PP1a Programmer Pilot, Pilot+ and VSI Control Systems PROGRAMMING AND DIAGNOSTICS SK73747/ Penny & Giles Drives Technology Ltd.

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1 PP1a Programmer Pilot, Pilot+ and VSI Control Systems PROGRAMMING AND DIAGNOSTICS SK73747/ Penny & Giles Drives Technology Ltd.

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3 PENNY+GILES DRIVES TECHNOLOGY CONTENTS CONTENTS CONTENTS...iii Chapter... 7 PROGRAMMING Introduction Use of a PP1a with Pilot, Pilot+ and VSI...8 Table 1 PP1a / Control System Compatibility PP1a Keypad Layout & Description Connection Menu Acceleration? Deceleration? Turn Accel n? Turn Decel n? Forward Speed? Reverse Speed? Pilot Reverse Speed? Pilot+ and VSI Reverse Speed? Turning Speed? Power? Sleep Timer? Joystick Throw? Manual Adjustment Programming Adjustment Steer Correct? Switch Bleep? Bleep Volume? Speed Adjust? Act. Selection? Actuator 1? Speed? End Force? Actuator 1? Speed? End Force? Profiles? iii

4 CONTENTS PENNY+GILES DRIVES TECHNOLOGY 4.19 Read Timer? Read System Log? Preset Unit? Chapter...19 DIAGNOSTICS Introduction Diagnostics Process Detecting a Trip has Occurred Flashing Rapidly Flashing Slowly Display is Steady Display Does Not Illuminate Establishing the Trip Type Rapidly Flashing TruCharge Figure 1 TruCharge Display Diagnostics Using a Programmer to Read the Trip Code Pilot Trip Table Pilot+ Trip Table VSI Trip Table Trip Types and Their Possible Causes Trip Type 1 - Low Battery Voltage Trip Type 2 Left Motor Disconnected Trip Type 3 Left Motor Wiring Fault Trip Type 4 Right Motor Disconnected Trip Type 5 - Motor Wiring Fault Trip Type 6 Charger Connected Trip Type 7 Possible Joystick Trip Trip Type 8 - Possible Controller Trip Trip Type 9 - Solenoid Brake Fault Trip Type 10 - High Battery Voltage Sleep Joystick Displaced at Power-up Inhibit Communications Error Power Loss Dual Attendant Module Trip Dual Joystick Displaced at Power-up Dual Communications Error Omni+ Trip Sip and Puff Out Of Calibration Omni+ Input Device iv

5 PENNY+GILES DRIVES TECHNOLOGY CONTENTS 7.22 Omni+ Analog Input Out of Calibration Right Motor Feedback Left Motor Feedback Charging Inhibit 2 Active Inhibit 3 Active Other Conditions Control System Will Not Switch On Wheelchair Drives Slowly Wheelchair Will Not Drive in a Straight Line One Motor or Brake becomes Very Warm Batteries Discharge Very Quickly Basic Tests General Inspection Brake Test Drive Test Gradient Test Servicing of Defective Units Appendix WARNINGS SUMMARY Introduction Chapter 1 Section Introduction Chapter 1 Section 3.0 Connection Chapter 2 Section 1.0 Diagnostics Chapter 2 Section 9.0 Basic Tests Chapter 2 Section Servicing v

6 CONTENTS PENNY+GILES DRIVES TECHNOLOGY vi

7 PENNY+GILES DRIVES TECHNOLOGY PROGRAMMING Chapter PROGRAMMING Introduction The main advantage of using programmable controllers is that they can be easily tailored to the specific needs and capabilities of a particular wheelchair while taking into account safe performance characteristics. The programmable controller 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 vehicles and users, using a simple, hand-held programmer. Please note, it is possible to set up a control system so that it is unsuitable for some users or even some wheelchairs. For all of the above reasons it is important that you contact Penny & Giles Drives Technology if you have the slightest doubts or if you need any advice on programming. WARNING Programming should only be conducted by healthcare professionals with in-depth knowledge of Penny & Giles electronic control systems. Incorrect programming could result in an unsafe set-up of a wheelchair for a user. Penny & Giles accept no liability for any losses of any kind if the programming of the control system is altered from the factory pre-set values. Chapter 1: 7

