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Dynamic DX, Installation Manual

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Dynamic DX Installation Manual Download Page 13

No. 60027, Issue 4. January 1998

5  Installation

10

5

Installation

5.1

Introduction

Installing a SLM requires the following steps:

1.

Mounting the SLM

 Refer Section 5.2

2.

SLM Connection with the DX system

 Refer Section 5.3

   
3.

SLM 21 Way Connector

Refer Section 5.4

4.

SLM Servo Connector

Refer Section 5.5

5.

Programming the SLM related parameters

Refer Section 7.0

5.2

Mounting

Optimum mounting orientation

Fit the SLM with the top label facing up.

Unacceptable Mounting Orientation

Do 

not

 mount with connectors facing up.

Do 

not

 mount with the top label facing down.

Other orientations are acceptable

.

Summary of Contents for DX

Page 1: ... DX control system 2 Due to continuous product improvement Dynamic reserves the right to update this Manual This Manual supersedes all previous issues which must not continue to be used 3 Any attempt to gain access to or in any way abuse the electronic components and associated assemblies that make up the wheelchair control system renders the Manufacturer s Warranty void and the Manufacturer free ...

Page 2: ...the DX System 12 5 3 1 DXBUS Connections 12 5 3 2 DX Module Interconnection Topology 13 5 3 3 DXBUS Length and Voltage Drop Restrictions 15 5 4 SLM 21 Way Connector 18 5 4 1 21 Way Connector Pin Definitions 18 5 4 2 21 Way Connector Wires and Terminations 18 5 4 3 Power Supply from the DXBUS 19 5 4 4 Power Supply form the Battery 20 5 5 5 SLM Connection to Lights 21 5 5 SLM Servo Connector 24 5 5 ...

Page 3: ...ers 32 7 3 1 Steering Profile Parameters 32 7 3 2 Other PCD Parameters 35 7 4 Using the PCD 43 7 5 Calibrating the SLM using the HHP 44 7 5 1 Initial Operation 44 7 5 2 Calibrating Parameters 46 8 Diagnostics 48 8 1 Troubleshooting 48 8 2 Flash Codes 48 8 3 PCD Diagnostics 53 8 3 1 Status Report 53 8 3 2 Fault History 54 9 Maintenance 57 10 Safety and Misuse Warnings 58 11 Warranty 59 12 Sales and...

Page 4: ...ng and either one or two motors to provide the driving power of the wheelchair Both functions are controlled by the DX Remote If two drive motors are used then a dual channel DX Power Module DX PM is required If only one drive motor is used then a single channel DX Power Module DX PM S is required The lighting consists of side lights and turn indicators The indicators can be flashed together to pr...

Page 5: ...as its own Installation Manual which describes the installation requirements of that particular module This manual describes the installation of the SLM only and must be read in conjunction with the Relevant DX Remote Installation Manual DX Power Module PM Installation Manual DX Hand Held Programmer HHP Manual DX Programming Configuration Diagnostic PCD Manual Installation Manuals for all other DX...

Page 6: ...a from a DX Remote is passed to the SLM rather than directly to the DX Power Module The SLM processes the speed data and then sends it directly to the DX Power Module The direction signal is processed by the SLM and applied to the servo steering motor A position sense potentiometer tells the SLM the steering position A microswitch is attached to the steering clutch so that when the clutch is relea...

Page 7: ...tted with approved regulated power supply SLM TÜV Electromagnetically compatible not susceptible to high levels of RFI emitting low levels of RFI protected against high levels of ESD Compact case for mounting under the wheelchair seat 3 2 Safety and Protection Features The SLM has the following safety and protection features Motor current limit and current limit timeout set to prevent overheating ...

Page 8: ...requirements Controlled power down in event of DXBUS disconnection or communication failure Hazard lights can be operated by an external switch Hazard lights will operate automatically if communication with the DX Remote is lost while turned on Indicator flash rate will double if a rear indicator bulb has failed Side lights will come on if battery charger is over charging the batteries or during r...

Page 9: ...system 12 A Servo Motor Output Symbol Parameter Conditions Min Nom Max Units SM Output Voltage When not in current limit VBAT 1 2V VBAT V IAV Continuous Over programmable 5 A Average Current time period Î Peak Output Current For up to 5 sec 30 A Servo Pot Input Output Symbol Parameter Conditions Min Nom Max Units SP Pot Supply Open circuit 4 5 5 0 5 5 V Output Voltage SP Pot Supply 0 0 V Output Vo...

