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Dynamic DS120 Installation Manual Download Page 16

 

 

Chapter 3: Installation and Testing  

16 

3.3.2

 

Wiring Diagram for DS90 and DS120 

 

3.3.3

 

Wiring Diagram for DS160 

 

 

 

Warning: 

The fuses shown in these diagrams should be located as close to the 

controller as is practical to minimise the length of unprotected cables. 

Summary of Contents for DS120

Page 1: ...RHINO2 DS90 DS120 and DS160 DS90 ACT DS120 ACT and DS160 ACT Scooter Controllers Installation Manual Rhino2 Installation Manual Issue 2 0 October 2011 GBK51948 ...

Page 2: ... The product is not user serviceable Specialised tools are necessary for the repair of any component Do not install maintain or operate this equipment without reading understanding and following this manual including the Safety and Misuse Warnings otherwise injury or damage may result This manual contains integration set up operating environment test and maintenance information needed in order to ...

Page 3: ...e Testing 24 3 7 Battery Charging and Programming Connections 24 3 7 1 Battery charger connections 25 3 7 2 Programmer Connections 27 3 8 Actuator Seat Lift Wiring DS90 ACT DS120 ACT DS160 ACT 28 3 8 1 Overview 28 3 8 2 Wiring 28 3 9 Tiller Connector 31 3 10 Throttle Configuration 32 3 10 1 ISO7176 14 2008 requirements 32 3 10 2 Single throttle wiper 33 3 10 2 1 Additional hardware to comply with ...

Page 4: ...keup Style 63 4 4 1 3 Swap Throttle Direction 64 4 4 1 4 Enable Beeper 64 4 4 1 5 Flash Code Beeper 64 4 4 1 6 Sleep Beeper 65 4 4 1 7 Motion Beeper 65 4 4 1 8 Reversing Beeper 65 4 4 1 9 Beeper Timing 65 4 4 1 10 Deep Discharge Beeper 66 4 4 1 11 Sleep on Fault or Inhibit 66 4 4 1 12 Power Off after Sleep 66 4 4 2 Throttle Configuration 67 4 4 2 1 Throttle Type 67 4 4 2 2 Throttle Input 67 4 4 2 ...

Page 5: ...ollbackStart End 86 4 4 5 4 Motor Reverse 86 4 4 5 5 Load Compensation 86 4 4 5 6 Maximum Load Compensation 88 4 4 5 7 Load Compensation Damping 88 4 4 5 8 Remembered Load Compensation 89 4 4 5 9 Current Limit 89 4 4 5 10 Boost Current Boost Time 90 4 4 5 11 Stall Timeout 90 4 4 5 12 Motor Testing 92 4 4 5 13 Maximum Motor Voltage 92 4 4 6 Park Brake Management 93 4 4 6 1 Park Brake Testing 93 4 4...

Page 6: ... 2 4 Type 4 Flash Codes 111 5 3 Diagnostics Tools 112 5 4 HHP Fault Codes with sub codes 113 5 5 Advanced Diagnostics Logs 115 5 6 Service Scheduler 116 6 Appendices 117 6 1 Neutral Detect Active States 117 6 2 Accessories Parts List 118 6 3 Intended Use and Regulatory Statement 120 6 4 Service life 120 6 5 Maintenance 121 6 6 Warranty 121 6 7 Safety and Misuse Warnings 122 6 8 Electromagnetic Com...

Page 7: ... stability Throttle Dual Decode requires ISO compliant speed pot provides extra safety in case of a throttle failure and allows OEMs to comply with the new requirements of ISO7176 14 2008 Intelligent motor and battery management providing automatic power flow optimisation auto battery configuration 5V and 12V battery capacity outputs Trucharge and in depth battery logging and analysis tools Suppor...

Page 8: ...Chapter 1 Introduction to the RHINO2 8 Note Unless otherwise specified all references in this manual apply to all variants of the RHINO2 controller ...

Page 9: ...imit Pot Pin 9 linear 90 100 110 kΩ Speed Reduction Wiper Pin 4 6 or 12 log 9 10 11 kΩ Current Rating DS90 Continuous 20 C ambient 36 A Peak 180 seconds 20 C initial See warning below 90 A Boost Current 10 A Boosted Current 100 A Boost Time 10 s Current Rating DS120 Continuous 20 C ambient 48 A Peak 180 seconds 20 C initial See warning below 120 A Boost Current 20 A Boosted Current 140 A Boost Tim...

Page 10: ...er Aluminium Top Base and Terminal cover Aluminium alloy ADC12 Protection Rating with cover Electronics rated to IP55 Protection Rating without cover Electronics rated to IP54 Shipping Weight Controller Unit Terminal cover DS90 120 160 DS90 ACT 120 ACT 160 ACT 952 grams 55 grams 988 grams 55 grams Min Nominal Max Units Operating Temperature Range 25 13 50 122 C F Storage Temperature Range 40 40 65...

Page 11: ...ries and motor is recommended to reduce the length of high current wires Use both screw positions to attach the controller M5 cap screws are recommended Other M5 fasteners can also be used Do not over tighten the mounting screws max 8Nm Use a magnetic tip screwdriver for removing and fitting fasteners Refer to section 3 1 2 for recommended mounting orientations Regardless of mounting orientation p...

Page 12: ...r side on the bottom and horizontal with connector facing upwards or downwards The horizontal with connector facing downwards mounting orientation is permitted to be tilted a further 30 for mounting Vertical Connector side on the bottom Mounting Orientation Horizontal Connector facing upwards Mounting Orientation Horizontal Connector facing downwards Mounting Orientation 30 max ...

Page 13: ... available for the RHINO2 controller This can be ordered separately see Accessories Parts List 6 2 for more details The terminal cover kit comprises a terminal cover and three M3x8mm screws To attach the terminal cover offer it towards the top case ensuring that the locating lugs see image below are positioned in the recesses in the top case and then screw the terminal cover to the top case with t...

Page 14: ...re possible Do not leave electrical connections unnecessarily exposed Insulate exposed connections for example with sleeving to reduce the risk of short circuits exposure to water and connection stress Make sure that all vehicle sub frames particularly the transaxle controller case and tiller head assemblies are electrically connected Make sure that the controller and speed setting potentiometers ...

