“ALL ABOUT BATTERIES & MORE” Visit the Technical Zone @ www.invacare.
Service & Parts Education DEEP CYCLE GELL BATTERIES How does a Gel Cell Work? A Gel cell is a “recombinant” battery. This means that the oxygen that is normally produced on the positive plate in all lead-acid batteries recombines with the hydrogen given off by the negative plate. The “recombination” of the hydrogen and oxygen produces water (H20), which replaces the moisture in the battery. Therefore, the battery is maintenance-free, as it never needs water. Source: MK Battery Technical Manual, www.
Service & Parts Education WHEELCHAIR BATTERIES WHAT CONSUMERS NEED TO KNOW ABOUT BATTERIES (courtesy of MK Battery) Battery Size: Always follow the manufacturers recommendations for battery size. Battery Type: Always use Deep Cycle batteries, due to the fact that they are designed to be discharged and recharged on a regular basis. Cold Cranking Amp or Marine type batteries are for starting purposes only, and are not intended for electronic type vehicles. Lead Acid vs.
Service & Parts Education BATTERY CARE & SAFETY Do Don’t Don’t perform any installation or maintenance without first reading the service manual. Read and understand the service manual and any service information that accompanies a battery and charger before working on the wheelchair or scooter. Don’t perform installation or maintenance of batteries in an area that could be damaged by battery spills.
Service & Parts Education REPLACING WHEELCHAIR BATTERIES Do you replace a set of batteries every time a customer says there bad? Before you do replace a pair of batteries, make sure you have accurately diagnosed the problem first. STOP! BEFORE YOU REPLACE YOUR NEXT SET OF BATTERIES, READ THIS INFORMATION Battery Testing Procedure: 1. Use your Digital Volt Meter to read the static battery voltage. A fully charged set of gel batteries will read at least 25.6 volts and above. 2.
Service & Parts Education BATTERY CONNECTIONS “SERIES CIRCUIT” A “series” system increases the voltage, but keep the battery capacity the same. Therefore, two 12-volt batteries connected in series (POS to NEG, NEG to POS) will deliver 24-volts at the same rating as one battery. During recharge, each battery will recieve the same amount of current (AMPS). Series hookup increases voltage.
Service & Parts Education **BATTERY SIZES CHART Power Chairs Qty. Volts Battery Type TDX3 TDX4 TDX5 2/3 22NF Optional 2/3 22NF Optional 2/3 22NF Optional 12@ 12@ 12@ 22NF/GR24 22NF/GR24 GR24 2G Storm Arrow 2G Storm Torque SP 2G Storm Ranger X 2 2 2 12@ 12@ 12@ GRP24/22NF GRP24/22NF GRP24/22NF 3G Storm Arrow 3G Storm Torque SP 3G Storm Ranger X 2 2 2 12@ 12@ 12@ GRP24 GRP24 GRP24/22NF Ranger II RWD Ranger II JR.
Service & Parts Education BATTERY STATE OF CHARGE Wet Lead Acid Type Deep Cycle Charge Level Specific Gravity Static Reading 100% 1.265 25.4 VDC On Charge 31.0 VDC 75% 1.225 24.8 VDC 29.0 VDC 50% 1.190 24.4 VDC 27.0 VDC 25% 1.155 24.0 VDC 26.0 VDC DISCHARGED 1.120 23.8 VDC 25.0 VDC GEL/SEALED Lead Acid Type Deep Cycle Charge Level Specific Gravity Static Reading On Charge 100% N/A 25.6 VDC 28.8 VDC 75% N/A 25.0 VDC 28.2 VDC 50% N/A 24.6 VDC 27.8 VDC 25% N/A 24.4 VDC 27.
Service & Parts Education HOW TO READ THE BDI ON MKIV JOYSTICKS (Battery Discharge Indicator) Single LED (BDI) 10 Segment LED (BDI) MKIV- X JOYSTICK 10 Segment LED (BDI) 10 Segment LCD (BDI) MKIV- A JOYSTICK MKIV- A+ JOYSTICK How To Read the BDI: The BDI (Battery Discharge Indicator) can be displayed in a Single LED, or a series of LED/LCD segments on the joystick face. The segments (or Single LED) directly relate to the status of the batteries reserve capacity, or state of charge.
Service & Parts Education CALIBRATING THE BATTERY DISCHARGE INDICATOR MKIV (MKIV RX, A, PSF, PSR, A+, & REMOTE DISPLAYS) BATTERY DISCHARGE INDICATOR The BDI is the fuel gauge for a power wheelchair. The BDI measures the battery voltage, and will show the status of the voltage on the BDI Display. Calibration of the BDI is done at the factory, but can be checked and recalibrated in the field.
Service & Parts Education HOW TO READ THE BDI ON MKV JOYSTICKS (Battery Discharge Gauge) SPJ Joysitck (NX/NX-LP) The joystick information gauge and the Remote Programmer give indications of the types of fault or error detected by the controller. When a fault is detected, the chair will stop and will not drive. All of the BGD (Battery Gauge Display) lights on the information gauge will beging to flash. The number of flashes idicates the nature of an abnormal condition.