8 PROGRAMMING PENNY+GILES DRIVES TECHNOLOGY 1.1 Use of a PP1a with Pilot, Pilot+ and VSI In general all PP1a Programmers can be used with Pilot, Pilot+ and VSI control systems. However, depending on the exact version of PP1a you have, then some functions may not be available. You can identify your PP1a by looking at the type number. This will be D49510/x, where x is the version number. The table below summarizes the full compatibility between the PP1a versions and the Pilot, Pilot+ and VSI control systems. Table 1 PP1a / Control System Compatibility Function ❶ Control System PP1a Version Acceleration? P, P+, VSI All Deceleration? P, P+, VSI All Turn Accel n? P, P+, VSI All Turn Decel n? P, P+, VSI All Forward Speed? P, P+, VSI All Reverse Speed? P, P+, VSI All Turning Speed? P, P+, VSI All Power? P+ ❸, VSI ❹ /7 onwards Sleep Timer? P ❷, P+, VSI /5 omwards Joystick Throw? P+, VSI /5 onwards Steer Correct? P ❷, P+, VSI /5 onwards Switch Bleep? VSI /6 onwards Bleep Volume? VSI /6 onwards Act. Selection? VSI /6 onwards Actuator 1 Speed? VSI /6 onwards Actuator 1 End Force? VSI /7 onwards Actuator 2 Speed? VSI /6 onwards Actuator 2 End Force? VSI /7 onwards Profiles? P+, VSI /7 onwards Read Timer? P+, VSI /5 onwards Read System Log? P, P+, VSI All Preset Unit? P, P+, VSI All ❶ P = Pilot, P+ = Pilot+ ❷ Not Pilots manufactured before June 1998 ❸ Not Pilot+ manufactured before February 2002 ❹ Not VSI manufactured before May 2002 Chapter 1: 8

9 PENNY+GILES DRIVES TECHNOLOGY PROGRAMMING 2.0 PP1a Keypad Layout & Description Help Button Pressing this button displays information regarding the function you have selected. In menus, HELP tells you what each option does. In options it tells you what to do next. Up/Yes Button This button increases settings or selects functions. Down/No Button This button decreases settings or de-selects functions. Enter Button This button selects options, settings or function states. Chapter 1: 9

10 PROGRAMMING PENNY+GILES DRIVES TECHNOLOGY 3.0 Connection The PP1a is connected to the control system via the charging socket, it does not matter which charging polarity type you have. The PP1a reacts differently depending on status of the control system. If the control system is on and working, and the PP1a is connected, its menu will be displayed and the PP1a may be used to change the programming parameters of the control system. The wheelchair may be driven while the PP1a is connected. If the controller is on and in a tripped state, and the PP1a is connected, a message relating to the trip will automatically be displayed. Once the message has been read, you can select the ENTER key to display the menu and begin programming the control system. If the control system is off and the PP1a is connected, it will display a no connection message. If the control system is now turned on, the PP1a will enter the programming menu. WARNING When the PP1a is connected to the control system, the Electromagnetic Compatibility (EMC) performance of the wheelchair may be affected. Disconnect the PP1a as soon as programming is complete and do not use the PP1a environments which are EMC sensitive. 4.0 Menu The menu contains all the parameters which set the normal drive characteristics of the wheelchair. From this menu you can also read the control system s log. Each menu option is explained in the following paragraphs. Chapter 1: 10

11 PENNY+GILES DRIVES TECHNOLOGY PROGRAMMING Depending on the control system you are programming, not all these programmable parameters will be present. Refer to section titled Use of PP1a with Pilot, Pilot+ and VSI. If you are programming a Pilot+ or VSI control system, there may be limits, other than 0 and 100, to the upper and lower values of the following parameters. These limits have been set by Penny & Giles in conjunction with the wheelchair manufacturer and are intended to help you keep the wheelchair within its optimum performance envelope. 4.1 Acceleration? Adjusts the value for the forward and reverse acceleration of the wheelchair, in increments of 1. A higher value gives a faster acceleration. 4.2 Deceleration? Adjusts the value for the forward and reverse deceleration (braking) of the wheelchair, in increments of 1. A higher value gives a faster braking rate. 4.3 Turn Accel n? Adjusts the value for the forward and reverse turn acceleration of the wheelchair, in increments of 1. A higher value gives a faster turn acceleration. 4.4 Turn Decel n? Adjusts the value for the forward and reverse turn deceleration (braking) of the wheelchair, in increments of 1. A higher value gives a faster braking rate 4.5 Forward Speed? Adjusts the value for maximum and minimum forward speed of the wheelchair. The maximum value occurs at the control system s maximum speed setting and the minimum occurs at the control systems minimum speed setting. Chapter 1: 11

12 PROGRAMMING PENNY+GILES DRIVES TECHNOLOGY 4.6 Reverse Speed? Adjusts the maximum value for the reverse speed of the wheelchair, in increments of 1%. The maximum value occurs when the control system s speed setting is at maximum and the minimum occurs at the control system s minimum speed setting. The minimum value is interpreted differently in Pilot, Pilot+ and VSI control systems Pilot Reverse Speed? This is automatically scaled in relationship to the forward speed setting and calculated as below. min. reverse = max. forward x min forward max forward Pilot+ and VSI Reverse Speed? This corresponds to the actual value selected with the PP1a Programmer. 4.7 Turning Speed? Adjusts the minimum and maximum values for the turning speed of the wheelchair, in increments of 1%. The maximum value occurs when the control system s speed setting is at maximum and the minimum occurs at the control system s minimum speed setting. 4.8 Power? Reduces the power output of the control system. The main purpose is to limit damage to furniture or doorways if the wheelchair is being used indoors. This is particularly useful on wheelchairs designed for children. If this parameter is used with the control system programmed for multiple drive profiles, then indoor and outdoor profiles can be set. The parameter is adjustable between 10% and 100%. Chapter 1: 12

