Invacare Docking station User guide

l

Yes, You Can.®

Invacare® Docking Station

Installation manua

Edition:16.03.2007

Mobitec Mobilitätshilfen GmbH

Herzog Odilostrasse 101
A-5310 Mondsee

Austria

 +43 - 6232 - 55 35 0
Fax: +43 - 6232 - 55 35 4
@: [e-mail]
@: [e-mail]
WWW: www.mobitec-austria.com

Invacare® n.v.

Autobaan 22
B-8210 Loppem (Brugge)

Belgium

Mobitec Rehab AG

Benkenstraße 260
CH-4108 Witterswil

Switzerland

Invacare Aquatec

Alemannenstraße 10
88316 Isny

Deutschland

Invacare® A/S

Sdr. Ringvej 39
DK-2605 Brøndby

Danmark

Invacare® SA

c/ Areny, s/n
Poligon Industrial de Celrà
17460 Celrà (Girona)

ESPAÑA

Invacare® Poirier SAS

Route de St Roch

F-37230 Fondettes

France

 +32 - (0)50 - 83 10 10
Fax: +32 - (0)50 - 83 10 11
@: [e-mail]
WWW: www.invacare.be

 +41 - (0)61 - 48 77 08 0
Fax: +41 - (0)61 - 48 77 08 1
@: [e-mail]
@: [e-mail]
WWW: www.mobitec-rehab.ch

 0 75 62 / 7 00 - 251
Fax 08 00 / 6 73 81 72
@: [e-mail]
WWW: www.invacare-aquatec.de

 (Kundeservice): +45 - (0)36 - 90 00 00
Fax (Kundeservice): +45 - (0)36 - 90 00 01
@: [e-mail]
WWW: www.invacare.dk

 : +34 - (0)972 - 49 32 00
Fax: +34 - (0)972 - 49 32 20
@: [e-mail]
WWW: www.invacare.es

 : +33 - (0)247 - 62 64 66
Fax : +33 - (0)247 - 42 12 24
@: [e-mail]
WWW: www.invacare.fr

Invacare® Ltd

South Road
Bridgend Industrial Estate
Mid Glamorgan - CF31-3PY

United Kingdom

Invacare Mecc San s.r.l.

Via Dei Pini, 62
I - 36016 Thiene (VI)

ITALIA

Invacare Ireland

Unit 5 Seatown Business Campus
Seatown Rd, Swords
Dublin

Ireland

Invacare® AS

Grensesvingen 9
Postboks 6230
N-0603 Oslo

Norge

Invacare® B.V.

Celsiusstraat 46
NL-6716 BZ Ede

The Netherlands

Invacare® PORTUGAL Lda

Rua Senhora de Campanhã 105
P-4369-001 Porto

PORTUGAL

 (Customer Service): +44 - (0)1656 - 664 321
Fax (Customer Service): +44 - (0)1656 - 667 532
@: [e-mail]
@: [e-mail]
WWW: www.invacare.co.uk

 +39 - 0445 - 38 00 59
Fax: +39 - 0445 - 38 00 34
@: [e-mail]
WWW: www.invacare.it

 +353 - 18 10 70 84
Fax: +353 - 18 10 70 85
@: [e-mail]

 (Kundeservice): +47 - (0)22 57 95 10
Fax (Kundeservice): +47 - (0)22 57 95 01
@: [e-mail]
WWW: www.invacare.no

 : +31 - (0)318 - 69 57 57
Fax: +31 - (0)318 - 69 57 58
@: [e-mail]
WWW: www.invacare.nl

 : [phone]
Fax: [phone]
@: [e-mail]
WWW: www.invacare.pt

2

Återförsäljare:
Invacare® AB

Fagerstagatan 9
S-163 91 Spånga

Sverige

Tillverkare:
Invacare® Deutschland GmbH

Kleiststraße 49
D-32457 Porta Westfalica

Deutschland

 (Kundtjänst): +46 - (0) 8 761 70 90
Fax (Kundtjänst): +46 - (0) 8 761 81 08
@: [e-mail]
@: [e-mail]
WWW: www.invacare.se

MÖLNDAL
 +46 - (0) 31 – 86 36 00
Fax: +46 - (0) 31 – 86 36 06
@: [e-mail]

LANDSKRONA
 +46 - (0) 418 – 285 40
Fax: +46 - (0) 418 – 180 89
@: [e-mail]

OSKARSHAMN
 +46 - (0) 491 – 101 40
Fax: +46 - (0) 491 – 101 80
@: [e-mail]