Page 15: ...r entry or suffer from physical strain abuse or damage such as cutting or crushing Take particular care on scooters with movable structures such as seat raise Make sure that the cables do not extend beyond the scooter so that they cannot be caught or damaged by external objects 2 Disconnect all the cables of the scooter at the powered end whenever units are replaced or moved 3 The user maintenance...

Page 16: ...Testing 16 3 3 2 Wiring Diagram for DS90 and DS120 3 3 3 Wiring Diagram for DS160 Warning The fuses shown in these diagrams should be located as close to the controller as is practical to minimise the length of unprotected cables ...

Page 17: ...g 17 3 3 4 Wiring Diagram for DS90 ACT and DS120 ACT 3 3 5 Wiring Diagram for DS160 ACT Warning The fuses shown in these diagrams should be located as close to the controller as is practical to minimise the length of unprotected cables ...

Page 18: ...nerally suitable for runs up to 800mm Longer runs will require heavier wire typically an extra 1 0mm2 for each additional 400mm run length The heavier the wire the better driving performance will be These notes are in addition to the General Wiring Recommendations as described in Section 3 3 1 The final connection to the Battery Positive terminal should not be made until the scooter is completely ...

Page 19: ...ller or the protection wire Check thoroughly to ensure that it provides the necessary degree of motor protection Model Fuse rating Circuit Breaker rating DS90 75A 60A DS120 85A 70A DS160 100A 80A If the two batteries are permanently wired together for example in a single battery box the best position for the circuit breaker is between the two batteries If the batteries are separated individual bat...

Page 20: ...yellow 10 12AWG 2 130171 1 The wire gauge recommendations above are the MINIMUM gauge and are generally suitable for runs up to 400mm Longer runs will require heavier wire typically an extra 1 0mm2 for each additional 200mm run length The heavier the wire the better driving performance will be In particular the length and gauge of wire affects the wire resistance and hence the optimum Load Compens...

Page 21: ...h power for a prolonged period In order to provide adequate protection the RHINO2 will remember the condition of the motor when it has been turned off Enable motor protection with the Motor Protection parameter 4 4 5 1 Note Enabling Motor Protection is only useful if its parameters are adapted to match the fitted motor See the motor specifications given by the motor manufacturer for the correct va...

Page 22: ...4 Molex Mini Fit Jr 2 socket housing 39 01 3028 GCN0771 Molex Mini Fit Jr Receptacles 18 24AWG 39 00 0039 The RHINO2 supports a 24V park brake that is connected to the park brake connector A manual park brake release lever can be fitted so the scooter can be pushed when the controller is turned off To meet ISO requirements if a manual park brake release lever is fitted a micro switch should be con...

Page 23: ... the scooter if the speed of the scooter is higher than the value that is set with the Roll away Speed parameter 4 4 3 14 This is to make sure that the scooter is limited to a safe speed on a slope while the park brakes are released Electronic Park Brake release wiring The park brake may also be released electrically by activating a switch in the tiller Park brake release functionality is availabl...

Page 24: ...k brake testing Pre Drive tests the park brake every time the throttle is moved out of neutral Driving tests the park brake every time the throttle is moved out of neutral and periodically while driving This test may result in some audible noise during driving Warning Do not turn off Park Brake Testing unless there are no park brakes installed 3 7 Battery Charging and Programming Connections Charg...

Page 25: ...revent driving while charging an appropriate inhibit pin in either the Charge Program or Tiller connector must be connected so that a connection between Battery and Inhibit is made when charging For off board chargers this connection must be made as soon as the charger is connected to the scooter independent of the charging state Charger inhibit functionality is available on pin 14 and pin P I of ...

Page 26: ...s a Multi function input and can be used for an alternative function if a charger is not plugged into this pin Warning A suitable fuse with a maximum rating of 8A must be installed in the Battery Positive wire to protect the scooter s wiring Connect the fuse as close as practical to the controller connector to minimise the length of unprotected wiring ...

Page 27: ...cket or into the 4 pin Molex Mini Fit Junior connector with the use of the AMP programming adapter If an on board charger is installed it will be necessary to disconnect it prior to programming through this connector The RHINO2 can be programmed with two different programming tools The DX HHP hand held programmer see 4 1 The PC based Wizard programmer see 4 2 Programming socket Adaptors needed XLR...

Page 28: ...is driving To prevent the actuator driving in potentially unsafe situations a drive inhibit input can be wired such that the scooter cannot be driven if the actuator is being driven or if it has reached a position that is unsafe e g the seat is raised to a level where there is a danger of tipping over If this function is required then a Multi function input has to be programmed to the function Slo...

Page 29: ...tor wiring should be a minimum of 0 8mm2 18AWG The maximum current of the actuator output is 12 5A Drive Seat Select Switch When the multifunction input pin configured for actuator drive is connected to Battery the throttle controls driving as normal When the multifunction input pin is not connected the throttle controls the actuator Wiring the drive select switch through the key switch reduces ba...

Page 30: ...Chapter 3 Installation and Testing 30 Drive Actuator Connector 14 Way Connector Battery Seat Seat Drive Select Switch Key Switch Actuator Battery Act Output B Act Output A Multifunction Input Pin 6 ...

Page 31: ...er TW 0 5mm 20AWG 2 Throttle Positive T 3 Multi function Output Beeper 4 Multi function Input Profile 2 5 Key Switch KS 6 Multi function Input Slow 7 Battery Positive B 1 0mm 18AWG 8 Throttle Negative T 0 5mm 20AWG 9 Speed Limit Pot SLP 10 Multi function Output Status Low 11 Multi function Output none 12 Multi function Input Reverse Drive 13 Battery Negative B 1 0mm 18AWG 14 Multi function Input C...

Page 32: ...w speeds increase the Throttle Response parameter 4 4 2 5 3 10 1 ISO7176 14 2008 requirements The ISO7176 14 standard requires that the scooter does not start to drive when the throttle circuit is faulty or not calibrated correctly To comply with this standard Dynamic Controls RHINO2 controller provides Dual Decode functionality The RHINO2 supports 3 throttle configurations Single throttle wiper 3...