Page 10: ... 1 VBAT 0 1 VBAT V ITIO Continuous Output 2 3 2 5 A Current Sidelight Head Tail Light Output VSLO Output Voltage 13 5 V regulator fitted 13 1 13 5 13 9 V VSLO Output Voltage 13 5 V regulator not fitted VBAT 1 VBAT 0 1 VBAT V ISLO Continuous Output 2 3 2 5 A 13 5 V Regulated Power Supply SLM TÜV only VREG Output voltage Voltage In 18 32V 13 1 13 6 14 0 V IMAX Maximum output Max total lighting 7 5 9...

Page 11: ...4 2 Mechanical Specifications Size 210 123 38 mm Weight 0 530 Kg Mounting M5 screws four places or placed in tray Case material Aluminium sheet powder coat finish Case sealing Tamper proof IP54 if mounted as per mounting instructions SLM Configuration ...

Page 12: ...aximum Units Operating ambient temperature range 25 50 C Storage temperature range 25 70 EC Operating and storage humidity 0 90 RH Electromagnetic Compatibility prEN12184 1997 pending Specification EMC Durability ISO7176 part 14 Vibration Specification 120 minutes 4 g s random vibration without damage ...

Page 13: ...stem Refer Section 5 3 3 SLM 21 Way Connector Refer Section 5 4 4 SLM Servo Connector Refer Section 5 5 5 Programming the SLM related parameters Refer Section 7 0 5 2 Mounting Optimum mounting orientation Fit the SLM with the top label facing up Unacceptable Mounting Orientation Do not mount with connectors facing up Do not mount with the top label facing down Other orientations are acceptable ...

Page 14: ...the SLM case by more than 12 mm The SLM must be mounted in a position which offers the maximum protection from water and mechanical abuse Since there are no user accessible controls on the SLM it can be mounted in a position which is inaccessible to the user e g under the seat Note For ease of diagnosis it is recommended that the SLM be mounted where the SLM Status LED can be seen without having t...

Page 15: ...Housing Part Order Number GCN 0792 Like all other DX Modules the SLM is connected to the DX system using the DXBUS Cables are available in the following standard lengths DXBUS CABLE Straight 0 1 M Part Order Number GSM 63001 DXBUS CABLE Straight 0 3 M Part Order Number GSM 63003 DXBUS CABLE Straight 0 5 M Part Order Number GSM 63005 DXBUS CABLE Straight 1 0 M Part Order Number GSM 63010 DXBUS CABL...

Page 16: ...Module DX Module DX Module DX Module DX Module DX Module DX Module DX Module DX Module DX Module DX Module DX Remote Battery 24V 5 3 2 DX Module Interconnection Topology Options The battery and DX Power Module combination are always considered the heart of a DX system Other DX Modules can be arranged in several ways Star DXBUS Topology In line DXBUS Topology ...

Page 17: ...se of one or more DX Splitter Boxes A Splitter Box is a separate panel of four DXBUS sockets that may be purchased from Dynamic or a Dealer The DX Splitter Box Part Order Number is DX SKT X4 For lowest cost and simplicity the In line topology is generally preferred provided the DXBUS length and voltage drop requirements described below can be met Warning If the SLM is between the PM and the Batter...

Page 18: ... to 12 A to protect the DXBUS wiring and connectors The topology and cable lengths used may reduce the DXBUS s upper limit to below 12 A For correct DX System operation the voltage drop on the DXBUS s DXB wire due to return currents must not exceed 1 0 V between any two modules within the DX System Use a topology and module placement that reduces this voltage drop as low as reasonably possible Vol...

Page 19: ...otor and lighting that the SLM is required to drive has a peak current of 10 A the interconnection order of the DX modules will have to be changed to place the SLM closer to the Power Module The above example illustrates a fundamental rule of DX Module interconnection All DX Modules that connect to high current loads e g actuators motors and lights must be connected as close to the Power Module as...

Page 20: ... Modules Nearest Pow er Module Low Current Modules Furthest away from Power Module H H H L L DX Power Module Battery 24V H L L H L L DX Power Module Battery 24V H H H H L L Splitter Box This favours topologies such as Rationalised In line Topology Two way star Topology Multi Star Topology ...

Page 21: ...nitions Note Other pins unused 5 4 2 21 Way Connector Wires and Terminations To build a matching connector To build a matching connector to fit to the 21 way connector the parts are DX 21W Plug Housing Part Order Number GCN 0796 DX 21W Boot Part Order Number GCN 0795 DX Positronics Contact FC114N2 Lge Part Order Number GCN 0793 DX Positronics Contact FC116N2 Med Part Order Number GCN 0797 DX Posit...