3

Table of Contents

Chapter Page

1 Introduction 5

1.1 General information ..................................................................................................................5

1.2 Notes on transport ....................................................................................................................6

1.3 Important symbols in this manual ...........................................................................................7

1.4 Important symbols on the docking station.............................................................................7

2 Safety and fitting instructions 8

2.1 Before any inspection or repair work......................................................................................8

2.2 General safety information and information about fitting / removal....................................8

3 Tightening torques 9
4 Fitting work 10

4.1 Installing the docking station in transport vehicles ............................................................10

4.1.1 Connecting the docking station to the transport vehicle electrical circuit (circuit

diagram)........................................................................................................................15

4.2 Installing the docking station hardware in the Invacare® Storm3.....................................17

4.2.1 Exploded drawing and parts list....................................................................................17

4.2.2 Fitting work ...................................................................................................................19

4.3 Function check / adjusting the docking station...................................................................24

4.3.1 How the user is secured within the wheelchair ............................................................25

4

1 Introduction

1.1 General information

This installation manual contains information on:

• scope of delivery

• important safety information and warning information

• relevant standards

• exploded drawings and parts list for all parts required for installation

• correct installation

• minimum specifications for all retaining components

• minimum loading capacity for locations on the vehicle to which the docking station will be

anchored

Use in accordance with regulations:

• The docking station is used for the fixing of an electric wheelchair for the transport of persons
in a suitable handicapped person transport vehicle.

• The docking station is exclusively designed for anchoring a wheelchair in the direction of travel
of the vehicle doing the transporting (wheelchair user is looking forwards).

Requirements which a wheelchair must fulfil in order to be used with an Invacare® Docking
Station:

• The Invacare® Docking Station may only be used in connection with Invacare® electric
wheelchair types intended for such use. Please contact Invacare for a list of usable
wheelchairs.

it is imperative that you observe the following points:

• Observe all safety information!

• Please see the operating manual for information about operation.

• You can find information about ordering spare parts in the spare parts catalogue.

• Only use authentic Invacare® spare parts. The warranty ceases if spare parts from other

manufacturers are used.

• Alterations to products which occur as a result of incorrectly or improperly executed
installation, maintenance or overhaul work lead to the exclusion of all liability on the side of
Invacare®.

• We reserve the right to make any alterations on the grounds of technical improvements.

• The Invacare Docking Station fulfils all requirements made by ISO 10542-1:2001 and ISO

10542-3:2005.

• If you have any problems or questions please contact Invacare Service.

The minimum requirements for installation technicians is:

• relevant training, e.g. as cycle, car or orthopaedics mechanic, or

• suitable long-standing professional experience.

• Special Invacare training is recommended.

• It is imperative that training is given by the manufacturer of the handicapped person transport

vehicle.

5

Scope of delivery:

• The scope of delivery includes a carton for the docking station itself (for installation in a
vehicle) and one carton for each hardware set to be fitted to the wheelchair.

1.2 Notes on transport

• If the docking station needs to be returned to the manufacturer, you should use the original
packaging (or equivalent) for transport.

• You should also include as accurate a fault description as possible!

6

1.3 Important symbols in this manual

WARNING!
This symbol warns you of danger!

• Always follow the instructions to avoid injury to the user or damage to the product!

EXPLOSION HAZARD!
This symbol warns you of an explosion hazard, which can be caused by excessive tyre

pressure in a pneumatic tyre!

• Always follow the instructions to avoid injury to the user or damage to the product!

BURN HAZARD!
This symbol warns you of burns due, for example, to leaking battery acid!

• Always follow the instructions to avoid injury to the user or damage to the product!

NOTE:
This symbol identifies general information which is intended to simplify working with your product
and which refers to special functions.

Requirements:

• This symbol identifies a list of various tools, components and items which you will need in
order to carry out certain work.

1.4 Important symbols on the docking station

Read the operating manual!

7

2 Safety and fitting instructions

These safety instructions are intended as prevention of accidents at work and it is imperative that
they are observed.

2.1 Before any inspection or repair work

• Read and observe this installation manual and the associated operating manual.

• Observe the minimum requirements for carrying out the work (see chapter entitled " General

information”).

2.2 General safety information and information about fitting / removal

Danger of crushing!

• Please note the high weight of some components!

• Secure a raised or tilted wheelchair with suitable supports and underlays before commencing

fitting work! If necessary, let a second person hold the wheelchair securely!