Page 33: ...iant with the standard extra hardware is required to check if the throttle signal is valid One way to achieve this is to use a Neutral Detect ND switch that indicates if the throttle is in the physical neutral position Normally the hardware transfers the Throttle Wiper voltage to the TW output directly However if the ND switch indicates Neutral but the wiper signal is not at the neutral value the ...

Page 34: ... 3 10 6 for details Note The Neutral Detect function assumes that the throttle is in Neutral when the Neutral Detect input is in its active state For optimal mechanical accuracy the neutral window of the Neutral Detect switch the range of physical throttle deflection at which the switch indicates Neutral should be as narrow as possible Make sure that the Throttle Dead band parameter 4 4 2 6 is set...

Page 35: ...on during use To maximise accuracy increase the diameter of the disk Wear and tear will decrease accuracy Make sure that the mechanical design conforms to the required lifespan of the throttle potentiometer Disk with optical switch Many other options are possible for example a disk with a slit that allows the light of a slotted optical switch to pass through in the neutral position This option pro...

Page 36: ...unction to SRW See Speed Limit Pot Connections 3 10 6 2 for more details Note If the throttle potentiometer is powered externally not by T and T take care to avoid ground shift Ground shift will result in a throttle fault 3 10 5 Throttle Calibration For correct throttle operation the electrical range of the throttle must be calibrated by correctly setting Swap Throttle Direction 4 4 1 3 Throttle N...

Page 37: ...ers 4 4 2 3 10 6 2 In parallel with the throttle For a speed pot in parallel use a 100kΩ potentiometer and set Speed Limit Pot to Yes If the Speed Limit Pot is at its minimum position the speed of the scooter at full throttle deflection is set by Minimum Forward Speed 4 4 3 7 and Minimum Reverse Speed 4 4 3 8 The Dual Decode variant already uses pin 9 for the second throttle wiper connection To us...

Page 38: ...Chapter 3 Installation and Testing 38 reduced use the Speed Scale parameters and leave the Speed Limit parameters at 100 ...

Page 39: ... a conventional User Control potentiometer the SRW supports the use of a 10k logarithmic pot wired as a variable resistor between Pin x 4 6 or 12 and B of the tiller SRW variable supports a user defined resistance value between Pin x 4 6 or 12 and B of the tiller which can be set with SRW Scaling Resistor Ohm To avoid a throttle dead band when the speed is reduced use the SRW Speed Scale parameter...

Page 40: ...ply to the tiller while Pin 13 provides the Battery Negative B return These pins have current ratings of 9A and can be used for wiring an XLR socket for an off board battery charger An external fuse maximum rating of 8A should be installed into the Battery Positive circuit Refer to Section 3 7 for further details about battery charging The B and B supplies must not be connected either directly or ...

Page 41: ...wo LEDs may be connected in series LEDs with voltage ratings for example 12V or 24V have internally fitted resistors and must not be used 3 10 10 Status Indicator Output Pins 3 10 and 11 on the tiller connector can be configured as dedicated status outputs Pin 10 also has the ability to be active either high or low Pin 10 is rated for 50mA sink and 10mA source whereas Pins 3 and 11 are capable of ...

Page 42: ... 5V or 12V voltmeter battery gauge display shown below Alternatively a digital LED display is supported by using the LED Battery Gauge wiring shown on the right The algorithm used is the same as the Dynamic Shark power chair controller and has built in filters to adjust for voltage dips under load and floating voltages after periods of idling This function is available on Pin 10 of the tiller conn...

Page 43: ...ay will also need to incorporate reverse polarity protection such as a series diode Note An LED array may exhibit a faint glow if not engaged The brake light will operate whenever the controller decelerates The reversing light will operate whenever the controller is driving in reverse LED Lighting Output Incandescent or Halogen bulb output 24V Relay 100mA 24V Relay with fly back and series diode 5...

Page 44: ...pin can be set to operate a specific function see table below Most functions are fully configurable as to the circuit state in which they are active or operating as well as the ability to become latched where the controller must be turned off and then on again to cancel the function In addition the speed to which a Slow input decelerates is fully customizable The table below shows the supported fu...

Page 45: ...on or a Charger Inhibit condition occurs a flash code will be displayed Due to the nature of the different functions some functions do not support the complete range of configuration See the table below for further details Active Slows to Latches Flashes SRW SRW variable Profile 2 Charger Inhibit Slow 0 only Reverse Drive Release Brake Slow Stop Fwd Slow Stop Rev Slow Stop Neutral Detect Actuator ...

Page 46: ...pulled up inactive when open Low or Open Input is active when pulled down or open inactive when pulled up High or Open Input is active when pulled up or open inactive when pulled down To pull up an input connect it to B To pull down an input connect it to B If a multi function input switch is connected to B put a diode in series for increased reliability If multiple switches are connected to B it ...

Page 47: ...hes The Latches parameter sets whether the function will become latched once active If a function is latched the active condition will have to be removed and the controller turned off and then on again before the function will be turned off Note If Latches is selected please select Flashes as well to indicate to the user why the scooter will not drive 3 11 1 4 Flashes The Flashes parameter sets wh...

Page 48: ... sections Status Indicator Output 3 10 10 Beeper Output 3 10 11 Battery Gauge Output 3 10 12 Brake and Reversing Lights 3 10 13 The table below shows the supported functionality for each input pin Pin 3 Pin 10 Pin 11 Beeper Brake Light Reversing Light Status Power Status Status High Status Low 5V Battery Gauge 12V Battery Gauge Other multi LED battery gauge display For more information see Multi f...

Page 49: ...off Ensure it turns off correctly Turn the key switch again to turn the RHINO2 back on 6 Ensure all installed hardware is functioning correctly by activating appropriate buttons switches etc 7 Move the throttle slightly out of neutral and listen for the click as the park brakes disengage 8 Move the throttle backwards and forwards and ensure that the wheels respond smoothly and in the correct direc...

Page 50: ... parameters for a safe response It is responsibility of the health care professional to make sure that the user is capable of both cognitively understanding and physically operating the programmed features and functions With inappropriate programming settings certain features and options may not be accessible or perform as expected The RHINO2 is programmed during manufacture with default settings ...

