PG DRIVE TECHNOLOGY NEWVSI Technical Manual Download

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NEW

VSI

ECHNICAL

ANUAL

RIVES

ECHNOLOGY

SK80151-1

About this manual

This manual is divided into 6 chapters.

Chapter 1 – Operation

This chapter covers the newVSI operating instructions.

Chapter 2 – Installation

This chapter covers the newVSI mounting, connection and wiring.

Chapter 3 – Programming

This chapter provides detailed information on the newVSI programmable parameters.

Chapter 4 – Diagnostics

This chapter summarizes the diagnostic procedure.

Chapter 5 – Warning Summary

This chapter summarizes the warnings shown throughout the manual.

Chapter 6 – Specifications

This chapter documents the newVSI technical specifications.

Icons

Throughout this manual, icons are used to draw the reader’s attention.

The icons used are:

Note – A general point for best practice.

Caution – A point of safety, which if ignored, could result in damage to the controller or the
vehicle.

Warning – A point of safety, which if ignored, could cause injury to the individual.

PG Drives Technology accepts no liability for any losses of any kind if these points are not followed.

Summary of Contents for NEWVSI

Page 1: ...TECHNICAL MANUAL SK80151 1 ...

Page 2: ...rnished for informational use only is subject to change without notice and should not be construed as a commitment by PG Drives Technology Except as permitted by such terms no part of this manual may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic mechanical recording or otherwise without the prior written permission of PG Drives Technology 44 0 142...

Page 3: ...dy 14 8 2 First LED flashing slowly 14 8 3 Battery Gauge Steps Up 14 8 4 All 5 LEDs in the battery display are flashing 14 8 5 Self Help Guide 14 8 6 Slow or sluggish movement 15 8 7 Maximum Speed Profile Indicator is Steady 15 8 7 1 Maximum Speed Indication 15 8 7 2 Profile Indication 15 8 8 Maximum Speed Profile Indicator Ripples Up and Down 15 9 Battery Gauge 16 9 1 How to Read the Battery Gaug...

Page 4: ...justment while Driving 41 4 7 Service Timer 41 5 Battery Parameters 41 5 1 Cable Resistance 41 5 2 Calibration Factor 42 5 3 Low Battery Alarm 42 5 4 Low Battery LED 42 5 5 Low Voltage Cut Out 42 5 6 Low Voltage Time 42 5 7 Output Voltage 42 6 General Parameters 42 6 1 Fast Brake Rate 42 6 2 Soft Stop Rate 43 6 3 Front Wheel Drive Rate 43 6 4 Soft Reverse Deceleration 43 6 5 Reverse Driving Alarm ...

Page 5: ...p 54 3 10 Trip Type 10 High Battery Voltage 55 3 11 Joystick Displaced at Power up 55 3 12 Timed Foldback Active 55 3 13 Controller in Sleep Mode 55 3 14 High Temperature 55 4 Basic Tests 55 4 1 General Inspection 56 4 2 Brake Test 56 4 3 Drive Test 56 4 4 Gradient Test 56 5 Servicing of Defective Units 56 Chapter 5 Warning Summary 57 1 Introduction 59 2 1 Cleaning 59 2 2 Heat Shield 59 2 3 Precau...

Page 6: ...izes the diagnostic procedure Chapter 5 Warning Summary This chapter summarizes the warnings shown throughout the manual Chapter 6 Specifications This chapter documents the newVSI technical specifications Icons Throughout this manual icons are used to draw the reader s attention The icons used are Note A general point for best practice Caution A point of safety which if ignored could result in dam...

Page 7: ...PG DRIVES TECHNOLOGY NEWVSI TECHNICAL MANUAL OPERATION SK80151 1 7 CHAPTER 1 OPERATION ...

Page 8: ...NEWVSI TECHNICAL MANUAL OPERATION PG DRIVES TECHNOLOGY 8 SK80151 1 ...

Page 9: ...our wheelchair make sure that the controller is well protected Avoid damage to cables 2 2 Operating 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 ...

Page 10: ...nts The battery gauge shows you that the wheelchair is switched on It also indicates the operating status of the wheelchair Details are given in section 8 0 3 2 Locking Unlocking the Wheelchair The newVSI controller can be locked to prevent unauthorized use The locking method is via a sequence of key presses and joystick movements as detailed below To lock the wheelchair While the controller is sw...

