understood and interpreted very carefully before jumping to conclusions Wheelchair manufacturers who have access to this facility should discuss the implications of the codes displayed in any particular fault log with Penny amp Giles before acting on them When the DPI is plugged into the the U l keys can be used to locate the Engineering Menu which is selected with the Enter key The 1 1 keys can then be used to find the Read Fault Log menu which is again selected with the Enter key The user can then scroll through the fault log with the U fl keys and see up to 8 different fault codes For example if the display shows 1 Code 3B00 5 then the DPI is displaying the first fault code in the list which is indicating a left motor
55. uring the voltage When the defect circuit is disconnected the voltage between chassis and battery terminal will cease See the electrical diagram in paragraph 8 6 Check the play in brake lever and adjust brake cable if necessary see paragraph 6 1 3 Control method Check if it 15 the engine there has a defect by exchanging the two wires from engines in power module with one and another If the chair is now turning to the opposite side the engine is proven defect Fault finding S 3 1 0 Introduction The primary objective of this chapter is to assist service personnel in finding the likely area of a detected fault within the whole wheelchair electrical system It is important to realise that even though the controller is signalling a fault it may not be the controller that 15 defective This is because the controller is able to detect faults in other electrical components motors batteries brake etc or more importantly the wiring to them Using this guide it is possible to define a fault as belonging to one of 10 types Once the fault type has been established there are suggestions as to what may be the possible cause This chapter should only be used to decide the starting point of your own diagnosis as it 15 possible for the controller to indicate a fault in another component even though the controller itself is at fault Nevertheless experience has shown that connectors and wiring are the major cause of wheelchair electric
56. using M4x12mm or 8 32UNCXx1 2 screw Be careful not to overtighten the screw See data sheet for further information 8 1 12 2 Orientation The Joystick Module must be mounted with the joystick shaft pointing vertically upwards If you want to use any other mounting attitudes then contact Penny amp Giles 8 1 13 0 ALM Mounting 8 1 13 1 General The ALM should be fitted to the wheelchair chassis with 2 off M5x8mm fixing screws Be careful not to overtighten these screws 8 1 13 2 Orientation The ALM is not sensitive to mounting orientation except where it is exposed to water or dust In this situation to maintain the IP54 rating the ALM must be mounted so that the fixing screws are lowermost 8 1 13 3 Position Do not mount the ALM in a position which would expose it to excessive shock or vibration S 1 13 4 Cables and secure all the cables to the ALM in such a way as to prevent damage to them for example by crushing or cutting S 1 14 0 Production Tests Perform the following tests In order on each wheelchair before dispatch 8 1 14 1 Mounting Make sure that all modules are securely mounted Do not overtighten any fixing screws 8 1 14 2 Cables and Connectors Check all cables for damage Make sure that all connectors are securely mated 8 1 14 3 Joystick and Gaiter Check that the joystick is not bent or damaged Check the thin rubber gaiter or boot around the base of the joystick shaft for dam
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