13 PENNY+GILES DRIVES TECHNOLOGY PROGRAMMING 4.9 Sleep Timer? Sets the period of time before the control system will go to sleep if the wheelchair is not driven. The time can be set between 1 and 10 minutes in steps of 1 minute. If the time is set to 0 the system will never go to sleep Joystick Throw? This allows you to program the control system so that full speed can be reached with a reduced joystick movement (throw). This is particularly useful for wheelchair users with limited hand or arm movement. The adjustment can be made manually or by programming actual values. This parameter is not present in Pilot controllers 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 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. Chapter 1: 13

14 PROGRAMMING PENNY+GILES DRIVES TECHNOLOGY 4.11 Steer Correct? This factor compensates for any mismatching of motors to ensure that the wheelchair drives directly forward when the control system s joystick is being pushed directly forward. It is normally set to zero but may be varied from -9 to +9 in increments of 1. If the chair is veering to the left, you should increase the setting. If the chair veers to the right, decrease the setting. Note, some Pilot+ control systems may be programmed such that this logic is reversed. If in doubt, contact the wheelchair manufacturer or Penny & Giles Switch Bleep? Sets whether a bleep occurs when a control system switch is operated. You can set this function to yes or no. This function is not preset in Pilot or Pilot+ control systems Bleep Volume? Adjusts the volume of the bleeper if Switch Bleep is set to yes. The volume can be set between 1 and is the quietest, 10 is the loudest. This function is not preset in Pilot or Pilot+ control systems Speed Adjust? Sets whether the control system s speed/profile buttons will be active while the wheelchair is driving. You can set this function to yes or no. yes means the control system s speed/profile buttons will be active while driving no means the buttons will only be active when the joystick is in the central position. This adjustment is particularly useful for users who may accidentally operate these buttons while deflecting the joystick. This function is not preset in Pilot or Pilot+ control systems. Chapter 1: 14

15 PENNY+GILES DRIVES TECHNOLOGY PROGRAMMING 4.15 Act. Selection? Sets whether the joystick can be used to select between actuator channels 1 and 2. You can set this function to yes or no. yes means that when the control system is in actuator mode, then left or right movements of the joystick will select between actuator channels 1 and 2. no means that when the control system is in actuator mode, then left or right movements of the joystick will have no effect. This function is not preset in Pilot or Pilot+ control systems. Refer to the wheelchair s operating manual for more information on actuator operation Actuator 1? There are two programmable parameters relating to actuator channel 1. This function is not preset in Pilot or Pilot+ control systems Speed? Sets the speed of travel of the actuator connected to channel 1. The speed can be set between 1 and 5. 1 is the slowest, 5 is the fastest End Force? This value should not normally require any adjustment and should not be altered without the permission of the wheelchair manufacturer Actuator 1? There are two programmable parameters relating to actuator channel 2. This function is not preset in Pilot or Pilot+ control systems Speed? Sets the speed of travel of the actuator connected to channel 2. The speed can be set between 1 and 5. 1 is the slowest, 5 is the fastest End Force? This value should not normally require any adjustment and should not be altered without the permission of the wheelchair manufacturer. Chapter 1: 15

16 PROGRAMMING PENNY+GILES DRIVES TECHNOLOGY 4.18 Profiles? The VSI or Pilot+ 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, Turn Speed and Power. The number of drive profiles is determined by this parameter. If the value is 0, there is one setting for each of the parameters listed previously, and the control system s maximum speed setting can be changed on the normal way. If the value is 2 to 5, there is a corresponding number of drive profiles and each listed parameter can be individually set within a profile. The normal method of maximum speed adjustment can then be used to switch between the available profiles. Note, although the value can be set to 1, the operation is the same as setting to 0 but without the ability to change maximum speed settings. If you are working with a Pilot+ control system, you must ensure the Joystick Module is capable of supporting multiple drive profiles. The wheelchair s manufacturer will be able to advise 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 the center position, and stops when the joystick is returned. The timer records the number of hours the wheelchair has been in use. This function is not present in Pilot controllers Read System Log? The control systems have a diagnostics log facility which stores the number of occurrences of the last eight trip codes. This allows you to view the contents. The display format is as below. 1: Code 2C00, #1 2: Code 3C00, #3 Chapter 1: 16

