Preston Ability BREEZE-C Maintenance Manual

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Maintenance Manual

[email protected] • www.prestonability.com

Tel NL 036 53 53 580 • Tel BE 014 75 73 40

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Contents

1. Safety instructions 3

2. Specific Tools for technicians 4

3. Specific Parts: 4

4. Options / Accessories assembling : 5

5. Mechanical Adjustments 6

6. Front Electronics Board Setup 8

7. Controller Programming / Setup 9

8. Periodic maintenance Check 14

9. Mechanical Fault troubleshooting 16

10. Control and Electronics system fault troubleshooting 18

10.1 General control system and Front Board Troubleshoots 18

10.2 Controller Troubleshoots 19

11. Mechanical assembly drawings 22

13. General Wiring diagram 23

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1. Safety instructions

1.1 General:

1.1.1 Technicians who are servicing the scooter should be authorized to service the scooter.

1.1.2 Technicians who are servicing the scooter should be aware and follow all safety instructions within the User Manual.

1.1.3 Technician should follow general safety instruction like using gloves, safety glasses when needed.

1.1.4 The scooter weight with batteries is about 100 kg even lifting 1 wheel is about 30 kg. Always use other people help or a appropriate lifting device.

1.1.5 When lifting always use your legs and not your back.

1.1.6 The battery weight is about 14 kg . The power unit weight is about 15 kg. The seat weight is about 15kg.

1.1.7 Never do any change in the product before consulting the manufacturer engineering. Remember the products are approve as they are , any change remove the manufacturer responsibility for the safety of the product.

1.2 Drive :

1.2.1 Technicians who are driving the scooter should be aware and follow all safety instructions within the User Manual.

1.3 Mechanic :

1.3.1 It is possible that a technician will need to operate the scooter when he is standing on the side ,working on different assemblies.

1.3.2 When no electric power and operation needed , always Stop the power by Switch OFF and disconnecting the battery terminals.

1.3.3 Never put any part of your body under the scooter parts.

1.3.4 If necessary, first place a wood block under, to make sure no injure will happen.

1.3.5 Use standard tools. Use them according to their safety instructions .

1.4 Electric :

1.4.1 If necessary to operate the scooter when you are not seating on it. In such cases you should be aware to the parts that can move by power – Power unit shafts and wheels.

1.4.2 Never put your hands close to a part that is moving or turning. Be aware that your cloth will not be trapped into one of the moving parts.

1.4.3 Batteries contain a large electric energy inside. This energy can cause sparks and heat metals when short circuiting.

1.4.4 When working on the battery terminals, make sure no to short circuit between any 2 terminals. This can cause strong spars and make the tools very hot.

1.4.5 When working on the batteries, use protecting gloves and safety glasses.

1.4.6 Battery contains acid. Never open any of the battery case. If you see any liquid or Gel aside, beware of it. It might be Acid.

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2. Specific Tools for technicians

 Standard tool box (wrenches, socket-head cap screw , hexagon keys, Phillips

(crosshead) tip and/or screwdrivers, etc.)

 Voltmeter (To measure 24VDC)

 Air pressure gauge (To measure 35 psi)

 Batteries tester (under load)

 Density meter

 Valve Wrench

 Wooden blocks to elevate the Breeze during checks, maintenance and repairs:

 2 blocks 20-22 centimeters height to place beneath the batteries box.

 2 blocks 14-16 centimeters height to place beneath the foot rest area.

 Remark : Always before operating a lifted Breeze make sure that the 2 rear

wheels are free to turn , so that the scooters will not move.

3. Specific Parts:

We recommend the availability of the following set of test and repair assemblies:

1. Front Board

2. Main Harnesses Cable.

3. Main Lights Harness Cable.

4. Main Supply Harnesses.

5. Controller SDrive 120A - P&G

6. Motor/Power Unit

7. Also it is very much recommended hold and use P&G SP-1 Programmer (for S-Drive,

possible to upgrade old model to modified free of charge).

