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Summary of Contents for PG DRIVE TECHNOLOGY NEWVSI
- Page 1 TECHNICAL MANUAL SK80151-1...
- Page 2 © PG Drives Technology 2011 All rights reserved. This manual is furnished under copyright and may only be used in accordance with the terms laid out by PG Drives Technology. The information in this manual is furnished for informational use only, is subject to change without notice, and should not be construed as a commitment by PG Drives Technology.
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Page 3: Table Of Contents
Charger Interlock ..........22 Getting Ready to Drive ......12 Connections ..........22 Tips for Using Your controller ..... 12 newVSI - Beau ............ 23 Driving - General ..........12 newVSI - Anderson ..........24 Driving Technique ..........12 Crimping ............25 Precautions for Use ........ - Page 4 VSI T PG D ECHNICAL ANUAL RIVES ECHNOLOGY Mounting ............29 Cable Resistance ..........41 Cables and Connectors ........30 Calibration Factor ..........42 Joystick and Gaiter ..........30 Low Battery Alarm ..........42 Preset Settings ............. 30 Low Battery LED ..........42 Operational Test ..........
- Page 5 PG D VSI T RIVES ECHNOLOGY ECHNICAL ANUAL Other conditions ..........52 2.13 Battery Wiring ............61 2.3.1 Controller will not switch on ......... 52 2.14 Drive Motors ............62 2.3.2 Wheelchair drives slowly ........52 2.15 Battery Charging ..........62 2.3.3 Wheelchair will not drive in a straight line ...
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Page 6: About This Manual
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. -
Page 7: Chapter 1 - Operation
PG D VSI T – O RIVES ECHNOLOGY ECHNICAL ANUAL PERATION CHAPTER 1 – OPERATION SK80151-1... - Page 8 VSI T PG D ECHNICAL ANUAL PERATION RIVES ECHNOLOGY SK80151-1...
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Page 9: Introduction
Heat Shield The newVSi is built with an integrated heat shield. The purpose of the heat shield is to protect the wheehchair user from exposure to metal parts of the controller. Should the heatshield become damaged it should be replaced immediately. -
Page 10: Controls
8.0. 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 switched on, depress and hold the on/off button. -
Page 11: Joystick
PG D VSI T – O RIVES ECHNOLOGY ECHNICAL ANUAL PERATION Release the joystick, there will be a long bleep. • The wheelchair is now locked. • To unlock the wheelchair: Use the on/off button to switch the controller on. The maximum speed / profile indicator will be rippling up and down. •... -
Page 12: Getting Ready To Drive
You can reset this condition by switching the controller off and on again. If the battery gauge flashes rapidly, then the newVSI has detected a problem somewhere in the wheelchair’s electrical system. Refer to section 8.5 for details. -
Page 13: Safety Checks
If you know that the controller or other crucial components require repair. • 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 the probability). -
Page 14: Servicing
All 5 LEDs in the battery display are flashing The controller safety circuits have operated and the controller has been prevented from moving the wheelchair. This indicates a system trip, i.e. the newVSI has detected a problem somewhere in the wheelchair’s electrical system. Please follow this procedure: Switch off the controller. -
Page 15: Slow Or Sluggish Movement
PG D VSI T – O RIVES ECHNOLOGY ECHNICAL ANUAL PERATION Below is a list of self-help actions. Try to use this list before you contact your service agent. Go to the number in the list which matches the number of flashes of the battery gauge and follow the instructions. If the problem persists after you made the checks described above contact your service agent. -
Page 16: Battery Gauge
To connect the charger plug, ensure the single pin is at the bottom, as shown in the following illustration, then offer the charger plug to the newVSI in a horizontal orientation. The molded guide on the newVSI will help you to locate the plug. Ensure the plug is pushed fully in position. -
Page 17: Programming
PG D VSI T – O RIVES ECHNOLOGY ECHNICAL ANUAL PERATION Do not exceed the maximum charging current of 12 Arms. 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. -
Page 18: Joystick Knobs
Warranty The newVSI controller is covered by a warranty period defined by the wheelchair manufacturer. For details of the warranty period, please contact your service agent. -
Page 19: Chapter 2 - Installation
PG D VSI T – I RIVES ECHNOLOGY ECHNICAL ANUAL NSTALLATION CHAPTER 2 – INSTALLATION SK80151-1... - Page 20 VSI T – I PG D ECHNICAL ANUAL NSTALLATION RIVES ECHNOLOGY SK80151-1...