17 PENNY+GILES DRIVES TECHNOLOGY PROGRAMMING no more entries This reads line by line as. Line 1 - trip code 2C00 has occurred once Line 2 - trip code 3C00 has occurred three times Only two trip types recorded Preset Unit? Selecting this sets all menu parameters to their default values. The default values are stored in the controller by Penny & Giles during manufacture. Chapter 1: 17

18 PROGRAMMING PENNY+GILES DRIVES TECHNOLOGY Chapter 1: 18

19 PENNY+GILES DRIVES TECHNOLOGY DIAGNOSTICS Chapter DIAGNOSTICS Introduction The primary objective of this guide 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 control system is signaling a fault, it may not be the control system itself that is defective. This is because the control system is able to detect problems in other electrical components (motors, batteries, solenoid brakes etc.) or, more importantly, the wiring to them. When a control system has detected a fault a system trip is indicated. This guide covers diagnostics of wheelchairs fitted with Penny & Giles Pilot, Pilot+ or VSI control systems. For a basic diagnostic capability it is not necessary to have a programmer to use this guide, as all these control systems have a sophisticated level of on-board diagnostics. Using this guide, it is possible to define a trip as belonging to one of 10 types. Once this type has been established, there are suggestions as to what the possible cause may be. The guide should only be used to decide the starting point of your own diagnosis, as it is possible for the controller to indicate a fault in another component even though the controller itself may be defective. Nevertheless, experience has shown that connectors and wiring are the major cause of wheelchair electrical problems, so it is necessary to examine these more vulnerable areas first. Chapter 2: 19

20 DIAGNOSTICS PENNY+GILES DRIVES TECHNOLOGY WARNING Diagnostics should only be conducted by healthcare professionals with in-depth knowledge of Penny & Giles electronic controllers. An incorrect or badly effected repair could result in an unsafe set-up of a wheelchair. Penny & Giles accept no liability for losses of any kind arising from an incorrect or badly effected repair. 1.1 Diagnostics Process For efficient and effective diagnosis the following basic steps should be taken. 1. Establish the type of control system fitted to the wheelchair. 2. Confirm there is a trip, or has been an intermittent trip. Refer to section Establish the trip type. Refer to section Refer to the relevant trip table for the control system you are working with. See section 4.0 for Pilot., section 5.0 for Pilot+ or section 6.0 for VSI. 5. Refer to the possible cause as indicated by the trip table, and carry out recommended investigative and corrective action. Section Carry out basic tests as described in section Detecting a Trip has Occurred Firstly observe the control system s TruCharge (battery gauge) display. The will behave as described in one of the following sections. Chapter 2: 20

21 PENNY+GILES DRIVES TECHNOLOGY DIAGNOSTICS 2.1 Flashing Rapidly The control system is tripped. To determine the trip type, refer to section 3.0. Connecting a programmer to the control system while this is happening will give you a trip code. 2.2 Flashing Slowly No trip is currently detected by the control system. The slow flash is an indication that the batteries require charging. A trip may have occurred previously, refer to Chapter 1 section 4.17 for details of how to read the control system s diagnostic log, then section 3.2 to establish the trip type. 2.3 Display is Steady The control system is not currently tripped. A trip may have occurred previously, refer to Chapter 1 section 4.18 for details of how to read the control system s diagnostic log, then section 3.2 to establish the trip type. 2.4 Display Does Not Illuminate No power is reaching the control system. Ensure the batteries are fully charged and that all connections between batteries and the control system are made. If these connections are good, then the control system may be defective, refer to Section Establishing the Trip Type If the Trucharge display is flashing rapidly refer to section 3.1. If you are using a programmer to read the trip code(s), refer to section Rapidly Flashing TruCharge The diagram overleaf shows you how the read the TruCharge battery gauge in the event of a control system trip. Please note that on VSI control systems the TruCharge reads left to right, rather than bottom to top. Chapter 2: 21

22 DIAGNOSTICS PENNY+GILES DRIVES TECHNOLOGY Figure 1 TruCharge Display Diagnostics Trip Type GREEN YELLOW RED Trip Description Type 1 Low Battery Voltage 2 Left Motor Disconnected 3 Left Motor Wiring Fault 4 Right Motor Disconnected 5 Right Motor Wiring Fault 6 Charger Connected 7 Possible Joystick Fault 8 Possible Controller Fault 9 Solenoid Brake Fault 10 High Battery Voltage You will see that 10 different trip types are defined. The number of bars flashing indicates the trip type. Once the trip type has been established, refer to section 4.0 for Pilot, section 5.0 for Pilot+ or section 6.0 for VSI. Chapter 2: 22