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4. Options / Accessories assembling :

Most accessories based on the rear square pipe :

The accessories are :

4.1  Rear Basket 4.2  Seat safety belt. 4.3  Walker Holder

4.4  Cane Clip Attachment. 4.5  Single Cane Holder 4.6  Double Cane Holder

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5. Mechanical Adjustments

Description

Where

How to Adjust

Seat Height

Seat pin under the battery cover.

See attached assembling drawing:

Release both secure bolt and level bolt. Change pin Level hole as required . Rescuer both level bolt and secure bolt.

Adjustments : 3 x 20 mm.

Arm rest

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Adjust the width .

Adjust the angle .

Front lights

Release the screw and adjust

The angle of the front lights.

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6. Front Electronics Board Setup

The Horns can be setup to work in one of the follows options :

Controller alarms, Tiller push button , Reverse alarm , Blinkers alarms.

The front board include setup options for the Horn. This can be

done with the dipswitch DSW1 that is on the front board.

Deep switch : User Modes setup with relate to user needs.

Dip Switches Setup is as follows : (Shown the Default Set Up)

State

Description

"1" = Off

Horn while blinker or hazard are on .

"2" = On

Horn while derive backward

"3" = Off

When the battery too low – the scooter stop.

"4" =

No use.

Diagram sketch :

"1"

"2"

"3"

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7. Controller Programming / Setup

If the user cannot find a position on the half speed limit switch control that suits him, the controller can be programmed to meet his needs. The controller can be programmed in two ways – with an SP1 Programmer or specialist PC software and interface cable.

The SP1 is a small hand-held unit which can be plugged into your controller to alter the program or into the charger socket .

The PC Programmer is a piece of PC software and an interface cable. When the software is installed onto a PC, it can then be connected to the controller by using the special interface cable. The controller can then be programmed using a windows type environment

The programming tools may be included with your scooter. If they are not, the scooter distributor or service agent or scooter manufacturer will are able to program the controller.

If you have a programmer, read the user guide before you use it.

If you re-program your controller, make sure that you observe any restrictions given in your scooter user manual. Note any changes you make for future reference.

Programming should only be conducted by healthcare professionals with in-depth knowledge of PGDT electronic controllers. Incorrect programming could result in an unsafe set-up of a scooter for a user. PGDT accept no liability for losses of any kind if the programming of the controller is altered from factory pre-set values.

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7.1 Controller Parameter List and programming with hand programmer SP1 :

BREEZE C PROGRAMER SET-UP . Programming version list : 8.0.16. 22/07/10 The list of parameters fit to power-units 950W-12km/h,10km/h and 15km/h. The parameters refer to "S-Drive 120" controller with hand programmer "SP1" To program through the "Charge Socket" use the adaptor.

Programmer SP1

Adaptor to the Charger Socket

Instructions to change the parameters :

1. Connect the adaptor to the programmer and connect to the "Charge Socket" – the programmer will start working.

2. The up / down arrows let you choose the parameters.

3. In order to change a parameter – stand on the parameter press "enter" the values will then appear in the display window.

4. With the help of the arrows you can change the values.

5. After changing the value push enter the scooter will beep – turn key switch off and then on.

6. The programmer will display the next parameter. To make further changes repeat step # 5

7. Press enter again to return to the parameter menu

8. When you get to the "Engineer Menu" press enter to get to the sub-menu

How to improve and to adjust parameters to the customer :

1. Change the accelerate of the scooter , forward .--- Line 1 .

2. Change the decelerate of the scooter , forward .--- Line 2

3. Change the accelerate of the scooter , reverse .--- Line 3.

4. Change the decelerate of the scooter , reverse .--- Line 4.

5. Change the max. speed - forward .--- Line 5 .

6. Change the max. speed – reverse .--- Line 7.

7. Change the direction of travel of the Wig-Wag. Invert Throttle --- Line 9 .

8. The time to enter to sleep mode when the key switch is "On" . Sleep Timer . Line 10 .

9. Reads the number of faults and how many times they occurred. Read System Log . Read System Log . Line 11 .

10. Working time of the scooter.Real timer . Line 12 .

11. Decelerate – soft stop.Line . 20 , 24 .

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The list of parameters for power-unit 950W-12km/h :

Comments

SETTINGS

Parameter

The time for acceleration forward.