Fire and burn hazard due to electrical short-circuit!

• The wheelchair must be switched to voltage-free before commencing fitting work on voltage­carrying wheelchair components! Disconnect the wheelchair batteries to do this!

• The vehicle must be switched to voltage-free before commencing fitting work on transport
vehicle voltage-carrying components! Disconnect the vehicle battery/batteries to do this!

• When working on voltage-carrying components, avoid short-circuiting the contacts. Fire and
burn hazard!

Injury hazard and danger of damage to vehicle due to improper or incomplete fitting work!

• The docking station is exclusively designed for the anchoring of a wheelchair in the direction
of travel of the vehicle doing the transporting (wheelchair user is looking forwards).

• Use only undamaged tools in good condition.

• Some moving parts are mounted in sockets with PTFE coating (Teflon™). These sockets

must on no account be greased!

• Never use "normal" nuts instead of self-locking nuts!

• Always use correctly-dimensioned washers and spacers!

• Cable ties which have been cut during removal must be replaced during refitting!

• Docking station components may not be modified or replaced with other parts without

previous consultation with Invacare!

• Check all fixings for tight fit after completing work / before initial startup! Check all parts for
correct interlocking!

• Ensure that electrical components have the correct polarity! Incorrect polarity can lead to
damage to the electronic system!

• When fitting the docking station, you must ensure that the function of any airbags fitted to the
vehicle is not restricted!

• An airbag is only an additional safety system and is never intended to replace a seatbelt!

• If you have any questions about correct installation, please contact Invacare or your vehicle

manufacturer!

• Always carry out a performance test when work is completed!

Note

All plugs are fitted with mechanical safety devices which prevent release of the connecting plugs
during operation. To release the connecting plugs the safety devices must be pressed in. When
reassembling ensure that these safety devices are correctly engaged.

8

3 Tightening torques

The tightening torques stated in the following table are dependent on the thread diameters for the
nuts and bolts for which no special values are determined. All values apply to dry and grease-free
threads.

Thread

Tightening torque

in Nm ±10%

Caution: All other nuts or plastic connectors not noted here must be tightened
FINGERTIGHT!

M4 M5 M6 M8 M10 M12 M14 M16

3 Nm 6 Nm 10 Nm 25 Nm 49 Nm 80 Nm 120 Nm 180 Nm

9

4 Fitting work

4.1 Installing the docking station in transport vehicles

When fitting the Invacare docking station, the qualifications possessed by the fitter are extremely
important. It is imperative that training is provided by the vehicle manufacturer. Correct fitting is
determined by many factors such as vehicle type, fitting situation and recommendations made by
the vehicle manufacturer. For this reason, this instruction manual should not be understood as a
step by step manual to be followed linearly. It does, however, contain important information about
individual work stages, and gives benchmark data, technical specifications and minimum
requirements.

WARNING!

• Drill holes for fixing bolts may only be drilled through the floor of the transport vehicle at
locations which have been approved by the vehicle manufacturer for this purpose!

• When fixing the docking station, please use 8 x M10 bolts, minimum strength 8.8

• The floor panel must have a minimum sheer strength of 100 kN! Use reinforcing plates!

Requirements:

• electric drill

• 11 mm drill bit

• 8.5 mm drill bit

• M10 thread cutter

• Standard open spanner set

• The facility to work underneath the transport vehicle, e.g. platform lift, pit or ramps.

• Anticorrosive agents

If the transport vehicle floor is uneven, the
docking station must be mounted on a
compensating/mounting plate (1) with a minimum
sheer strength of 100 kN. This plate must be at
least large enough to fit the wheelchair on top of
it with all wheels on the plate.

10

• When using a
compensation/mounting
plate, position it in the
vehicle but do not bolt it in
place yet.

• Place the docking station
loosely on top of it.

• Run the wheelchair onto the
mounting plate/docking station as a
positioning aid.

The anchorage point (1) of the transport vehicle seatbelt
should be located behind and above the wheelchair user's
shoulder. See chapter "How the user is secured within
the wheelchair" on page 25.

In doing so, you must take into account that the movement
range of the upper body in the case of a crash is dependent
on the position of the top seat belt anchorage .amongst
other things. The higher or further behind the wheelchair
user's shoulder the anchorage point is located, the larger
the movement range in a crash.

11

The wheelchair must be positioned so
that the area in front and behind the
wheelchair user is free of hard or sharp
objects. The figure on the right shows
these areas.