23 PENNY+GILES DRIVES TECHNOLOGY DIAGNOSTICS 3.2 Using a Programmer to Read the Trip Code If you connect a programmer while the TruCharge display is flashing rapidly, then a four digit trip code will be displayed. The trip code can be referred to the trip types using the tables is sections 4.0, 5.0 or 6.0, depending on the type of control system you are working with. Please note, you must connect the programmer to the control system after the TruCharge display has started flashing. If the programmer is already connected when the flashing commences the trip code will not be displayed. 4.0 Pilot Trip Table Use the table below to determine the trip description then refer to the section indicated. Trip Code Trip Type Description (refer to section..) 0A00 Sleep See section Solenoid brake fault (7.9) Solenoid brake fault (7.9) High battery voltage (7.10) 1E00 6 Charger connected (7.6) 2C00 1 Low battery voltage (7.1) 2F00 User See section 7.12 or 7.7 3B00 2 Left motor disconnected (7.2) 3C00 4 Right motor disconnected (7.4) 3D00 3 Left motor wiring fault (7.3) 3D01 3 Left motor wiring fault (7.3) 3E00 5 Right motor wiring fault (7.5) 3E01 5 Right motor wiring fault (7.6) All other codes 7 or 8 Possible joystick or controller trip (7.7 or 7.8) If any other trip code is experienced, please contact Penny & Giles for further details. Chapter 2: 23

24 DIAGNOSTICS PENNY+GILES DRIVES TECHNOLOGY 5.0 Pilot+ Trip Table Use the table below to determine the trip description then refer to the section indicated. Trip Code Trip Type Description (refer to section.) 0A00 Sleep See section Solenoid brake fault (7.9) Solenoid brake fault (7.9) Solenoid brake fault (7.9) High battery voltage (7.10) 1E03 6 Charger connected (7.6) 1E04 Inhibit See section F01 2 See section F02 2 See section See section See section C00 1 Low battery voltage (7.1) 3B00 2 Left motor disconnected (7.2) 3C00 4 Right motor disconnected (7.4) 3D00 3 Left motor wiring fault (7.3) 3D01 3 Left motor wiring fault (7.3) 3E00 5 Right motor wiring fault (7.5) 3E01 5 Right motor wiring fault (7.5) See section See section Joystick Module (7.7) See section A 7 Joystick Module (7.7) 710B 7 Joystick Module (7.7) 710C 7 Joystick Module (7.7) 710D User See section E 7 Joystick Module (7.7) 710F 7 Joystick Module (7.7) Joystick Module (7.7) Chapter 2: 24

25 PENNY+GILES DRIVES TECHNOLOGY DIAGNOSTICS Joystick Module (7.7) See section Joystick Module (7.7) Joystick Module (7.7) Joystick Module (7.7) See section See section See section See section See section See section A Sip/Puff See section B 7 See section C 7 See section D 7 See section E 7 See section F 7 See section See section See section See section See section See section See section See section See section See section See section User See section A 7 See section B 7 See section C 7 See section D User See section E 7 See section F 7 See section See section See section 7.16 Chapter 2: 25

26 DIAGNOSTICS PENNY+GILES DRIVES TECHNOLOGY See section See section See section 7.16 All other codes 8 Possible Power Module trip (7.8) If any other trip code is experienced, please contact Penny & Giles for further details. Chapter 2: 26

27 PENNY+GILES DRIVES TECHNOLOGY DIAGNOSTICS 6.0 VSI Trip Table Use the table below to determine the trip description then refer to the section indicated. Trip Code Trip Type Description (refer to section..) 0A00 Sleep See section Solenoid brake fault (7.9) Solenoid brake fault (7.9) Solenoid brake fault (7.9) High battery voltage (7.10) 1E03 Charging See section E04 6 See section E05 6 See section C00 1 Low battery voltage (7.1) 2F00 User See section 7.12 or 7.7 3B00 2 Left motor disconnected (7.2) 3C00 4 Right motor disconnected (7.4) 3D00 3 Left motor wiring fault (7.3) 3D01 3 Left motor wiring fault (7.3) 3E00 5 Right motor wiring fault (7.5) 3E01 5 Right motor wiring fault (7.6) All other codes 7 or 8 Possible control system trip (7.7 or 7.8) If any other trip code is experienced, please contact Penny & Giles for further details. 7.0 Trip Types and Their Possible Causes Once the trip type has been established, refer to the relevant section below for further information. Chapter 2: 27