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Page 21: Documentation
Soft-Stop The newVSI has a programmable value called Soft Stop Rate which sets the emergency stopping distance. You must ensure that the emergency stopping distance is within the distance specified for the country in which the wheelchair will be used. TÜV Product Service (Germany) specify the distance to be as stated in EN12184. -
Page 22: Immobilizing The Wheelchair
PGDT accepts no liability for losses of any kind arising from failure to comply with this condition. Connections There are two generic connector configurations of the newVSI controller. newVSI - Beau newVSI – Anderson... -
Page 23: Newvsi - Beau
ECHNICAL ANUAL NSTALLATION newVSI - Beau This configuration uses the industry standard 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. -
Page 24: Newvsi - Anderson
VSI T – I PG D ECHNICAL ANUAL NSTALLATION RIVES ECHNOLOGY newVSI - Anderson This configuration uses Anderson connectors for battery, motor and brake connections. SK80151-1... -
Page 25: Crimping
You are responsible for establishing the suitability of the particular wiring arrangement used on the wheelchair. PGDT can make general recommendations for wiring for newVSI controllers, but PGDT accepts no responsibility for the wiring arrangement used. -
Page 26: Wire Gauge And Types
PGDT can make general recommendations for wiring for newVSI controllers, but PGDT accepts no responsibility for, and accepts no liability for losses of any kind arising from, the actual wiring arrangement used. -
Page 27: Motor Wiring
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... -
Page 28: Batteries
Contact PGDT for advice on battery selection. Battery Charging All newVSI controllers have a battery charging socket mounted on their front face for connection to an off-board charger. While the battery is being charged the newVSI’s TruCharge display will continuously ripple or step upwards. -
Page 29: Mounting
PG D VSI T – I RIVES ECHNOLOGY ECHNICAL ANUAL NSTALLATION Ensure that the charger plug pins are of the correct polarity to be compatible with the pin polarity shown on the controller’s specific data sheet. Failure to observe this condition could result in a burn hazard or fire hazard. -
Page 30: Cables And Connectors
In addition, ensure that the requirements in section 1.3 of this chapter are satisfied. Electromagnetic Compatibility (E.M.C.) The newVSI controller has been tested for compliance with the EMC requirements of EN12184. The guidelines in this section will help you to make sure that your wheelchair installation will meet the requirements of the directive. -
Page 31: Motor Suppression
10.2 Immunity The newVSI controller has been stringently tested for susceptibility to electromagnetic radiation over the frequency range 26 MHz to 1 GHz. The test was conducted on a typical wheelchair installation and passed the requirements of EN12184. Follow the recommendations in section 12.1.2 to ensure maximum immunity to electromagnetic radiation. - Page 32 VSI T – I PG D ECHNICAL ANUAL NSTALLATION RIVES ECHNOLOGY SK80151-1...
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Page 33: Chapter 3 - Programming
PG D VSI T – P RIVES ECHNOLOGY ECHNICAL ANUAL ROGRAMMING CHAPTER 3 – PROGRAMMING SK80151-1... - Page 34 VSI T – P PG D ECHNICAL ANUAL ROGRAMMING RIVES ECHNOLOGY SK80151-1...