Page 11: ...ere are five speed settings step 1 is the lowest speed and step 5 is the highest speed For details of how to change the maximum speed setting see sections 3 6 and 3 7 3 4 2 Profile Indicator This is an indicator that shows the selected drive profile There may be up to 5 drive profiles available this depends on the programming of the controller refer to Chapter 3 For details of how to select drive ...

Page 12: ...ition 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 5 2 Driving Technique The controller interprets your joystick movements and produces appropriate movements of your wheelchair You will need very little co...

Page 13: ...ity for losses of any kind arising from failure to comply with this condition It is the responsibility of the chair manufacturer to ensure that the wheelchair complies with appropriate National and International E M C legislation PGDT accepts no liability for losses of any kind arising from failure to comply with this condition The wheelchair user must comply with all wheelchair safety warnings PG...

Page 14: ...n the controller 8 1 Battery Gauge is Steady This indicates that all is well 8 2 First LED flashing slowly The controller is functioning correctly but you should charge the battery as soon as possible 8 3 Battery Gauge Steps Up The wheelchair batteries are being charged You will not be able to drive the wheelchair until the charger is disconnected and you have switched the controller off and on ag...

Page 15: ... A controller fault is indicated Make sure that all connections are secure 9 Flashes The parking brakes have a bad connection Check the parking brake and motor connections Make sure the controller connections are secure 10 Flashes An excessive voltage has been applied to the controller This is usually caused by a poor battery connection Check the battery connections 8 6 Slow or sluggish movement I...

Page 16: ... 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 9 1 How to Read the Battery Gauge If the battery gauge show...

Page 17: ...es of any kind arising from failure to comply with this condition Only use the battery charger that has been supplied with your wheelchair The use of incorrect chargers could damage the batteries wheelchair controller or charger itself or may result in parts overheating creating the potential for burns or even fire PGDT accepts no liability for losses of any kind if the charger is incompatible wit...

Page 18: ...ng any unauthorized adjustments or modifications to the controller or its components will invalidate any warranty and may result in hazards to yourself or other people and is strictly forbidden PGDT accept no liability for losses of any kind arising from unauthorized opening adjustment or modifications to the newVSI controller If the controller is damaged in any way or if internal damage may have ...

Page 19: ...PG DRIVES TECHNOLOGY NEWVSI TECHNICAL MANUAL INSTALLATION SK80151 1 19 CHAPTER 2 INSTALLATION ...

Page 20: ...NEWVSI TECHNICAL MANUAL INSTALLATION PG DRIVES TECHNOLOGY 20 SK80151 1 ...

Page 21: ... 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 est...

Page 22: ...arger Interlock ISO 7176 14 requires you to provide a means of preventing the use of the wheelchair while the batteries are being charged When a charger is connected to the charger port on the newVS drive is inhibited until the charger is removed and power cycled The wheelchair manufacturer is responsible for providing a means of preventing the use of the wheelchair while the batteries are being c...

Page 23: ...ndard 9 way Beau connector for battery motor and brake connections Only use Beau part S9G 5409CCT PG part 63 20 012 as the mating connector Refer to the following Illustration for connection details The Illustration shows 12V brakes connected in series It is possible to use 24V brakes connected in parallel refer to section 4 5 ...

Page 24: ...NEWVSI TECHNICAL MANUAL INSTALLATION PG DRIVES TECHNOLOGY 24 SK80151 1 3 2 newVSI Anderson This configuration uses Anderson connectors for battery motor and brake connections ...

Page 25: ...ondition Only use the exact parts specified in for the mating connectors The connectors can be purchased from PG Drives Technology or from Anderson directly Hand tools for crimping and extraction are available from Inconnect The references are as below Crimp tool for 0 5 1 0mm2 wire ICT 249 Crimp tool for 2 5 4 0mm2 wire ICT 531 Crimp tool for 4 0 6 0mm2 wire ICT 532 Extraction tool for 0 5 1 0mm2...

Page 26: ...Gauge and Types The table below gives the minimum recommended wire sizes defined in ISO7176 2008 Controller Current Limit A Battery wire size mm2 Motor Wiring size mm2 For Length 1000mm For length 1000mm 1500mm For Length 1000mm For length 1000mm 1500mm 30 2 5 3 0 2 5 2 5 40 3 0 4 0 2 5 3 0 50 4 0 5 0 3 0 4 0 Manufacturers must confirm these recommendations by carrying out suitable tests in partic...