28 DIAGNOSTICS PENNY+GILES DRIVES TECHNOLOGY 7.1 Trip Type 1 - Low Battery Voltage This occurs when the control system detects that the battery voltage has fallen below 16V. Check the condition of the batteries and the connections to the control system. If the trip is still present after the batteries and connections have been checked, then the control system may be defective. In the case of a Pilot+ system, the term control system refers to the Power Module. Refer to Section Trip Type 2 Left Motor Disconnected This occurs when the control system detects that the left hand motor has become disconnected. Check the left hand motor, motor connectors and wiring. If the trip is still present after the above checks have been made, then the control system may be defective. In the case of a Pilot+ system, the term control system refers to the Power Module. Refer to Section Some Pilot+ or VSI control systems may be programmed to exchange the left and right motor outputs. In this instance, this section will refer to the right hand motor. Consult the wheelchair manufacturer for more details. 7.3 Trip Type 3 Left Motor Wiring Fault This occurs when the control system detects a fault in the wiring to the left hand motor, in particular if a motor connection has short-circuited to a battery connection. Check the left hand motor connectors and wiring. If the trip is still present after the above checks have been made, then the control may be defective. In the case of a Pilot+ system, the term control system refers to the Power Module. Refer to Section Some Pilot+ or VSI control systems may be programmed to exchange the left and right motor outputs. In this instance, this section will refer to the right hand motor. Consult the wheelchair manufacturer for more details. Chapter 2: 28

29 PENNY+GILES DRIVES TECHNOLOGY DIAGNOSTICS 7.4 Trip Type 4 Right Motor Disconnected This occurs when the control system detects that the right hand motor has become disconnected. Check the right hand motor, motor connectors and wiring. If the trip is still present after the above checks have been made, then the control system may be defective. In the case of a Pilot+ system, the term control system refers to the Power Module. Refer to Section Some Pilot+ or VSI control systems may be programmed to exchange the left and right motor outputs. In this instance, this section will refer to the left hand motor. Consult the wheelchair manufacturer for more details. 7.5 Trip Type 5 - Motor Wiring Fault This occurs when the control system detects a fault in the wiring to the right hand motor, in particular if a motor connection has short-circuited to a battery connection. Check the right hand motor connectors and wiring. If the trip is still present after the above checks have been made, then the control system may be defective. In the case of a Pilot+ system, the term control system refers to the Power Module. Refer to Section Some Pilot+ or VSI control systems may be programmed to exchange the left and right motor outputs. In this instance, this section will refer to the left hand motor. Consult the wheelchair manufacturer for more details. 7.6 Trip Type 6 Charger Connected This occurs when the control system detects that an off-board charger is connected. Check that the battery charger is disconnected. If the trip is still present after the charger has been disconnected then the control system may be defective. In the case of the Pilot+ system, the term control system refers to the Joystick Module. Refer to Section Trip Type 7 Possible Joystick Trip If you are working with a Pilot or VSI control system, this occurs if the control detects a fault within its own joystick. The joystick can only be replaced by an authorized person. Refer to Section Chapter 2: 29

30 DIAGNOSTICS PENNY+GILES DRIVES TECHNOLOGY If you are working with a Pilot+ control system, this occurs if there is a fault detected a fault in the Joystick Module, or there is a communications error between the Joystick Module and Power Module. A communications error is indicated by flashing the green LEDs below the TruCharge display (Note, this flash pattern may only occur for a few seconds before the system automatically powers down. The pattern can be re-observed by powering up the system again.). If these LEDs are flashing then the most likely cause of the problem is the cable between Joystick Module and Power Module. The cable should only be repaired by an authorized person. Refer to Section If the LEDs are not flashing, then the most likely cause of the problem is the Joystick Module. The Joystick Module can only be repaired by an authorized person. Refer to Section Trip Type 8 - Possible Controller Trip If you are working with a VSI or Pilot control system, this occurs if the control system detects a fault within itself. The Pilot or VSI can only be repaired by an authorized person. Refer to Section If you are working with a Pilot+ control system, this occurs if the Power Module detects a problem within itself. The Power Module can only be repaired by an authorized person. Refer to Section Trip Type 9 - Solenoid Brake Fault This occurs when the control system detects a fault in the solenoid brakes or the connections to them. Check these connections and the solenoid brakes. If the trip is still present after the above checks have been made, then the control system may be defective. Refer to Section Trip Type 10 - High Battery Voltage This occurs when the control system 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 control system and the batteries. Check the batteries and the connections to them. Chapter 2: 30

31 PENNY+GILES DRIVES TECHNOLOGY DIAGNOSTICS If the trip is still present after the batteries and connections have been checked, then the control system may be defective. Refer to Section Sleep This condition is indicated by the TruCharge display blinking on once every 2.5 seconds. It is not a trip condition, but an indication that the control system has gone to sleep. To awake the system, switch off and on again. The control system goes to sleep after a programmed period of time. If you want to adjust this time or remove the function altogether, refer to Chapter 1 section Joystick Displaced at Power-up The most common cause of this trip is if the joystick is deflected away from center before the control system is switched on. When the control system is switched on, the battery gauge will blink for a short time. Check that the user is not deflecting the joystick before the blink finishes. If the problem persists, trip type 7 must be assumed Inhibit The Pilot+ control system can be inhibited via pin 3 of the control socket. This inhibit signal can originate from devices such as on-board battery chargers or seat height switches. The polarity of the signal depends on the programming of the Power Module. Refer to the wheelchair operating manual to ascertain the polarity of the inhibit signal, then check the output of the device from which it originates. If the trip is still present after these checks then the Power Module may be defective. Refer to Section Communications Error On a Pilot+ control system, a communications error is signaled by a trip type 7 and the flashing of the maximum speed indicator LEDs (Note, this flash pattern may only occur for a few seconds before the system automatically powers down. The pattern can be re-observed by powering up the system again.). The most likely cause of a communications error is a Chapter 2: 31