• HHT = Head Height (head height of
user sitting in wheelchair)

• FCZ = Front Clear Zone (650 mm
with breast belt, 950 mm without
breast belt).

• The rear free zone 400 mm is
measured from the back of the user'
head. The front free zone is
measured from the forehead.

Hard or sharp vehicle parts which may
be located in the free zones should be
commissioned with the material which
complies with the requirements of
FMVSS 201 or ECE 21.

Additional cushioning must be hardly
inflammable in accordance with ISO

3795.

• Check correct position of wheelchair by sitting tests or
measuring of distances.

• Carefully remove the wheelchair
from the mounting plate/docking
station.

• Correct the position of the mountain
plate or docking station if
necessary.

12

The figure on the right shows
optimum positions for the fixing
bolts.

The position of the front and rear
bolts should be retained. The
position of the middle four bolts
can be varied slightly depending
on the condition of the vehicle
floor.

If a compensation/mounting plate
is used, the position of the
middle bolts should be retained.

• Mark the position of the holes for
the fixing bolts by lightly drilling with
the 11 mm drill bit.

• The positions of the holes (1) for the
fixing bolts are now marked (in the
picture, 4 out of 8 drill markings are
visible).

• Remove the mounting plate from
the vehicle.

• Drill the drill holes with the 8.5 mm
drill bit.

• Cut an M10 thread with the thread
cutter in the mounting plate drill
holes.

13

If you are using a mounting plate, fix
the docking station to the mounting
plate. Otherwise, the docking station is
fixed directly to the vehicle floor.
Counter the fixing bolts against turning
through by using open-ended spanner.

The picture on the right shows two of
the fixing bolts viewed from underneath
the vehicle. Attach reinforcing plates
(1) as recommended by the vehicle
manufacturer.

• Bolt the docking station to the
transport vehicle or to the
mounting plate. The mounting
plate can also now be bolted in
place.

14

4.1.1 Connecting the docking station to the transport vehicle electrical circuit
(circuit diagram)

Item Designation

1Actuator MBL Type LL-1001
2Linak TR-EM-208-H electronics box
3Actuator cable
412 V car battery
512V battery cable
6DPAK06 control panel

15

• Connect the docking station to the vehicle electrical circuit as
shown in the circuit diagram.

• Install the control panel in the vehicle. We recommend
installing the control panel on or near the dashboard. The
control panel can be fixed with two screws.

16

4.2 Installing the docking station hardware in the Invacare® Storm3

4.2.1 Exploded drawing and parts list

17

Item Designation No.

1 Position sensor 1
2 DIN 985-M3-8/vz nut 2
3 DIN 985-M8-8/svz nut 4
4 DIN 7985-M3x16-8.8/vz bolt 2
5 M8x16 cheese head screw 2
6 M8x30 ISO 7380 cheese head screw 2
7 Cable clip small 1
8 Expanding rivet 1

9 DIN 125-3,2-St/svz washer 4
10 DIN 125-8,4-St/svz washer 4
11 Docking Station fixing 1

Pos. 12 to 27 not represented in drawing

12 Angle plate cpl. 1
13 CC tension relief clip 1
14 DIN 7982-2,9x13/vz bolt 2
15 12V green LED 1
16 Green button 1
17 Distance roll10/5 2
18 Battery cable 1
19 Battery cable 1
20 Circuit board 1
21 H03VV-F cable 3.1 m
22 Plug housing 1
23 AMP 180 908-0 contact 2
24 Ø 9 HSS drill bit, length 1
25 Ø18 plugs 1
26 ISO 7380-M5x12-10.9/svz 1 bolt
27 Case 1
28Velcro strap 1

18

4.2.2 Fitting work

Requirements:

• All parts listed in the parts list under "Exploded drawing and parts list" on page 17.

• Soft mat such as blanket to put under wheelchair when it is on its side to prevent damage.

• Phillips screwdriver

• Open spanner, 11 mm.

• Clamp

• Wooden block approx. 15 x 7 x 4 cm

• Electric drill

• Remove battery cover.

• Remove plastic clips (1) and remove the

equipment rack upwards to the rear.

• Pull the battery terminal caps upwards and
push them back to allow access to the
battery terminals.

• Loosen all the battery terminal clamps (2)
with the jaw spanner.

• Swivel the device support upwards (it may
be necessary to loosen the additional
connection plug).

• Withdraw the batteries

19

• Pull the Velcro strap (1) off the rear edge of
the battery case.