Page 27: ...tly if the brake current is less than approximately 100mA The maximum continuous current is 1A 4 5 1 newVSI Anderson The newVSI Anderson can independently detect open circuit brake faults on either the left or right brake connections This aids the diagnostic process For details of the fault codes refer to chapter 4 section 3 4 5 2 newVSI Beau It is recommended that the wheelchair is fitted with tw...

Page 28: ...t unauthorized chair Failure to observe this warning could result in an unsafe set up for the wheelchair user and may create a fire hazard depending on the motors wiring connectors and circuit breakers installed on the unauthorized chair PGDT accepts no liability for losses of any kind arising from failure to comply with this condition 6 Batteries The controller is designed for operation with 24 V...

Page 29: ...be secured using two M5 screws with a maximum penetration of 12mm Be careful not to over tighten the screws See data sheet for further information 8 1 Orientation The controller is not sensitive to mounting orientation except where it is exposed to water or dust In this situation the controller must be mounted with the joystick shaft pointing vertically upwards to maintain resistance to IPx4 as st...

Page 30: ...the joystick slowly forwards until you hear the parking brakes operate The chair may start to move Immediately release the joystick You must be able to hear each parking brake operate within a few seconds Repeat the test a further three times pushing the joystick slowly backwards left and right 9 6 Test Drive Drive the wheelchair and make sure that it operates correctly for all positions of the us...

Page 31: ...Follow the recommendations in section 12 1 2 to ensure maximum immunity to electromagnetic radiation 11 Battery Gauge For optimum accuracy of the battery gauge and low battery indicator the controller should be programmed with the approximate nominal capacity of the wheelchair battery However accuracy is not greatly affected if the programmed type and capacity do not closely match the battery The ...

Page 32: ...NEWVSI TECHNICAL MANUAL INSTALLATION PG DRIVES TECHNOLOGY 32 SK80151 1 ...

Page 33: ...PG DRIVES TECHNOLOGY NEWVSI TECHNICAL MANUAL PROGRAMMING SK80151 1 33 CHAPTER 3 PROGRAMMING ...

Page 34: ...NEWVSI TECHNICAL MANUAL PROGRAMMING PG DRIVES TECHNOLOGY 34 SK80151 1 ...

Page 35: ...the wheelchair to an individual user These parameters are Acceleration Sleep Timer Deceleration Joystick Throw Turn Acceleration Invert Joystick Turn Deceleration Steer Correct Forward Speed Bleep Volume Reverse Speed Reverse Alarm Turning Speed Speed Adjust Torque Profiles Tremor Damping Power The PP1a and DTT can also be used to read the System Log and Read Timers For details of how to use the P...

Page 36: ...rammable parameters comprising of Acceleration Deceleration Turn Acceleration Turn Deceleration Forward Speed Reverse Speed Turning Speed Power Torque and Tremor Damping The number of drive profiles is determined by the programmable parameter Number of Drive Profiles If the value of Number of Drive Profiles is 0 there is one setting for each of the parameters listed previously and the controller s...

Page 37: ...Correct Switch Bleep Volume Speed Adjustment while Driving Service Timer Battery Section 5 Cable Resistance Calibration Factor Low Battery Alarm Low Battery LED Low Battery Cut Out Low Battery Time Output Voltage General Section 6 Fast Brake Rate Soft Stop Front Wheel Drive Rate Soft Reverse Deceleration Rate Reverse Driving Alarm Brake Disconnected Alarm Lock Function Enabled Brake Fault Detect J...

Page 38: ...m Turn Acceleration parameter 3 4 Turn Deceleration Adjusts the value for turning deceleration or braking of the wheelchair Adjustable in steps of 1 from 0 to 100 A higher value gives faster deceleration This programmed value of deceleration occurs when the controller has speed setting 5 selected Its value at other settings depends on the value of the Minimum Turn Deceleration parameter 3 5 Forwar...

Page 39: ...e acceleration of the wheelchair Adjustable in increments of 1 of the Acceleration value This percentage of the Acceleration value occurs when the newVSI speed setting is at it s minimum 1 bar illumination See following example Acceleration 80 and Minimum Acceleration 25 Acceleration at step 1 25 of 80 20 Speed settings 2 3 and 4 will interpolate linearly between 20 and 80 Acceleration at step 2 3...

Page 40: ...centage of the Turn Deceleration value occurs when the newVSI speed setting is at it s minimum 1 bar illumination See following example Turn Deceleration 80 and Minimum Turn Deceleration 25 Turn Deceleration at step 1 25 of 80 20 Speed settings 2 3 and 4 will interpolate linearly between 20 and 80 Turn Deceleration at step 2 35 Turn Deceleration at step 3 50 Turn Deceleration at step 4 65 4 Operat...