Page 22: ...6N2 2 0 mm motors 10 A FC114N2 Steering Power 1 0 mm motors 10 A FC116N2 2 0 mm motors 10 A FC114N2 DXBUS 1 0 mm FC116N2 Lighting 1 0 mm FC116N2 5 4 3 Power Supply from the DXBUS The DXBUS is suitable for powering low speed servo motors and non TÜV lighting where the DX System current requirement is less than the 12 A DXBUS rating The DXBUS is not suitable for powering the SLM if TÜV compliance is...

Page 23: ... require more current than the 12 A DXBUS current rating has available the SLM must be powered directly from the battery Both battery negative terminals on the SLM must be used to achieve TÜV compliance Note Heavy lines denote 3 mm or heavier wire All other wires from the 21 way connector as specified in section 5 4 2 ...

Page 24: ... This is to ensure that a break in one battery will not disable driving or lights Battery Type The DX System is designed to perform optimally with either Lead Acid or Gel Cell deep cycle batteries Consult Dynamic Controls for other battery types It is recommended that two 12 V batteries with capacity greater than 20 A hours be used 5 4 5 SLM Connection to Lights There are three lighting outputs Pi...

Page 25: ...d SLM TÜV the lights are wired to Pin 5 When not fitted SLM the lights are wired to Pin 16 For convenience the standard SLM which has no such regulator has Pin 5 connected to Pin 16 internally This allows the lights to be wired to Pin 5 Pin 16 supplies the power to operate the lighting control circuits and also the 13 5 V regulator if fitted Example of Lighting Wiring ...

Page 26: ... lighting outputs are Pin 2 Side Lights Pin 3 Left Indicators Pin 4 Right Indicators Note The SLM TÜV is designed to blow fuses leading to shorted lamps When wired as shown a blown fuse will not prevent other lamps on the same circuit from continuing to operate Hazard Switch An external Hazard Switch can be connected between Pins 6 and 7 When this switch is closed both indicator outputs will flash...

Page 27: ...rvo Connector Wires and Terminations To build a matching connector To build a matching connector to fit the Servo Connector the parts are AMP Mate N Lok Connector Housing AMP Part Number 1 480 704 0 DCL Part Number GCN 0201 Amp Universal Mate N Lok Contact AMP Part Number 350690 1 For 0 5 mm wires DCL Part Number GCN 0202 Amp Universal Mate N Lok Contact AMP Part Number 350547 For 1 0 and 2 0 mm w...

Page 28: ... Motor 1 0 mm motors 10 A 2 0 mm motors 10 A Clutch Switch 0 5 mm AMP 350690 Position Sense Pot Wiper 0 5 mm AMP 350690 AMP Split pin or Solid pin part numbers given above 5 5 3 SLM Connection to Servo Devices When the steering wheels are centred there should be equal resistance between the Position Sense Pot wiper and each end of the pot Small differences can be overcome during calibration refer ...

Page 29: ... SLM is operated by a DX Remote Each DX Remote has different facilities and not all support a full lighting system The operation of the lighting is therefore very dependent on what remote it is used with Please consult the User Manual for the DX Remote used in your SLM application ...

Page 30: ...r OEM and Dynamic Controls Ltd Some parameters may be modified later using the HHP for individual user requirements If more than one type of wheelchair is to be used by the customer each wheelchair type may have its own set of optimum settings Non module specific programming of a DX System is contained in the PM and DX Remote Installation Manuals A servo steered DX System with one drive motor uses...

Page 31: ...nal wheelchair program to a servo application using the PCD the complexity of the operation makes it inadvisable When changing to a servo steered system select a servo wheelchair program and modify to suit the requirements of the wheelchair type Similarly to change a DX Remote from a servo to a conventional application select a conventional wheelchair program to edit as required and download to th...

Page 32: ...ameters The lighting parameters must be enabled so that lights will operate SLM TÜV Parameter Purpose Side Lights Enable If set to yes sidelights front and rear are enabled State yes no If set to no there will be no response to a DX Accessed by OEM Remote sidelight button being pressed other than a beep for some varieties of remotes Indicators Enable As for the Side Lights Enable parameter State y...

Page 33: ...um Turning Speed is not Accessed DCL a single performance setting but a pointer to select one of eight Steering Programs see section 7 3 1 The Steering Programs are defined by the PCD in the SLM wheelchair program The Maximum Turning Speed value selects a Steering Program as follows 10 49 selects Steering Program 1 50 54 selects Steering Program 2 55 59 selects Steering Program 3 60 64 selects Ste...

Page 34: ...No 60027 Issue 4 January 1998 7 Programming 31 ...