FAST: 40

Slow: 40

Forward Acceleration Profile

Parameter to change the stopping distance-FF.

FAST: 15

Slow: 15

Forward Decel'n?

The time for acceleration – Reverse .

FAST: 40

Slow: 40

Reverse Accel'n

Parameter to change the stopping distance-Rev.

Fast : 20

Slow : 20

Reverse Deceln ?

Parameter to lower the maximum forward speed

Fast: 100 Slow: 100

Max Forward Speed?

Parameter to lower the minimum speed forward. (minimum speed on the potentiometer)

Fast: 50 Slow: 50

Min Forward Speed?

Parameter to lower the maximum reverse speed

Fast: 50 Slow: 50

Max Reverse Speed ?

Parameter to lower the minimum speed reverse. (minimum speed on the potentiometer)

Fast: 25 Slow: 25

Min Reverse Speed ?

Change the direction of travel of the Wig-Wag (standard NO)

No/Yes Invert Throttle?

The time to enter to sleep mode when the key switch is "On" . "0" – the function doesn’t work .

0 m

Sleep Timer?(Minute)

Reads the number of faults and how many times they occurred

1 E09, #144

Read System Log

Working time of the scooter.

Elapsed:

110 H

Real Timer :

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Operation

settings

ENGINEER MENU

Min: 21A

Max: 110A

Current Limit

Maximum voltage that

the motor can receive

(over 24v the supply is

cut off)

24V

Output Voltage

Current :

130A

Time : 10 s

Drive Boost

Threshold

:120A

Time :10 s

Drive Foldb'k-1

Level : 100 %

Temp : 80°c

Drive Foldb'k-2

Time : 120 s

Motor Cooling

Motor CMP

:20 MΩ

Cmpensation

Param1: 8

Parameter-1

Param2

:1050

Parameter-2

Param 3 : 0

Parameter-3

Param 4 : 30

Parameter-4

Soft Stop :

Soft Sto ?

Threshold:

Time out : 15

Free Wheel?

Changing the range of

the pull of the trottle

Gain : 130

Throttle gain ?

Dead band

:10%

Throttle D'band ?

Off

Iso Test

0-Single-ended,1-Wig-

Wag, 2-Unipolar

Type : 1

Throttle Type :

Not programmed

Mode :2 Displaced mode :

Not programmed

Yes

Check Refs:

Pot enabled :

Yes .

Speed Limit Pot :

750

Brake Time?

yes Brake Check?

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Brake disconnected

Alarm

If using computer connection "on"

Yes Brake Alarm?

If using computer

connection "on"

No Brake Light?

0 Status Output?

4 Diagnostic Flash

If using computer

connection "on"

Yes Diagnostic Alarm

Mode :1 Inhibit 1 mode?

Speed 0% Inhibit 1 Speed

Latched : Yes

Inhibit 1 Latch?

Mode:1

Inhibit 2 mode

Speed 0 %

Inhibit 2 Speed?

Latched: Yes

Inhibit 2 Latch?

Mode :1

Inhibit 3 mode?

Speed : 0 % Inhibit 3 Speed

Latched : Yes

Inhibit 3 Latch?

Not programmed

Erase log :

No.

Clear System log ?

Not programmed

Clear timer :

Clear Timer?

With or without beep

when driving

backwards

On/Off Reverse Alarm

If using computer

connection "on"

Pulsed : Yes

Pulse Rev Alarm

Cable Yes :

40 mΩ

True charge Cable?

Calibration:

100

Tru charge Cal?

Not programmed

Flash level : 2

Low Batt Flash?

Low Bat

Alarm: Off

Low Btt Alarm ?

Back to Root ?

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8. Periodic maintenance Check

No.

Type of Service

Who

Frequency

Check air pressure in all tires.

User

Every week

Check normal drive and stop

User

Every Month

Check tires wear

User

Every Month

Check for missing parts and damaged parts .Use the figures

User

When receiving the Breeze C or after a long

time not using it.

Check secure of all screws and parts

Technician

Once a year by technician.

Batteries replacing.

Technician

Every 2-3 years , after about 300-400 full cycles of charge/discharge. When short travel distance and/or technician check.