Service & Parts Education CALIBRATING THE BATTERY DISCHARGE GAUGE MKV (MKV MPJ, DPJ, & REMOTE DIPLAYS) MPJ & Remote Displays Joystick (EX & TT-EX Only) During normal operation the active drive is displayed on the left half of the first line. The left half of the second line is the BDG (Battery Discharge Gauge). It provides information on the remaining charge in the batteries. At full charge solid blocks fill in all five (5) segments between E (Empty) and F (Full).
Service & Parts Education REMOTE PROGRAMMER BATTERY QUALITY MENU INSTRUCTIONS (can be found in the calibration menu on all chairs) BATTERY QUALITY BATTERY IS NOW 25.6 V LOAD TEST WAS GOOD @00008HR, NOW = 00016HR TOTAL AH =00024 The first line gives the current battery voltage. Fully charged batteries should indicate 25.0 Volts or above. The battery voltage must be over 25 Volts, and the chair must be driven for more than five minutes in order for the controller to perform a load test.
Service & Parts Education FIELD LOAD TEST Old batteries lose their ability to store and release power, due to increased internal resistance. This means that as you try to take power from the battery, some of that power is used up in the process of passing through the battery, resulting in less voltage at the posts. The more power drawn, the lower the voltage available. When this lost voltage drops (as a pair) the output 0-2 volts their GOOD, 2-2.5 their POOR, 2.5 or higher replace the batteries. 4.
Service & Parts Education USING HYDROMETER TO CHECK BATTERY CELLS (FOR LEAD ACID BATTERIES ONLY, SEE FIGURE 2) WARNING NUMBER OF FLOATING BALLS NEVER smoke or strike a match near the batteries. If the caps of the battery cells are removed, NEVER look directly into them when charging the battery. 0 Discharged 1 25% Charged 2 50% Charged The use of rubber gloves and safety glasses is recommended when testing the battery cells.
Service & Parts Education CHARGING BATTERIES TECHNICIANS NOTE: New batteries MUST be fully charged prior to initial use of the wheelchair. There have been occasions where new batteries have failed out of the box. Save yourself a service call, and charge the batteries the night before your delivery or before the customer is scheduled to pick up the chair. The range per battery charge (using recommended batteries) should be approximately 5 to 9 hours of typical operation.
Service & Parts Education FULLY AUTOMATIC BATTERY CHARGERS *1061411 = 4 Amp *1053161 = 8 Amp Lester type Dual Mode chargers are available in a 4 amp and an 8 amp version, (the 12 amp version has been discontinued). The Dual Mode switch on the front panel can be set for Lead Acid Batteries or Gel Type Batteries. On the front panel as well, is the On/Off power switch and a green diagnostic LED. Cutoff voltage for Lead Acid Batteries is set at 31.0 volts, and 28.8 volts for Gel Batteries.
Service & Parts Education WIRING HARNESS TESTING 1. Check the wiring harness for visible damage, broken/loose connections, and corrosion. If any damage is found replace harness, or repair it with factory equivalent parts. If the damage is due to corrosion, clean all connections thoroughly. Corrosive connections create high resistance, which could cause problems with the electronics. 2. Check all fuses in the system, which includes inside the battery boxes. 3.
Service & Parts Education WIRING HARNESS AND BATTERY BOX FUSES PTO Plug 1090117 - 15 Amp BUSS ATM-15 (Blue - 15 Short) 50000X166- 60 Amp BUSS 2-1/4” Not Shown 1042740 - 30/50 Amp Shaumut 1-1/2” 1089385 - 80 AMP MIDI 1101099 - 20 Amp BUSS ATC-20 (Yellow - 20 Long) 1098892 - 15 Amp BUSS ATC-15 (Blue - 15 Long) Pronto M91 75 Amp Wire Harness, Battery Front 1115349 Wire Hraness, Battery Rear 1115350 Course # 1 Manual Rev.
Service & Parts Education CHARGER & WIRING HARNESS ACCESSORIES 1053831 - New Round Plug to Old Square Plug Charger Adapter *1098905 - PTO to Dual Anderson 24 Volt Accessory Cable *NOTE: Original wiring harness, must have a fused PTO connector. 1083929 - 24” Round Charger Extension Cable Not Shown 1013399 - 34” Square Charger Extension Cable 1092912 - Programmer Extension Cable (Std.
Service & Parts Education WIRING CONNECTORS & HOUSINGS Motor Connectors 1007043 4-Pole Housing w/ Latch 1007044 4-Pole Housing w/o Latch 1007032 Housing Hardware: 2 Screws 1 Clamp 1 Roll Pin Anderson Housing Connectors 1007034 Red 1007035 Black 1007036 White 1007042 30 Amp Contacts (Motor) 1007041 15 Amp Contacts (Brake) Controller 75 Amp Anderson Connector 50000X161 Blue Anderson Connector 98000X031 75 Amp Contacts Black 75 Amp Battery Connector 1022461 Black Anderson Housing with Spring & Contacts 1108