Page 41: ...are not active while the wheelchair is being driven so the joystick must be released and the wheelchair at rest before maximum speed setting adjustments or different drive profile selections can be made 4 7 Service Timer The service timer function is used to set the number of hours that need to elapse before the controller notifies the user that a new service is required The service timer can be p...

Page 42: ...s to sell product into China 5 5 Low Voltage Cut Out This parameters sets the battery voltage threshold that must be read for the period set by Low Voltage Time before the controller ceases to operate This parameter is programmable between 16V and 22V in steps of 0 5V 5 6 Low Voltage Time This parameters sets the time the controller must read the low voltage cut before the controller ceases to ope...

Page 43: ...hair tipping when reversing down a gradient Adjustable between 25 to 100 in steps of 1 The value is a percentage of the Deceleration parameter A typical value is 70 6 5 Reverse Driving Alarm Sets whether the newVSI gives an audible warning while driving in reverse The parameter can be set to on or off On Means there is an audible alarm given Off Means there will be no audible alarm 6 6 Brake Disco...

Page 44: ...ir manufacturer PGDT accept no liability for losses of any kind resulting from the adjustment of these parameters 7 Motor Parameters 7 1 Current Limit Max This parameter sets the long term current output of the newVSI it is programmable between 20 50A in steps of 1Amp 7 2 Current Foldback Threshold Current Foldback Time and Current Foldback Level These parameters can be used to protect the wheelch...

Page 45: ...ally be 40mOhms Example Motor has armature resistance of 200mOhms Cables and connectors are 40mOhms Set Motor Compensation to 0 7 x 200 40 170mOhms Never exceed the 70 relationship described above The chair manufacturer is responsible for ensuring that the controller is matched to the motor resistance Failure to do this may result in poor control characteristics which in extreme instances can make...

Page 46: ...n be set to on or off On Means the motor outputs will be swapped Off Means the motor outputs will not be swapped 7 6 Torque The Torque parameter boosts the current to the motors at low speed settings If the motor is stalled for example the wheelchair is stuck against an obstacle such as a door threshold then this will be automatically detected and the current to the motors will be increased allowi...

Page 47: ...s the wheelchair has been in use 8 2 Clear Timer This function resets the newVSI s timer This function is only present in the OEM and Manufacturing versions of the PC Programmer 8 3 Read System Log The newVSI has a diagnostic log facility which stores the number of occurrences of the last eight detected system problems This allows you to view the contents 8 4 Erase System Log This function clears ...

Page 48: ...NEWVSI TECHNICAL MANUAL PROGRAMMING PG DRIVES TECHNOLOGY 48 SK80151 1 ...

Page 49: ...PG DRIVES TECHNOLOGY NEWVSI TECHNICAL MANUAL DIAGNOSTICS SK80151 1 49 CHAPTER 4 DIAGNOSTICS ...

Page 50: ...NEWVSI TECHNICAL MANUAL DIAGNOSTICS PG DRIVES TECHNOLOGY 50 SK80151 1 ...

Page 51: ...erable areas first Diagnostics should only be conducted by healthcare professionals with in depth knowledge of PGDT electronic controllers An incorrect or badly effected repair could result in an unsafe set up of a wheelchair PGDT accept no liability for losses of any kind arising from an incorrect or badly effected repair 2 Diagnostics 2 1 Diagnostics Process For efficient and effective diagnosis...

Page 52: ...section 5 Check the cable from the controller If this appears to be good then the controller may be defective refer to section 5 2 3 2 Wheelchair drives slowly This could be caused by one of the following The controller has been incorrectly programmed Defective motor or defective brake 2 3 3 Wheelchair will not drive in a straight line This could be caused by a defective motor or defective brake 2...

Page 53: ...JS Time Exceeded 3 7 3D01 3 Left Motor Wiring Trip 3 3 1500 9 Solenoid Brake Trip 3 9 3E00 5 Right Motor Wiring Trip 3 5 1505 9 Left Solenoid Brake Trip 3 9 3E01 5 Right Motor Wiring Trip 3 5 1506 9 Right Solenoid Brake Trip 3 9 4401 8 Control System Trip 3 8 1600 10 High Battery Voltage 3 10 7100 7 Joystick Trip 3 7 2C00 1 Low Battery Voltage 3 1 7821 Thermal Foldback Active 3 14 2C02 Low Battery...