Note: To Replace the batteries, the Seat and Battery Cover located under the Seat must be removed.

Cleaning

User

Technician

External – when needed.

Internal – Once a year.

Check power unit

Technician

Check noise , clearance , current on surface should be 12 to 14 Amp.

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Removing the Seat and the Batteries Cover (2) ????

Turn the Seat by using the lifting Lever so that the Lever will point 45º Right or Left. The Seat can be removed only at this position.

Remove the Seat (7): Hold the Seat in your two hands – one hand on the backrest and a second hand at the front lower part of the seat and lift the seat up from its pivot.

Warning! The seat weight is 21 Kg (44lbs).

Keep lifting with your Knees/legs and not loading your Back. Release Battery Cover (2) securing screws (2.6).

Lift the Battery Cover (2) until it is released from the Seat Pivot .

Replacing the Batteries Cover(2)

The replacement of the Cover is done in reverse order; MAKE SURE that the Cover (2) fits onto it’s place. Secure with the 4 screws (2.6).

Batteries

Batteries weight each ~14 Kg (~30 lbs) and over.

Lift each battery only with the appropriate handle. Keep lifting with your Knees/legs and not loading your Back.

Tires

Correct air pressure in the tires is essential for optimal

steering and stability of the Breeze C. Check air pressure

every two weeks.

Inflate to the proper air pressure: 25 ±2 psi. Breeze 4W front tires: 25±2 psi. Golf wheels tires : 25±2 psi.

Cleaning

Use only a damp cloth and mild detergent. Never use a hose for cleaning. This may severely damage the power and electronic components.

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9. Mechanical Fault troubleshooting

Description

Probable cause

Repair action

Noises from front steering and suspension system

Check front suspension for clearances and secure of bolts.

Check front shock absorbers.

Check the ,rod end for clearance.

Replace wear parts, secure bolts.

Replace if needed. 2

Front suspension not functioning properly.

Check front shock absorbers.

Replace if needed.

Excessive wear of front tires after short period.

Wear of bushings that cause clearances in the system.

Un adjusted steering system.

Replace wear parts , Adjust the steering and secure.

Rear suspension Noisy.

Wear in power unit absorbing Rubbers.

Check for clearances and unsecured parts.

Check the shock absorbers.

Replace the absorbing rubbers if needed.

Secure parts.

Replace shock absorbers if needed.

Rear suspension not functioning

Check user weight and the fit of the absorbers.

Faulty shock absorbers

Replace if needed

Noise from power unit.

Wear in power unit

Check and replace power unit if needed

Too short distance travel between charging

Power unit wear, consume high current. Also might be noisy.

Battery – low voltage -

Check noise and current and replace if needed.

Replace the battery.

Check the charger.

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Clearances in tiller

Unsecured screws and gas piston faulty

Check secure of screws. Replace gas piston if needed.

Scooter does not have power or does not brake well or go to high speed downhill.

Wear in motor brushes.

Replace motor brushes.

Noises from motor

Wear of brushes.

Faulty motor.

Check brushes and replace if needed.

Replace motor.

Flat tire and uneven and not smooth drive

Flat tire

Repair / replace tire's tube.Take out the cuver. Open the central nut.Take out the air. Open the 4 screws.

Replace the tube. Inflate the tub a little bit before assemble. After assemble inflate to 25 +/- 2 psi.

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10. Control and Electronics system fault troubleshooting

10.1 General control system and Front Board Troubleshoots

The front board is the center of all peripheral functions of the scooter : Lights , Horn , Information goes to the LCD display . Elimination troubleshoots: The Front Board wiring connections are all quick connectors. If you suspect the Front Board to be faulted we recommend as a quickest way to find if the Front Board is faulty, Doing by elimination – Just replace temporarily the Front Board with another working one and thus make sure if the problem is within the Front Board or somewhere else.

Check all connection of the Front Board, following the wiring diagram that can be found within this maintenance manual. Check main and Charging fuses, located near the rear wheels. Also always check related function switch , as example Light does not work , first check the light switch for continuity ,when is in ON position. Use the wiring diagram to figure the proper terminals to check each function switch terminals.