32 DIAGNOSTICS PENNY+GILES DRIVES TECHNOLOGY defective cable between the Power Module and the Joystick Module. The cable should be checked for continuity, and replaced if found to have a fault. If the problem persists then either the Power Module or the Joystick Module could be defective. Refer to Section Power Loss This can be caused by a defective cable or a defective Joystick Module. Check the cable for continuity. If the cable appears to be in working order, then the Joystick Module must be assumed to be defective. Refer to Section Dual Attendant Module Trip The Pilot+ Dual Attendant Module is defective. Refer to Section Dual Joystick Displaced at Power-up The most common cause of this trip is if the joystick in the Pilot+ Dual Attendant Module is deflected away from center before the control system is switched on. When the control system is switched on, the battery gauge will blink for a short time. Check that the user is not deflecting the joystick before the blink finishes. If the problem persists, a problem within the Dual Attendant Module must be assumed. Refer to Section Dual Communications Error There is a communications error between the Joystick Module, the Dual Attendant Module and the Power Module. Check each cable for continuity. If the cables appear to be in working order, then the Dual Attendant Module must be assumed to be defective. Refer to Section Omni+ Trip The Omni+ Module is defective. Refer to Section Chapter 2: 32

33 PENNY+GILES DRIVES TECHNOLOGY DIAGNOSTICS 7.20 Sip and Puff Out Of Calibration The Omni+ requires a calibration its Sip and Puff input. This can be easily performed by referring to Omni+ Technical Manual Omni+ Input Device The Omni+ is not receiving a valid signal from the user input device. Refer to the Omni+ Technical Manual for the electrical specifications for input devices. Refer also to the operating instructions for the input device type in use Omni+ Analog Input Out of Calibration The Omni+ requires a calibration its analog input. This can be easily performed by referring to Omni+ Technical Manual Right Motor Feedback This trip type is only present in Pilot+ Brushless Motor Power Modules (BLPM). It is most likely to be caused by defective wiring from the right motor s motor sensors to the BLPM, or by a defective sensor within the right motor Left Motor Feedback This trip type is only present in Pilot+ Brushless Motor Power Modules (BLPM). It is most likely to be caused by defective wiring from the left motor s motor sensors to the BLPM, or by a defective sensor within the left motor Charging This occurs when an off-board battery charger is connected to the charging socket of the VSI, and is indicated by the TruCharge battery gauge stepping up. Check that the battery charger is disconnected. If the trip is still present after the charger has been disconnected then the control system may be defective. Refer to Section Chapter 2: 33

34 DIAGNOSTICS PENNY+GILES DRIVES TECHNOLOGY 7.26 Inhibit 2 Active This occurs when the VSI s Inhibit 2 input is active. The Inhibit 2 input is via the blue 2 way connector and is normally associated with actuator functions. The operation of Inhibit 2 will depend upon the programmed settings of the VSI and the wheelchair on which it is being used. Check all wiring and switches connected to Inhibit 2. If these appear to be in working order, then the VSI may be defective. Refer to section Inhibit 3 Active This occurs when the VSI s Inhibit 3 input is active. The Inhibit 3 input is via the 3 way on-board charger (OBC) and is normally associated with this function. The operation of Inhibit 3 will depend upon the programmed settings of the VSI and the wheelchair on which it is being used. Check all wiring, switches and OBC (if fitted) connected to Inhibit 3. If these appear to be in working order, then the VSI may be defective. Refer to section Other Conditions This section covers conditions that are not displayed as trip codes or on the TruCharge display. This may be because: either the control cannot switch on; the condition is not considered critical enough to force a trip ; or the control system cannot detect the condition. 8.1 Control System Will Not Switch On Check the battery connections to the control system. If these appear to be good, then in the case of the Pilot and VSI the control system may be defective. Refer to section 10.0 In the case of a the Pilot+ control system, check the cable between the Power Module and the Joystick Module. If this appears to be good, then either module may be defective. Refer to section Wheelchair Drives Slowly This could be caused by one of the following. Chapter 2: 34