Page 35: ...ogram by the Turning Accel Pt parameter Turning Deceleration The rate of response when the joystick is deflected left or right towards neutral A value of 15 gives slow Range 15 100 response 100 gives fast response Accessed by DCL This defines the rate at which the SLM attempts to respond to a large decrease in steering lock A small decrease in lock demand is approached at the maximum possible dece...

Page 36: ...e Parameters For each of the eight Steering Profiles Program 1 Program 8 there are 12 Steering Profile parameters which define the Maximum Turning Speed see section 7 2 Parameter Purpose Range Max Fwd Spd 25 Turn 35 100 Max Fwd Spd 50 Turn 25 100 Max Fwd Spd 75 Turn 20 100 Max Fwd Spd 100 Turn 15 100 Max Rev Spd 25 Turn 35 100 Max Rev Spd 50 Turn 25 100 Max Rev Spd 75 Turn 20 100 Max Rev Spd 100 T...

Page 37: ...ssibly 50 Turn to 100 As a general guide speed at 25 turn should be twice that at 100 turn speed at 50 turn should be 1 4 times that at 100 turn and speed at 75 turn should be 1 2 times that at 100 turn Values are assigned to these eight parameters for each of the eight Steering Profiles The maximum forward and reverse speeds at zero turning are defined by the standard Drive Program parameters Tur...

Page 38: ...ncrease The higher the value of this parameter the higher the speed that the turning angle scaling begins and the less the turning angle is limited The lower the value the lower the speed that the turning angle begins to be scaled and the greater the limiting of the turning angle A lower value is suitable for high speed 10 km h wheelchairs and higher values up to 100 are suitable for slower wheelc...

Page 39: ... 7 3 2 Other PCD Parameters Parameter Purpose Enable Lighting If set to en lighting functions are enabled State en dis If set to dis there will be no response to a DX Accessed by OEM Remote lighting button being pressed other than a beep for some varieties of remotes Current Limit The current limit for the servo motor The SLM will ensure that no more than the stated current will go Range 4 40 ampe...

Page 40: ...oystick must be deflected to point c to achieve 100 forward or reverse speed A Speed Scalar value of 100 will double the speed demand so that 100 speed will occur at point d mid way between neutral and point c The purpose of this adjustment is to allow full speed to be achieved with some turning deflection Veer right The adjustment of the neutral steering position so that the wheelchair does not v...

Page 41: ...chanically possible Accessed by Dealer User HHP calibrated A physical limitation calibrated using the HHP refer to section 7 5 Right Lock The ratio of the Position Sense Pot Wiper voltage to the full pot voltage when the steering wheels are Range 5 95 moved as far right as is mechanically possible Accessed by Dealer User HHP calibrated A physical limitation calibrated using the HHP refer to sectio...

Page 42: ... higher than the Pot Voltage Tol parameter to avoid an error when the wheelchair is in full left or right lock Warning Setting Max Pot End V too high or Min Pot End V too low may prevent some position sense potentiometer faults being detected Max Pot End V The maximum allowable voltage at the end of the position sense potentiometer If the voltage Range 3200 5000 mV exceeds this value a Steering Fa...

Page 43: ...h or low value can make the wheelchair unstable Range Restrict Fwd Spd 25 60 100 Restrict Fwd Spd 50 40 100 Restrict Fwd Spd 75 20 100 Restrict Fwd Spd 100 0 100 Restrict Rev Spd 25 60 100 Restrict Rev Spd 50 40 100 Restrict Rev Spd 75 20 100 Restrict Rev Spd 100 0 100 Accessed by Dealer User The maximum forward and reverse speeds for four HHP calibrated non zero lock positions 25 50 75 and 100 tu...

Page 44: ...r to Diagnostics section 8 I T If set to on motor I T is enabled State on off I T parameters define the thermal characteristics of Accessed by DCL OEM the motors used in wheelchair The OEM must provide sample motors or detailed motor specifications to Dynamic Controls Ltd Dynamic will provide recommended setting to ensure correct motor protection against overheating I T Threshold I T parameter see...

Page 45: ...e this battery voltage no driving speed will be available Range 28 V 33 V Accessed by DCL This value should be greater than the High Voltage Roll b Start value Waggle Time The time taken to perform and thereby the severity of the Waggle Test Refer to the Waggle Range 20 5100 ms 5 1 sec Test parameter Accessed by DCL Waggle Test If set to on a Waggle Test is performed when the DX System is turned o...