Trouble Shoot Table:

Description

Probable cause

Repair action

Front light doesn't work

Front LED board faulty

Replace front LED board

Front Board faulty

Replace Frond Board

Front Blinker/s doesn't work

Front Blinker board faulty

Replace front Blinker board

Front Board faulty

Replace Frond Board

Rear pilot/s light does work

Rear Blinker board faulty

Replace Rear Blinker board

Front Board faulty

Replace Frond Board

Rear Blinker/s doesn't work

Rear Blinker board faulty

Replace Rear Blinker board

Front Board faulty

Replace Frond Board

Horn does not work properly

Horn is faulty

Replace Horn

Horn is faulty

Replace Frond Board

Front Board faulty

Replace Frond Board

Hazard doesn't work

Hazard switch fault

Check switch and repair

Front Board faulty

Replace Frond Board

Reverse function doesn't work

Reverse switch fault

Check switch and repair

Front Board faulty

Replace Frond Board

Electric EMB release function does not work

EMB release Switch faulty

Check switch and repair 10

No Charge start

Charger fault

Replace charger

Charge fuse popup or faulty

Reset /Replace charge fuse

Travel distance very low

Charger fault

Replace charger

Old / Weak batteries

Check Batteries / charge batteries, Replace if needed.

No power or main fuse pop out

Over load Mechanical fault Fault controller Faulty power unit Short circuit occur

Try to reset 2 times. Troubleshoot the fault. Replace the controller. Replace the power unit. Find and repair short circuit.

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10.2 Controller Troubleshoots

The controller is the center of all driving functions of the Breeze S: Speed control , acceleration , deceleration , EMB (Electro Magnetic Brake used as parking brake) , Reverse drive , Speed limiting etc. . But still the functions of the controller are all connected to all the wiring, connectors and as well the Front board, power units and batteries. If any driving misbehave occur Elimination troubleshoots: The controller wiring connections are all quick connectors. If you suspect the controller to be faulted we recommend as a quickest and way to find if the controller is faulty, Doing it by elimination – Just replace temporarily the controller with another working one and thus make sure if the problem is within the controller or somewhere else.

Check all connection of the controller, following the wiring diagram that can be found within this maintenance manual.

Trouble Shoot Table:

Description

Probable cause

Repair action

Power is On in the LCD display but Scooter does not drive. No code shown.

Controller fault Wiring connectors fault. Front board fault

Replace controller Check repair wiring /connector. Replace front board.

The "LED" On/Off Indicate the problem By flash code sequence

2.2

* *

Low battery .

Battery empty .need to recharge Change the charger. Replace the battery.

2.3

* * *

High Battery voltage

Check the charger.

2.5

* * * * *

E.M.B problem.

Check the wire from E.M.B, Change the E.M.B.

2.6

* * * * * *

Throttle trip

The accelerate lever pressed while turn the key switch to On. Check the wires to the controller

2.7

* * * * * * *

Throttle trip

The accelerate lever pressed while turn the key switch to On. Check the wires to the controller

2.8

* * * * * * * *

Motor disconnect

Check the wires to the Motor.

2.9

* * * * * * * * *

Controller fault

Replace the Controller.

Power is On display and a code is shown. Scooter does not drive .

A known fault of the controller has been found

See follows Fault Bars table and repair the according.

No power is On panel display.

Power supply or another control system

Follows (10.1)- General Control system trouble shoot.

Jerky movement

Uncharged batteries. Weak /Old batteries.

Charge / Check batteries and replace if needed.

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Controller faults: Can be found using the LCD fault indication within the battery indicator as

detailed in the follows paragraph.

Error massage will should displayed in the LED "ON" . Further specification of the fault can

be found using the SP1 programmer. When the fault exists, connect the SP1 programmer's

connector directly to the controller SDRIVE120 or to the charging socket, using a special

wiring adaptor.

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10.3 - The fault code from the SP1 Programmer :

More codes you can see on the hand programming SP1 .

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11. Mechanical assembly drawings

See attached assembling drawings: "Breeze C (3, 4W) assembling.pdf".

12. Spare parts list .

See attached file.

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13. General Wiring diagram