35 PENNY+GILES DRIVES TECHNOLOGY DIAGNOSTICS The control system has been incorrectly programmed. A speed limiting function is active, e.g. seat in a raised position on wheelchairs fitted with lifting seats. Defective motor or defective brake. 8.3 Wheelchair Will Not Drive in a Straight Line This could be caused by a defective motor or defective brake. 8.4 One Motor or Brake becomes Very Warm This could be caused by a defective motor or defective brake. 8.5 Batteries Discharge Very Quickly The batteries can discharge very quickly for several reasons, these described below. Worn or damaged batteries check battery condition. Charger defective or incorrect charger being used check charger operation (refer to wheelchair s operating manual). Incorrect batteries being used refer to wheelchair manufacturer s instructions for correct battery types. One motor or brake jamming. Pleas note also that ambient temperature has a significant effect on battery capacity. Therefore, if the temperature is lower than normal the wheelchair s range will be reduced. In this situation, the TruCharge battery gauge still gives an accurate state-of-charge reading. 9.0 Basic Tests After a repair had been carried out, the following tests should be carried out. These are minimum recommendations, depending on the nature of the original trip then additional tests may be required. Chapter 2: 35

36 DIAGNOSTICS PENNY+GILES DRIVES TECHNOLOGY Penny & Giles accept no liability for losses of any kind arising from the carrying out of the described tests, or from not carrying out additional relevant tests. WARNING These tests are a minimum recommendation only. It is the responsibility of the service person(s) other tests relevant to the original trip and wheelchair type are carried out. Refer to the wheelchair s Technical Manual for exact information of other tests. 9.1 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. Make sure that all components of the control system are securely mounted. Do not overtighten any securing screws. 9.2 Brake Test These tests should be carried out on a level floor with at least one meter clear space around the wheelchair. i) Switch on the control system. ii) iii) iv) Check the TruCharge display remains on, or flashes slowly, after one second. Push the joystick slowly forwards until you hear the parking brakes operate. The wheelchair may start to move. Immediately release the joystick. You must be able to hear each parking brake operate within 2 seconds. Chapter 2: 36

37 PENNY+GILES DRIVES TECHNOLOGY DIAGNOSTICS v) Repeat the test a further three times, pushing the joystick slowly backwards, left and right. 9.3 Drive Test With the maximum speed control in the minimum position, drive the wheelchair in all directions, ensuring the drive is comfortable and easy to control for the user. Repeat the above but with the speed control set to maximum. 9.4 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 joystick forwards and continue driving up the slope. Ensure the pick up is smooth and positive. Stop the wheelchair and reverse down the 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. Chapter 2: 37

38 DIAGNOSTICS PENNY+GILES DRIVES TECHNOLOGY 10.0 Servicing of Defective Units There are no serviceable parts in any of the Penny & Giles control systems. Consequently, any defective units must be returned to Penny & Giles or a Penny & Giles approved service organization for repair. Opening or making any unauthorized adjustments or modifications to a control system or its components will invalidate any warranty and may result in hazards to the vehicle user, and is strictly forbidden. WARNING Penny & Giles accept no liability for losses of any kind arising from unauthorized opening, adjustments or modifications to a any component of a control system Chapter 2: 38

39 PENNY+GILES DRIVES TECHNOLOGY WARNINGS SUMMARY Appendix WARNINGS SUMMARY A 1.0 Introduction This section summarizes all of the very important warnings for use that appear throughout the text of this manual. Do not use the PP1a or carry out any diagnostic procedures without reading, understanding and observing the following warnings. Failure to observe these warnings could result in UNSAFE CONDITIONS for the user of a wheelchair of affect the reliability of the controller. Penny & Giles accepts no liability for losses of any kind arising from failure to comply with any of the conditions of the warnings listed below. Chapter 1 Section Introduction WARNING Programming should only be conducted by healthcare professionals with in-depth knowledge of Penny & Giles electronic control systems. Incorrect programming could result in an unsafe set-up of a wheelchair for a user. Penny & Giles accept no liability for any losses of any kind if the programming of the control system is altered from the factory pre-set values. Appendix A: 39

40 WARNINGS SUMMARY PENNY+GILES DRIVES TECHNOLOGY Chapter 1 Section 3.0 Connection WARNING When the PP1a is connected to the control system, the Electromagnetic Compatibility (EMC) performance of the wheelchair may be affected. Disconnect the PP1a as soon as programming is complete and do not use the PP1a environments which are EMC sensitive. Chapter 2 Section 1.0 Diagnostics WARNING Diagnostics should only be conducted by healthcare professionals with in-depth knowledge of Penny & Giles electronic controllers. An incorrect or badly effected repair could result in an unsafe set-up of a wheelchair. Penny & Giles accept no liability for losses of any kind arising from an incorrect or badly effected repair. Chapter 2 Section 9.0 Basic Tests WARNING These tests are a minimum recommendation only. It is the responsibility of the service person(s) other tests relevant to the original trip and wheelchair type are carried out. Refer to the wheelchair s Technical Manual for exact information of other tests. Chapter 2 Section Servicing WARNING Penny & Giles accept no liability for losses of any kind arising from unauthorized opening, adjustments or modifications to a any component of a control system Appendix A: 40

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