Page 51: ...program parameters as instructed by the scooter manufacturer The DX HHP Manual should be read and understood before attempting to use the HHP Turn on the scooter before you connect the programmer to the RHINO2 All changes are saved immediately it is not necessary to disconnect the HHP or to cycle the power to save changes For this reason it is not possible to cancel a change other than to set the ...

Page 52: ...ired parameter is shown 4 Press UP or DOWN to adjust the parameter to the desired value Please note that each change is effective immediately there is no option to cancel a change To undo a change manually set the parameter back to its original setting with UP or DOWN 5 Press EXIT twice to return to the Main Menu For each drive profile the following parameters can be adjusted Parameter Section Max...

Page 53: ...eter back to its original setting with UP or DOWN 5 Press EXIT twice to return to the Main Menu In the Non Profiled Menu the following parameters can be adjusted Parameter Section Sleep Timer 4 4 1 1 Enable Beeper 4 4 1 4 Swap Throttle Direction 4 4 1 3 Battery Capacity Higher settings make the battery gauge react slower Service Scheduler Service Period 4 4 8 1 Beep on Fault Flash Code Beeper 4 4 ...

Page 54: ...een fitted then the SLP must be set for full speed when performing throttle calibration Throttle calibration may fail if the SLP is set to a lower speed 1 In the Main Menu screen press PROG to enter the Programming Menu 2 To select Throttle Calibration press NEXT three times and then press YES 3 Wait until Deflect Forward is shown on the HHP 4 Deflect the throttle FULLY forward This procedure meas...

Page 55: ...controller cannot measure the throttle correctly or when there is no expected throttle activity for 20 seconds during any of the calibration screens the HHP will show Failed If this happens press RETRY to repeat the calibration from the start and go back to step 4 Throttle Calibration Successful EXIT NEXT Programming Menu Calibration Menu Main Menu Throttle Calibration Deflect Reverse EXIT Program...

Page 56: ...deflected Drive Count The total number of times that the throttle has been deflected and returned to neutral 5 Press NEXT to see the unit identification Press MORE to see the parameters one by one Model ESN and Software version Identification Description Model The model number of the unit DS90 ACT etc ESN The serial number of the unit Version The software version number of the unit 6 Press EXIT to...

Page 57: ...u the following parameters can be adjusted Parameter Section Load Compensation 4 4 5 5 Soft Start Period 4 4 3 9 Soft Finish 4 4 3 10 Also the following parameters can be read real time Parameter Typical Battery Voltage 23 28 V Motor Voltage 0 Battery Voltage Motor Current 0 unit rating Controller Temperature 10 80 degrees Throttle Voltage 0 5 V TECHNICIAN Load Compensation 100 mOhm EXIT NEXT DOWN...

Page 58: ...lowed to be edited or seen based on the dongle level In addition the Wizard can also generate comprehensive diagnostics reports For more information see the Wizard user manual 4 2 1 Software revisions You can check the software version of your controller with the main screen of the HHP see 4 1 the Wizard Tools Change Module Version ...

Page 59: ...eep Beeper No Yes Yes Motion Beeper None Reverse Forward Reverse Reverse Beeper On Time 100 1500ms 300ms Beeper Off Time 0 1500ms 700ms Deep Discharge Beeper No Yes Yes Sleep on Fault or Inhibit No Yes Yes Power Off after Sleep No Yes Yes Throttle Configuration 4 4 2 Throttle Type Wig wag Single ended Uni polar Wig wag Throttle Input Single Dual Single Throttle Neutral Offset 0 63 0 62 V 0 V Throt...

Page 60: ... 2 DS160 35 Profile1 35 Profile 2 Reverse Acceleration 0 100 DS90 DS120 30 Profile1 30 Profile 2 DS160 15 Profile1 15 Profile 2 Reverse Deceleration 0 100 50 Profile1 50 Profile 2 Minimum Forward Speed 0 100 20 Profile1 20 Profile 2 Minimum Reverse Speed 0 60 20 Profile1 20 Profile 2 Soft Start Period 0 2550ms DS90 DS120 800ms DS160 1000ms Soft Finish 0 100 35 Emergency Deceleration 0 100 80 Slam ...

Page 61: ... 120A DS120 160A DS160 36A DS90 48A DS120 64A DS160 Motor Heating Time 1 255s 20s Motor Cooling Time 4 1020s 32s Motor Reverse No Yes No Load Compensation 0 225mΩ DS90 60mΩ DS120 40mΩ DS160 28mΩ Maximum Load Compensation 0 225mΩ DS90 DS120 200mΩ DS160 100mΩ Load Compensation Damping 15 60 50 Remembered Load Compensation 15 60 50 Current Limit DS90 0 90A DS120 0 120A DS160 0 160A DS90 90A DS120 120...

Page 62: ...ensitivity 0 170 40 System Options 4 4 8 Service Scheduler No Yes No Service Period 0 5100h 5000h Actuator Time Out 0 60s 10s Multi function Inputs Configuration 4 4 9 Pin 4 Function None Reverse Drive Release Brake Charger Inhibit Profile2 Slow Slow Stop Slow Stop FWD Slow Stop REV SRW SRW variable Neutral Detect Actuator Wig Wag Actuator Control Profile 2 Pin 6 Function Slow Stop Pin 12 Function...

Page 63: ...mer minutes When the RHINO2 sleeps it is partially turned off to reduce energy consumption and to make sure that the scooter does not move if the user accidentally moves the throttle In Sleep Mode the scooter does not respond to commands To wake up the RHINO2 take the action that is selected with Wakeup Style If Wakeup Style is set to Key Throttle the Status Light gives a short flash every 5 secon...

Page 64: ...r 4 4 5 4 also reverses the direction of the scooter but it does not swap the behaviour of the reversing buzzer or the speed limit parameters If Motor Reverse is set to Yes the reversing buzzer will beep when the scooter moves forward and the forward speed will be limited by the Maximum Reverse Speed parameter For this reason do not use Motor Reverse for left handed operation Use Swap Throttle Dir...

Page 65: ...r beeps only when it is moving in the reverse direction Forward Reverse The scooter beeps when it is moving in any direction 4 4 1 8 Reversing Beeper Parameter Possible Values Default HHP Lite Std Adv Reversing Beeper Yes No No Note that the Reversing Beeper parameter does not exist in the Wizard since the Motion Beeper parameter can be used to switch on the beeper for reversing When using the HHP...