• Carefully turn the electric wheelchair onto its
side on the soft mat.

• Hang the docking station fixing into place at
the battery case (1) and press firmly from
the rear.

• Fix the docking station fixing in the rear area
using the collar and the wooden block at the
battery case.

• The docking station fixing has four drill holes
for fixing, two at the rear (1) and two at the
front (2). You can use these holes as a drill
template.

20

• Drill holes in the battery case for fixing the
docking station fixing in the rear area.

• Bolt the docking station fixing at the rear with
2 x 2x M8 x 16 mm cheese head screws , 2x
DIN 985 nuts and 2x DIN 125-8 washers
(see exploded drawing).

• Loosen the collar and apply it to the front.

• Drill holes in the battery case for fixing the

docking station fixing at the front.

• Bolt the docking station fixing at the rear with
2 x 2x M8 x 30 mm cheese head screws , 2x
DIN 985 nuts and 2x DIN 125-8 washers
(see exploded drawing).

• Set the wheelchair carefully upright.

• Place the battery in the battery case.

• A new battery cable needs to be installed so

that the remote extension (with control lamp
and LED) can be connected to the
wheelchair circuitry.

• Battery cable (1) is used for wheelchair with
gearless motors (TrueTrack®) , battery
cable (2) is used with standard ACS
systems.

• Select a suitable battery cable and fit it.

21

• Now route the new battery cable plug
through the opening in the equipment rack.

• Connect the battery cable connector plug
with the power module and press it firmly
together (the picture shows the TrueTrack®
power module connector plug).

• The remote extension is fixed to the remote
with two screws (1).

• Route the remote extension cable parallel to
the bus cable and secure it with cable ties.

• Route the position sensor cable (1) as
shown in the picture.

• Fix the position sensor (2) as shown in the
exploded drawing.

22

• Connect the wiring harness plug for the
position sensor/remote extension with the
battery cable connecting plug (1) and press
firmly together.

• Position the equipment rack again and fix
using the plastic clips.

• Stick the Velcro strap to the rear edge of the
docking station fixing.

• Reassemble the rear panelling.

23

4.3 Function check / adjusting the docking station

• Run the electric wheelchair onto
the docking station.

• Operate the docking station.
Ensure that the locking procedure
is correct. The T-anchor (1) must
fit into the rear recess of the
anchor guide, and the acoustic
check must beep once.

• If the T-anchor is too low or too
high its height must be adjusted.
To do this, loosen the T-anchor
locknut, adjust the height and
retighten the locknut afterwards.

• The clear space between the
bottom of the T-anchor and the top
of the anchor guide should be
approx. 5 mm.

• Ensure that the T-anchor is
correctly oriented! The magnetic
strip must face the electric
wheelchair!

• If the acoustic check does not
beep, the space between the T­anchor magnetic strip and the
reed sensor (2) is probably too
large. To remedy this problem,
loosen the reed sensor fixing bolt
(3) and then reduce the distance
to the T-anchor by moving the
reed sensor within its elongated
hole. Retighten the fixing bolts.

• Actuate the docking station again,
and ensure that the acoustic
signal is functioning correctly.
Repeat the procedure until the
reed sensor is correctly adjusted.

• When the docking station is
locked, press the docking station
check button (A) on the remote
extension. The control LED (B)
illuminates green.

• The check button can be pressed
at any time to confirm that the
docking station is in locked
condition.

24

4.3.1 How the user is secured within the wheelchair

Caution: there is a danger of injury if the user is not properly secured within the
wheelchair!

• Even if the wheelchair is fitted with a securing belt, this is no substitute for a proper seatbelt
in a travelling vehicle! It is imperative that a seatbelt tested to ISO 7176/19-2001 standards is
used!

• Seatbelts must be in contact with the user's body! They must not be held at a distance from
the user's body using parts of the wheelchair such as armrests or wheels!

• Seatbelts must be pulled as tightly as possible without causing the user discomfort!

• Seatbelts must not be positioned while twisted!

Seat belts may not be held at a distance

The pelvic belt should be positioned in the
from the user's body using parts of the
wheelchair such as armrests or wheels.

The safety belt of the transporting vehicle should
be applied as shown in the illustration at right.

1) Centre line of the body

2) Centre of the sternum

area between the user's pelvis and thighs
so that it is unobstructed and not too loose.
The ideal angle of the pelvic belt to the
horizontal is between 45° and 75°. The
maximum permissible angle is between
30° and 75°. The angle should never be
less than 30°!

25