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Page 35: Introduction
OEMs which gives access to all standard newVSI controller parameters and one for use by OEM’s on their production lines. These are known as Dealer, OEM and Manufacturing respectively. For details of how to use these software packages with the newVSI, refer to the documentation supplied with the software. Safety Fences Limits (or fences) can be applied to some dealer accessible programmable parameters. -
Page 36: Drive Profiles
Drive Profiles The newVSI can operate with single or multiple drive profiles. A drive profile is a collection of programmable parameters comprising of Acceleration, Deceleration, Turn Acceleration, Turn Deceleration, Forward Speed, Reverse Speed, Turning Speed, Power, Torque and Tremor Damping. -
Page 37: Programmable Parameters
PG D VSI T – P RIVES ECHNOLOGY ECHNICAL ANUAL ROGRAMMING Programmable Parameters The parameters have been separated into workable groups for easy referencing. Speeds - Section 3 Acceleration Deceleration Turn Acceleration Turn Deceleration Forward Speed Reverse Speed Turning Speed Power Number of Drive Profiles Minimum Acceleration... -
Page 38: Speed Parameters
VSI T – P PG D ECHNICAL ANUAL ROGRAMMING RIVES ECHNOLOGY Speed Parameters Acceleration Adjusts the value for forward and reverse acceleration of the wheelchair. Adjustable in steps of 1 from 0 to 100. A higher value gives faster acceleration. This programmed value of acceleration occurs when speed setting 5 is selected. Its value at other settings depends on the value of the Minimum Acceleration parameter. -
Page 39: Power
Adjusts the minimum value for forward and reverse 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. -
Page 40: Minimum Turn Acceleration
Adjusts the minimum value for turning acceleration of the wheelchair. Adjustable in increments of 1% of the Turn Acceleration value. This percentage of the Turn Acceleration value occurs when the newVSI speed setting is at it’s minimum 1 bar illumination. See following example. -
Page 41: Steer Correct
Battery Parameters Cable Resistance This parameter should be set to the total value of the electrical resistance of wires between the batteries and the newVSI body. This parameter ensures the TruCharge battery gauge gives an accurate reading under all driving conditions. -
Page 42: Calibration Factor
This allows further fine calibration of the TruCharge battery gauge. This is normally set at the factory and should not need further adjustment. Low Battery Alarm This parameter sets whether the level newVSI will signal a low battery condition. O = Off, 1= Red LED flashing, 2= Red LED steady. -
Page 43: Soft Stop Rate
Adjustable between 0 and 200 in steps of 1. Front Wheel Drive Rate Front Wheel Drive Rate adjusts the driving characteristics of the newVSI to suit a wide range of front wheel drive wheelchairs. Adjustable between 1 and 100 in steps of 1. -
Page 44: Joystick Stationary Time
The parameters Time and Level can be used to protect the motors from overheating. If the motor current exceeds the value set by Threshold for a period set by Time, then the newVSI’s current output will be reduced to a value set by Level. -
Page 45: Current Foldback Threshold
This is useful for protecting motors against potential damage when the wheelchair is being used on a long gradient. After 15 seconds the current output of the newVSI will reduce to 25% of 50A = 12.5A. After 5 x 15s = 75s, the current output will return to 50A. -
Page 46: Invert M1 Direction
Means the motor will rotate in the normal direction. Motor Swap This swaps the motor output channels of the newVSI. I.e. left becomes right and right becomes left. The parameter can be set to on or off. Means the motor outputs will be swapped. -
Page 47: Memory Functions
Read Timer The newVSI has a timer which records how long the wheelchair is in use. The timer runs whenever the joystick is moved away from the center position, and stops when the joystick is released. The timer records the number of hours the wheelchair has been in use. - Page 48 VSI T – P PG D ECHNICAL ANUAL ROGRAMMING RIVES ECHNOLOGY SK80151-1...
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Page 49: Chapter 4 - Diagnostics
PG D VSI T – D RIVES ECHNOLOGY ECHNICAL ANUAL IAGNOSTICS CHAPTER 4 – DIAGNOSTICS SK80151-1... - Page 50 VSI T – D PG D ECHNICAL ANUAL IAGNOSTICS RIVES ECHNOLOGY SK80151-1...