Page 66: ...r Inhibit Parameter Possible Values Default HHP Lite Std Adv Sleep on Fault or Inhibit No Yes Yes Enables going to sleep if a fault or inhibit condition is active If set to no the unit will not go to sleep but will signal the fault indefinitely Notes If the value of Sleep Timer is zero the value of Sleep on Fault or Inhibit is ignored During a throttle fault or OONAPU fault the controller will nev...

Page 67: ...ith the Forward Reverse switch This allows left handed and right handed operation of the same wigwag without reprogramming the scooter The standard direction of the scooter can be swapped with Swap Throttle Direction 4 4 1 3 If a Forward Reverse switch is needed connect it to one of the Multi function Inputs 3 11 1 and set the corresponding Pin X Function parameter see 4 4 9 to Reverse Drive For s...

Page 68: ...re ignored and all positive values are multiplied by 2 which mean that a Wizard setting of 0 5V will produce an actual neutral offset of 1 0V 4 4 2 4 Throttle Full Scale Deflection Parameter Possible Values Default HHP Lite Std Adv Throttle Full Scale Deflection 20 100 75 Set the percentage of total throttle movement that will result in full speed The scale of this parameter ranges between Throttl...

Page 69: ...rameter Possible Values Default HHP Lite Std Adv Throttle Dead band 0 100 25 Also commonly referred to as Neutral Window Throttle Dead band sets how far the throttle must be moved out of neutral before the controller will begin to drive The percentage range is dependent on the value of the Throttle Type parameter 4 4 2 1 Wig wag and Uni polar 0 2 5V Throttle Neutral Offset 4 4 2 3 100 Throttle Ful...

Page 70: ...meter Possible Values Default HHP Lite Std Adv Maximum Throttle Voltage 0 5 V 4 90 V Minimum Throttle Voltage 0 5 V 0 10 V Maximum Throttle Voltage sets the maximum expected throttle voltage Set this parameter to the voltage that is present at the RHINO2 throttle wiper input pin 1 of the tiller head connector when the wiper of the throttle is moved fully to the Throttle Positive position pin 2 Min...

Page 71: ... to return the throttle to the neutral position within 5 seconds None An OONAPU fault will never occur Do not use except for testing purposes or throttle calibration The flash code that is shown depends on the Flash Code Type parameter 4 4 10 1 Note If an OONAPU fault does not go away after the scooter has been turned off and on the throttle may be faulty or incorrectly calibrated See section 3 10...

Page 72: ... when no speed pot is connected to pin 9 when the speed pot is wired in series with the throttle instead of in parallel the RHINO2 will read pin 9 as if the speed pot is at its lowest setting and will always limit the speed of the scooter to the lowest forward and reverse speeds If the voltage at pin 9 is the same as Throttle Positive T the maximum speed of the scooter at 100 throttle deflection i...

Page 73: ...rottle movement in the opposite direction is set with Slam Brake Threshold During a slam brake the scooter decelerates with the rate that is set with the Slam Braking parameter 4 4 3 12 Be careful when enabling slam braking because this setting may not be suitable for all scooter types 4 4 2 13 Enable SRW Open Circuit Testing Parameter Possible Values Default HHP Lite Std Adv Enable SRW Open Circu...

Page 74: ...ut pin is activated 4 4 3 1 Maximum Forward Speed Parameter Possible Values Default HHP Lite Std Adv Maximum Forward Speed 20 100 DS90 DS120 100 Profile1 60 Profile 2 DS160 100 Profile1 50 Profile 2 Sets the maximum speed in the forward direction when the highest speed has been selected with the speed limit pot see 3 10 6 and the throttle is fully deflected forward Dealers can adjust this paramete...

Page 75: ...ooter reaches full forward speed in 10 s 100 From standstill the scooter reaches full forward speed in 0 4 s Low acceleration values give a softer performance and a less sensitive throttle response High acceleration values give a more aggressive performance and a fast throttle response Note This parameter cannot be set higher than the value of the Acceleration Limit parameter 4 4 4 5 that has been...

Page 76: ... braking distance High deceleration values produce a more aggressive stop but can be uncomfortable Adjust this parameter to the preference of the user Note This parameter cannot be set higher than the value of the Deceleration Limit parameter 4 4 4 6 that has been set by the scooter manufacturer Warning Setting Forward Deceleration too low or too high can result in a scooter that is unsafe Test th...

Page 77: ...eed Limit parameter 4 4 4 2 that has been set by the scooter manufacturer 4 4 3 5 Reverse Acceleration Parameter Possible Values Default HH P Lite Std Adv Reverse Acceleration 0 100 DS90 DS120 30 Profile1 30 Profile 2 DS160 15 Profile1 15 Profile 2 Sets how quickly the reverse speed increases after the throttle has been deflected reverse 0 From standstill the scooter reaches full reverse speed in ...

Page 78: ...ooter complies with local regulatory requirements for maximum allowable braking distance 4 4 3 7 Minimum Forward Speed Parameter Possible Values Default HHP Lite Std Adv Minimum Forward Speed 0 100 20 Profile1 20 Profile 2 This parameter is only used when Speed Limit Pot 4 4 2 11 is set to Yes Minimum Forward Speed sets the maximum speed in the forward direction when the lowest speed has been sele...

Page 79: ...r cannot be set lower than the value of the Minimum Reverse Speed Limit parameter 4 4 4 4 that has been set by the scooter manufacturer 4 4 3 9 Soft Start Period Parameter Possible Values Default HHP Lite Std Adv Soft Start Period 0 2550ms DS90 DS120 800ms DS160 1000ms Whenever there is a change in speed demand the soft start function temporarily reduces the acceleration decelaration rate during t...

Page 80: ...soft finish at all 100 Very smooth transition For most applications the default value of 35 works fine 4 4 3 11 Emergency Deceleration Parameter Possible Values Default HHP Lite Std Adv Emergency Deceleration 0 100 80 Emergency Deceleration sets how quickly the scooter comes to a halt when travelling forward and a Stop input is active or a fault that requires an emergency stop occurs or the key sw...