Page 54: ...en made then the controller may be defective Refer to Section 5 3 6 Trip Type 6 Not Used 3 7 Trip Type 7 Possible Joystick Trip This occurs if the controller detects a problem within its own joystick The joystick can only be replaced by a person authorized by the wheelchair manufacturer 1D05 Joystick Stationary Time Exceeded This occurs when the joystick has been held stationary for an excessive p...

Page 55: ...e Status Indicator blinking on once every 2 5 seconds It is not a trip condition but an indication that the controller has gone to sleep To awake the system switch off and on again 3 14 High Temperature This occurs when the controller is in Thermal Foldback i e the current has been reduced in order to protect the controller There are two trip codes associated with this condition 7821 The current h...

Page 56: ... the speed control set to maximum 4 4 Gradient Test Before carrying out this test ensure another person is present to prevent the wheelchair from tipping backwards Drive the wheelchair forwards up its maximum rated gradient While on the gradient release the joystick and ensure the wheelchair comes to rest and the brakes are applied without the front wheels lifting of the ground Deflect the joystic...

Page 57: ...PG DRIVES TECHNOLOGY NEWVSI TECHNICAL MANUAL WARNING SUMMARY SK80151 1 57 CHAPTER 5 WARNING SUMMARY ...

Page 58: ...NEWVSI TECHNICAL MANUAL WARNING SUMMARY PG DRIVES TECHNOLOGY 58 SK80151 1 ...

Page 59: ... 4 2 3 Precautions for Use In the event of the wheelchair moving in an unexpected way RELEASE THE JOYSTICK This action will remove drive and power to the electro magnetic brakes Chapter 1 Section 6 2 4 Hazards Although the newVSI 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 ...

Page 60: ...rising from failure to comply with this condition Only use the battery charger that has been supplied with your wheelchair The use of incorrect chargers could damage the batteries wheelchair controller or charger itself or may result in parts overheating creating the potential for burns or even fire PGDT accepts no liability for losses of any kind if the charger is incompatible with the controller...

Page 61: ...liability for losses of any kind arising from failure to comply with this condition Chapter 2 Section 2 2 2 12 Wiring The chair manufacturer is responsible for establishing the suitability of the particular wiring arrangements used on the wheelchair for both normal use and stalled conditions PGDT can make general recommendations for wiring for newVSI controllers but PGDT accepts no responsibility ...

Page 62: ...failure to comply with this condition Chapter 2 Section 5 2 15 Battery Charging Do not exceed the maximum charging current of 12 A rms Always use an off board charger fitted with a Neutrik NC3MX plug Failure to observe these conditions could result in poor contact resistance in the charger connector resulting in overheating of the charger plugs This presents a potential burn hazard for the user PG...

Page 63: ...a chair uncontrollable and potentially unsafe PGDT accepts no liability for losses of any kind arising from failure to comply with this condition Users must not move a controller from one chair type to install it on a different chair type controllers with different part numbers may have both hardware and software differences to ensure that they are compatible with the electrical and dynamic charac...

Page 64: ... person s to perform other tests relevant to the original trip and wheelchair type Refer to the wheelchair s Technical Manual for exact information of other tests PGDT accept no liability for losses of any kind arising from failure to carry out of the described tests or from not carrying out additional relevant tests These tests should be conducted in an open space and a restraining device such as...

Page 65: ...PG DRIVES TECHNOLOGY NEWVSI TECHNICAL MANUAL SPECIFICATIONS SK80151 1 65 CHAPTER 6 SPECIFICATIONS ...

Page 66: ...NEWVSI TECHNICAL MANUAL SPECIFICATIONS PG DRIVES TECHNOLOGY 66 SK80151 1 ...

Page 67: ...cy 19 5kHz 1 Brake Voltage 24Vdc Brake Current 1 25A max Battery Charging Current 12Arms max Charger Connector Use only Neutrik NC3MX Maximum Drive Current 50A Moisture Resistance IPx4 Operating Temperature 25 C to 50 C Storage Temperature 40 C to 65 C EMC tested on sample wheelchair Susceptibility Tested at 30V m to EN12184 and ANSI RESNA requirements Emissions To EN55022 Class B ESD IEC801 part ...

Page 68: ...NEWVSI TECHNICAL MANUAL SPECIFICATIONS PG DRIVES TECHNOLOGY 68 SK80151 1 ...

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