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Page 51: Introduction
PG D VSI T – D RIVES ECHNOLOGY ECHNICAL ANUAL IAGNOSTICS Introduction The primary objective of this section is to assist service personnel in finding the likely area of a detected fault within the whole wheelchair electrical system. It is important to realize that even though the controller is signaling a fault, it may not be the controller itself that is defective. -
Page 52: 2.2.3 Display Is Steady
VSI T – D PG D ECHNICAL ANUAL IAGNOSTICS RIVES ECHNOLOGY 2.2.3 Display is steady No trip is currently detected by the controller. • A trip may have occurred previously, read the controller’s diagnostic log, then refer to section 3 to establish the trip type. -
Page 53: Trip Diagnosis
PG D VSI T – D RIVES ECHNOLOGY ECHNICAL ANUAL IAGNOSTICS Trip Diagnosis There are two methods of trip diagnosis. 2.4.1 Trip diagnosis with the battery gauge The battery gauge Flash Codes are illustrated in Chapter 1 Section 8. 2.4.2 Using a programmer to read the trip code If you connect a programmer while the battery gauge is flashing, then a four digit trip code will be displayed. -
Page 54: Trip Type 3 - Left Motor Wiring Trip
VSI T – D PG D ECHNICAL ANUAL IAGNOSTICS RIVES ECHNOLOGY If the trip is still present after the above checks have been made, then the controller may be defective. Refer to Section 5. Trip Type 3 – Left Motor Wiring Trip This occurs when the controller detects a fault in the wiring to the left motor, in particular if a motor connection has short-circuited to a battery connection. -
Page 55: Trip Type 10 - High Battery Voltage
PG D VSI T – D RIVES ECHNOLOGY ECHNICAL ANUAL IAGNOSTICS 3.10 Trip Type 10 - High Battery Voltage This occurs when the controller detects that the battery voltage has risen above 35V. The most common reasons for this are overcharging of the battery or bad connections between the controller and the batteries. -
Page 56: General Inspection
VSI T – D PG D ECHNICAL ANUAL IAGNOSTICS RIVES ECHNOLOGY General Inspection Make sure all connectors are securely mated. • Check the condition of all cables and connectors for damage. • Check the thin rubber gaiter or boot around the base of the joystick shaft for damage. Check visually only, do not handle the gaiter. -
Page 57: Chapter 5 - Warning Summary
PG D VSI T – W RIVES ECHNOLOGY ECHNICAL ANUAL ARNING UMMARY CHAPTER 5 – WARNING SUMMARY SK80151-1... - Page 58 VSI T – W PG D ECHNICAL ANUAL ARNING UMMARY RIVES ECHNOLOGY SK80151-1...
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Page 59: Introduction
This section summarizes all of the very important warnings that appear throughout the text of this manual. Do not install, maintain or operate the newVSI controller without reading, understanding and observing the following warnings. Failure to observe these warnings could result in UNSAFE CONDITIONS for the user of a wheelchair or affect the reliability of the controller. PG Drives Technology accepts no liability for losses of any kind arising from failure to comply with any of the conditions in the warnings listed below. -
Page 60: Battery Charging
Servicing 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 occurred through impact or dropping, have the product checked by qualified personnel before operating. PGDT accepts no liability for losses of any kind arising from failure to comply with this condition. -
Page 61: Warranty
UMMARY Warranty The warranty will be void if the newVSI has not been used in accordance with newVSI Technical Manual SK80151, the newVSI has been subject to misuse or abuse, or if the newVSI has been modified or repaired by unauthorized persons. Chapter 1 Section 14. -
Page 62: Drive Motors
VSI T – W PG D ECHNICAL ANUAL ARNING UMMARY RIVES ECHNOLOGY 2.14 Drive Motors 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 a chair uncontrollable and potentially unsafe. -
Page 63: Safety Fences
PG D VSI T – W RIVES ECHNOLOGY ECHNICAL ANUAL ARNING UMMARY 2.18 Safety Fences PGDT accepts no liability for losses of any kind if the chair manufacturer does not specify appropriate safety fence values for a particular vehicle application. Chapter 3 Section 2.1. 2.19 Joystick Stationary Time &... -
Page 64: 2.23 Diagnostics - Introduction
VSI T – W PG D ECHNICAL ANUAL ARNING UMMARY RIVES ECHNOLOGY 2.23 Diagnostics - Introduction 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. -
Page 65: Chapter 6 - Specifications
PG D VSI T – S RIVES ECHNOLOGY ECHNICAL ANUAL PECIFICATIONS CHAPTER 6 – SPECIFICATIONS SK80151-1... - Page 66 VSI T – S PG D ECHNICAL ANUAL PECIFICATIONS RIVES ECHNOLOGY SK80151-1...
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Page 67: Electrical Specifications
PG D VSI T – S RIVES ECHNOLOGY ECHNICAL ANUAL PECIFICATIONS Electrical Specifications Supply Voltage: 24Vdc Operating Voltage: 16Vdc to 35Vdc Reverse Battery Protection: -40Vdc PWM Frequency: 19.5kHz ± 1% Brake Voltage: 24Vdc Brake Current: 1.25A max. Battery Charging Current: 12Arms max. - Page 68 VSI T – S PG D ECHNICAL ANUAL PECIFICATIONS RIVES ECHNOLOGY SK80151-1...
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