Page 81: ...4 3 13 Push Speed Parameter Possible Values Default HHP Lite Std Adv Push Speed 5 100 15 This feature will limit the scooter to a safe speed if rolling away on a slope when the controller is on and the park brakes have been released electrically this would normally be the case if the scooter is being pushed If the scooter is being pushed by an external force at a higher speed than Push Speed the c...

Page 82: ...arameter Possible Values Default HHP Lite Std Adv SRW Forward Speed Limit 0 100 50 SRW Reverse Speed Limit 0 100 50 SRW Forward Speed Scale 0 100 50 SRW Reverse Speed Scale 0 100 50 These parameters are only used when Pin 4 Function 4 4 9 where x is 4 6 or 12 is set to SRW or SRW variable When Pin 4 Function where x is 4 6 or 12 is set to SRW or SRW variable the RHINO2 reduces the speed proportion...

Page 83: ...nd independently of each other If any of the parameters is set to 100 it disables the reduction effect of that specific parameter 4 4 3 16 SRW Scaling Resistor Ohm Parameter Possible Values Default HHP Lite Std Adv SRW Scaling Resistor Ohm 400 25500Ω 3200Ω Sets the maximum resistor value to be used in the SRW circuit when Pin x Function where x is 4 6 or 12 is set to SRW variable Its range is 400 ...

Page 84: ...to 100 for no effect 4 4 4 3 Minimum Forward Speed Limit Parameter Possible Values Default HHP Lite Std Adv Minimum Forward Speed Limit 0 100 0 Sets the minimum value that can be set by a dealer for the Minimum Forward Speed parameter 4 4 3 7 Set to 0 for no effect 4 4 4 4 Minimum Reverse Speed Limit Parameter Possible Values Default HHP Lite Std Adv Minimum Reverse Speed Limit 0 100 0 Sets the mi...

Page 85: ... DS160 Motor Heating Time 1 255s 20s Motor Cooling Time 4 1020s 32s These parameters are only used if Motor Protection is set to Yes Adapt these parameters to match the motor that is fitted on the scooter See the motor specifications given by the motor manufacturer for the correct values Motor Continuous Current is the current at which the motor can run continuously without becoming too hot Motor ...

Page 86: ...opposite direction No The polarity of the motor pins is as described in section 3 5 Note Do not use Motor Reverse to setup the scooter for left handed use set the Swap Throttle Direction parameter see 4 4 1 3 to Yes instead Motor Reverse only swaps the motor polarity not other forward reverse features such as the Forward Reverse speed setting and the reversing beeper Using Motor Reverse to setup t...

Page 87: ... low speeds the most probable cause is a Load Compensation value that is set too low Determining the correct motor resistance by looking at the scooter behaviour Tools needed 1 A scooter with a RHINO2 controller fitted 2 A Hand Held Programmer HHP or a laptop with the Wizard Programmer 3 A slope that you can drive up to Procedure Set Load Compensation to 20 Drive the scooter onto a slope and incre...

Page 88: ...Compensation Damping is used to dampen the effects of the load compensation to avoid bucking and instability at high Load Compensation settings The recommended value for this parameter is between 25 50 It s important to avoid higher values of Load Compensation Damping as this can lead to the load compensation continuing to be applied when the motor current has fallen causing problems such as the s...

Page 89: ...bucking while keeping the system responsive 3 Adjust the Park Brake Neutral Delay parameter to provide acceptable rollback on slopes and prevent jerking higher values decrease jerking but give more rollback and vice versa 4 Adjust the Remembered Load Compensation to give acceptable starting performance when the park brakes are released both when driving on the flat and on slopes Note this paramete...

Page 90: ...Current value again the motor current must stay below the value of Current Limit for at least twice as long as it was above Current Limit 4 4 5 11 Stall Timeout Parameter Possible Values Default HHP Lite Std Adv Stall Timeout 0 51s 15s If the throttle is deflected but the scooter can not drive because It is on a slope that is too steep or It tries to climb up a curb that is too high or It is trapp...

Page 91: ...he country in which the scooter is to be used to determine what the correct Stall Timeout value is If Stall Timeout is set to zero the RHINO2 will deliver as much power as it can for as long as it can while still protecting itself This is not recommended because it can be against local regulations and can cause motor damage ...

Page 92: ... unless for testing in a controlled environment Do not set this parameter to Open or Short unless the motors used are failing the test and they have been fully tested to make sure that they are healthy 4 4 5 13 Maximum Motor Voltage Parameter Possible Values Default HHP Lite Std Adv Maximum Motor Voltage 0 64V 26 2V Maximum Motor Voltage sets the maximum voltage that the RHINO2 will apply to the m...

Page 93: ...riving None The RHINO2 does not check the park brake for an open circuit fault This option allows the RHINO2 to be used without an electric park brake Short circuit faults are still checked Warning For safety reasons do not use None if the scooter has an electric park brake 4 4 6 2 Park Brake Neutral Delay Parameter Possible Values Default HHP Lite Std Adv Park Brake Neutral Delay 0 25500ms 200ms ...

Page 94: ...e Delay Parameter Possible Values Default HHP Lite Std Adv Park Brake Release Delay 0 25500ms 100ms While stopped sets the delay between throttle movement and the park brakes being disengaged Throttle deflected Energise park brake t Park Brake Release Delay speed ...

Page 95: ... Values Default HHP Lite Std Adv Undervoltage Rollback Start 18 32 2V 21V Undervoltage Rollback End 17 21V 18V If the battery voltage falls below Undervoltage Rollback Start the RHINO2 reduces the maximum throttle input value so the user cannot ask for full speed anymore This protects the battery gives the scooter a longer range before the battery is completely empty and gives the user a physical ...

Page 96: ...sible Values Default HHP Lite Std Adv Battery Gauge Minimum 16 24V 22V Battery Gauge Maximum 19 27V 24 4V Battery Gauge Minimum sets the voltage at which the battery gauge indicates an empty battery Battery Gauge Maximum sets the voltage at which the battery gauge indicates a full battery ...

Page 97: ...falls below 90 of this value the RHINO2 gives the user an audible warning The cut off level for lead acid batteries is 21V Note An audible deep discharge warning is required to comply with ISO7176 14 4 4 7 6 Battery Gauge Dead band Parameter Possible Values Default HHP Lite Std Adv Battery Gauge Dead band 0 6V 3 5V Prevents the battery gauge from increasing when the battery voltage recovers after ...

Page 98: ...t slower with high capacity batteries to ignore fast voltage fluctuations that happen when the scooter encounters temporary loads such as a ramp If the battery voltage is less than the battery gauge currently indicates the battery gauge decreases by 5 after Battery Gauge Sensitivity x 1 5 seconds The 100 range of the battery gauge falls between Battery Gauge Minimum and Battery Gauge Maximum For b...

Page 99: ...on or wakes up from sleep to indicate that a service is due To clear the service indication either increase the value of Service Period to a value larger than the current drive time or erase the controller history with the Wizard Tools Erase Controller History Note Erasing the controller history erases the fault log as well Consequently erasing the controller history to erase the fault log will re...

Page 100: ... 14 of the tillerhead connector can be configured as input pins Connect external switches or potentiometers to the input pins to activate one of the following functions None No function normal drive in all states Reverse Drive When this function is active it swaps the throttle direction This function can be used for a Reverse switch when Throttle Type 4 4 2 1 is set to Single ended or Uni polar If...

Page 101: ... Profile 2 is a user selectable slow speed mode that can be used indoors while Profile 1 is selected for outdoor use Apart from changing the maximum speed the indoor profile can have its acceleration and deceleration adjusted as well Available on all input pins Slow Limits the maximum speed of the scooter to the value that is set with Slows To Has no effect on scooter acceleration or deceleration ...

Page 102: ...d by a faulty electrical throttle circuit this function compares the throttle signal with the signal from a neutral switch The neutral switch must be mechanically connected to the throttle so that it activates when the throttle is in the true neutral position If the throttle now gives an out of neutral output signal when the neutral switch is still active the RHINO2 does not drive and the Status l...

Page 103: ...led up inactive when open or pulled down Open Input is active when open inactive when pulled up or pulled down Low or High Input is inactive when open active when pulled up or pulled down Low or Open Input is inactive when pulled up active when open or pulled down High or Open Input is inactive when pulled down active when open or pulled up To pull up an input connect it to B To pull down an input...

Page 104: ...9 10 Battery Low Bad Motor Connection Motor Short Circuit Stall Time out Controller too hot unused Drive Inhibit Speed Pot Throttle Fault Controller Fault Park brake Fault High Battery Voltage 1 1 1 2 1 3 1 4 1 5 2 1 2 2 2 3 2 4 3 1 3 2 3 3 3 4 3 5 4 1 4 2 4 3 4 4 Thermal Cut back Stall Throttle Trip Speed Limit Pot Fault Under Voltage Fault Over Voltage Fault Main Contactor Driver Off Fault Unuse...

Page 105: ...rake light flashes at 0 5 Hz when the scooter drives in reverse Connect the light between B and the pin that has Reverse Light selected Beeper The output pin drives a 24V beeper Connect the beeper between B and the pin that has Beeper selected To activate any beeper sounds set Enable Beeper 4 4 1 4 to Yes Other beeper options can be selected with Flash Code Beeper 4 4 1 5 Sleep Beeper 4 4 1 6 Moti...

Page 106: ...Status the light used can be a 24V LED array max 500mA or a relay driven incandescent or halogen bulb If a relay is used a fly back diode and a series diode must be installed If an LED array is used it must have its own internal current limiting system An LED array must also have reverse polarity protection such as a series diode An LED array may show a faint glow if the output is not active If th...

Page 107: ...ED between B and pin 10 Install a resistor that limits the current to 50 mA at 24 V See also Status Indicator Output section 3 10 10 5V Gauge The pin will show the state of the battery on an analogue 5V voltmeter battery gauge Connect the battery gauge between pin 10 and B See also Battery Gauge Output section 3 10 12 12V Gauge The pin will show the state of the battery on an analogue 12V voltmete...

Page 108: ...r to a suitably programmed output and setting the Flash Code Beeper parameter 4 4 1 5 to Yes Depending on the condition the scooter may or may not allow driving In some cases driving may be allowed but in a reduced speed limp mode 5 2 Flash Code Display To make the most of your existing industry knowledge of products the RHINO2 has the ability to display a variety of different flash code types The...

Page 109: ...switch is active or the park brake is faulty Check the park brake and associated connections and wiring Ensure any associated switches are in their correct positions 6 Drive Inhibit Either a Stop function is active or a Charger Inhibit or OONAPU condition has occurred Release the Stop condition seat raised etc Disconnect the Battery Charger Ensure the throttle is in neutral when turning the contro...

Page 110: ... on again Check the motor and associated connections and wiring 4 Current Limit Time out or Controller too hot The motor has been exceeding its maximum current rating for too long The scooter may have stalled Turn the controller off leave for a few minutes and turn back on again The motor may be faulty Check the motor and associated connections and wiring 5 Park Brake Fault Either a park brake rel...

Page 111: ...olves the use of twin flashes to identify the type of fault Flash Description 1 1 Thermal Cut back Stall 1 2 Throttle Trip 1 3 Speed Limit Pot Fault 1 4 Under Voltage Fault 1 5 Over Voltage Fault 2 1 Main Contactor Driver Off Fault 2 2 Unused 2 3 Main Contactor Fault 2 4 Main Contactor Driver On Fault 3 1 Drive inhibit OONAPU Proc or Wiring Fault 3 2 Brake On Fault 3 3 Precharge Fault 3 4 Brake Of...

Page 112: ...l error When the hand held programmer is plugged in it will display a flash code 9 on the screen DYNAMIC Wizard Wizard is the preferred diagnostics tool in the workshop environment providing a full fault history last 16 and verbal descriptions of each flash and associated servicing code If after analysing the data the condition cannot be diagnosed it is possible to save a Status Report for further...

Page 113: ...o Replace motor brushes or motor 02 Motor terminal connected to battery negative Check if the motor has been connected correctly Check the motor cables for damage 03 Motor terminal connected to battery positive Check if the motor has been connected correctly Check the motor cables for damage 04 Motor voltage is not what it should be during drive Possible motor short circuit o check the motor cable...

Page 114: ...ble for damage Replace SRW 04 Out Of Neutral At Power Up OONAPU Release the throttle and try again 05 Calibration fault Recalibrate throttle Check the throttle cables for damage Replace the throttle pot 06 Throttle calibration in progress Finish the calibration instructions 07 Neutral detect out of neutral Check the throttle cables for damage or loose connections Replace the neutral detect hardwar...

Page 115: ...vailable in both Wizard and HHP Counter Description Powered Up Time The total amount of time hours the controller has been turned on Powered Up Count The number of times the controller has been turned on Drive Time The total amount of time hours the controller has been driving park brakes disengaged Drive Count The number of times the controller has been driving number of times the park brakes hav...

Page 116: ...up from sleep to indicate the service is due To enable the Service Scheduler function set Service Scheduler 4 4 8 1 to Yes and set Service Period to the desired number of drive time hours before a service is due To clear the service indication either increase the value of Service Period to a value larger than the current drive time or erase the controller history with the Wizard Tools Erase Contro...

Page 117: ...hort circuit while driving Open wire in neutral Open wire while driving Low Closed B Pin 13 no Fault no Fault no Fault no Driving FC7 FC7 Cannot start driving with an open wire but a wire break during driving is not detected High Closed B Pin 7 no Fault no Fault no Fault no Driving FC7 FC7 Cannot start driving with an open wire but a wire break during driving is not detected Open Open B Pin 13 or ...

Page 118: ...V 0 Loom Kit RHINO2 4W Motor 6W Battery GSM51988 N A V 0 Loom Kit RHINO2 Ring Terminals GSM51989 N A V 0 Crimp Terminal M5 Ring Yellow 10 12AWG GCN1286 0190700123 8 V 0 Crimp Terminal Female Spade 18 22AWG Red Insulated GCN1282 0190170014 2 V 0 Tyco 250 Series Lance Connector Housing 4 Way Plug GCN0688 GCN51970 172134 1 N A 1 V 2 V 0 Tyco 250 Series Lance Connector Housing 6 Way Plug GCN0689 GCN51...

Page 119: ...and adapter no dongle DWIZ KIT 1 Dynamic Wizard Programming Adapter DWIZ ADAPT 1 Molex Programming Adapter DR PRGLM02 1 Serial to USB Adaptor DX USB COM 1 PCD Cable Assembly DWIZ CABLE 1 Wizard Dongles USB port OEM Advanced version Enhanced dealer Standard version Dealer Lite version Factory version DWD OEM U DWD EDL U DWD DLR U DWD FAC U 1 1 1 1 DX Hand Held Programmer includes DWIZ ADAPT and DR ...

Page 120: ...evice classification the RHINO2 scooter controller is designed to enable the scooter manufacturer to comply with the relevant requirements of the European Medical Device Directive 93 42 EEC and 21 CFR 820 30 The RHINO2 scooter controller has been designed such that the combination of the scooter and controller along with accessories as applicable complies with the Essential Requirements of the MDD...

Page 121: ...re or agent Warning It is the responsibility of the end user to maintain the unit in a state of good repair at all times If any component is damaged in any way or if internal damage may have occurred for example by being dropped have it checked by qualified personnel before operating 6 6 Warranty All equipment supplied by Dynamic Controls is warranted by the company to be free from faulty workmans...

Page 122: ...ving press the On Off button or turn the key switch to perform an emergency stop and turn the controller off Do not drive the vehicle if the controller indicates that the battery is low If the battery becomes completely empty it will be damaged and the vehicle will stop suddenly Make sure that the battery charger that is used with the vehicle has a drive inhibit function that is correctly connecte...

Page 123: ... programmable options before the vehicle is used After you have configured the vehicle check to make sure that the vehicle performs to the specifications entered in the programming procedure If the vehicle does not perform to specifications reprogram it Repeat this procedure until the vehicle performs to specifications If the wanted operation cannot be reached contact your service agent After main...

Page 124: ... be tested The guidelines in this section are written to assist with meeting EMC requirements Minimising Emissions To minimise emissions and to maximise the immunity to radiated fields and ESD follow the General Wiring Recommendations in section 3 3 1 of this manual 6 9 Environmental statement This product has been supplied from an environmentally aware manufacturer Please be environmentally respo...

Page 125: ...leration Limit 84 Deep Discharge Beeper 66 Deep Discharge Count 115 Drive Count 115 Drive Time 115 Dual Decode 32 37 DYNAMIC Wizard 112 E EMC Emissions 14 Emergency Deceleration 80 Enable Beeper 64 Enable SRW Open Circuit Testing 59 73 ESD Immunity 14 F Fault Log 112 Flash Code 108 Flash Code Beeper 64 Flash Code Type 104 Forward Acceleration 75 Forward Deceleration 76 H Hand Held Programmer HHP 5...

Page 126: ... Pin X Function 100 Pin 12 Function 100 Pin 14 Function 100 Pin 4 Function 100 Pin 6 Function 100 Prog Inh Pin Function 100 Pin 10 Function 107 Pin 11 Function 105 Pin 3 Function 105 Power Off After Sleep 66 Powered Up Count 115 Powered Up Time 115 Profile 2 39 101 Protection Rating 10 Push Speed 81 Q Quiescent Current idle 9 Quiescent Current Key Off 9 Quiescent Current sleep 9 R Release Brake 10...

Page 127: ...ttle Neutral Offset 68 Throttle OONAPU Testing 71 Throttle Positive 31 33 37 Throttle Resistance Pin 2 Pin 8 9 Throttle Response 69 Throttle Testing 70 Throttle Type 67 Throttle Wiper 31 33 Tiller Connector 27 31 Tiller Head 31 Type 3 Flash Codes Bad Motor Connection 111 Controller Fault 111 Controller too hot 111 Current Limit Time out 111 Drive Inhibit 111 High Battery Voltage 111 Low Battery 11...

Page 128: ...scooters Dynamic Controls was established in 1972 and is headquartered in New Zealand Regional centres are located in Europe United States Asia and Australasia ISO 13485 certified Dynamic Controls goes above and beyond industry standard expectations to ensure customers receive the best products possible ...

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