Page 46: ...Cumulative Steering Error is likely to accumulate If it goes above a preset threshold refer to the Steer Err Threshold parameter a Steering Error SLM Flash Code 3 is produced refer to Diagnostics section 8 Steer Err Threshold If the Cumulative Steering Error reaches the Steer Err Threshold a Steering Error SLM Flash Range 10 100 Code 3 is displayed by the SLM refer to Accessed by DCL Diagnostics s...

Page 47: ... Edit Custom Wheelchair Program where appropriate 4 Select the chair program that you wish to view or edit 5 Select the Edit Module Parameters menu option 6 Select SLM or UCM Remote 7 Scroll through the list of parameters See sections 7 2 and 7 3 for the list of parameters that require programming and their functions Adjust parameters as required 8 Press ENTER to accept the changes or ESC to exit ...

Page 48: ...HP are approached sequentially The eight Restrictor Plate parameters are grouped and calibrated in one operation of the HHP 7 5 1 Initial Operation 1 Plug HHP into the Programmer Socket on the DX Remote and turn the DX System on The initial screen appears for two seconds Dynamic DX Programmer VERSION 1 10 2 Then the main menu screen reads MAIN MENU View or edit Program 1 NEXT YES 3 Press NEXT unti...

Page 49: ...e correct password When the password reads correctly press the EXIT button 5 The screen now reads MAIN MENU Technician Mode enabled Disable NEXT YES Step four toggles this screen between Technician Mode Enabled to Technician Mode Disabled 6 Press NEXT until the screen reads MAIN MENU View or edit Servo Steering Module NEXT YES Press YES 7 Press YES The display reads VIEW EDIT SERVO MOD Veer compen...

Page 50: ...nsation value so that the wheelchair does not veer when the joystick is pushed directly forwards or backwards If the wheelchair veers right press LEFT if the wheelchair veers left press RIGHT If a large compensation value is required the mechanical position of the position sense potentiometer may require adjustment see section 5 3 3 2 Calibrate the Right Lock Parameter The range is 0 100 VIEW EDIT...

Page 51: ...re calibrates the speed for four forward and four reverse turning positions VIEW EDIT SERVO MOD Restrictor plate calibration EXIT NEXT START Press START VIEW EDIT SERVO MOD Trace joystick outline EXIT SAVE Move the joystick around the outer physical extremities of the restrictor plate Ensure that all corners are pressed into Press SAVE to return to the previous screen 6 Press NEXT to return to or ...

Page 52: ...The Battery Charger may be overcharging or charging at too high a rate 2 The SLM is between the Battery Charger and the PM and the DXBUS cables are too long See section 5 3 2 3 The PCD parameter High Voltage Roll b Start may be set too low Chair starts to veer but no flash codes are reported 1 Mechanical slipping of the body or shaft of the steering position sense potentiometer 2 Mechanical slippi...

Page 53: ...ue driving Some faults will automatically clear when the fault condition is removed non latched while others are latched and must be cleared by turning the DX System off and then on again If the suggested action does not remove the fault contact a Dynamic Sales and Service Centre refer to section 12 DX System Status LED Flash Code SLM Status LED Flash Code Likely Cause of Fault and Possible Action...

Page 54: ...tem Check the servo motor connector and wiring Note If this problem only occurs when large steering movements are requested the SLM s motor speed parameter may need to be recalibrated using an HHP 2 4 Lighting Fault Cause 1 A fault is detected in the lighting circuits or the internal regulator if fitted 2 Indicator lights are flashing faster than Action Check the lighting circuitry for shorts and ...

Page 55: ... 17 V Action Check battery connections and terminals Check fuses have not blown or circuit breakers tripped Replace battery if worn out 9 9 CANL Fault Cause 1 An invalid voltage has been detected on the DXBUS CANL line 2 Communication is not possible using the CANL wire Action Check the continuity of the DXBUS cable Check for shorts between DXBUS pins An open or short circuit on another DX module ...

Page 56: ...on Check the continuity of the DXBUS cable Check for shorts between DXBUS pins An open or short circuit on another DX module can cause this fault If the Hazard Lights were already switched on when the DX System was turned on Flash Code 10 and Limp Mode slow driving may result To clear this fault turn the Hazard Lights off then turn the DX System off then on again 11 11 Stall Timeout Fault Cause Th...

Page 57: ...ew diagnostics 1 Enter the PCD s Main Menu screen as described in the PCD Manual 2 Select Diagnose Faults The PCD displays the following menu Status Report Fault History Erase Fault History Print Fault History Terminal Emulation 8 3 1 Status Report To view the Status Report 1 Perform steps 1 and 2 above 2 Select Status Report 3 From the Modules Attached menu select SLM ...

Page 58: ... Fault Cause Internal Fault Action Replace SLM Consult an approved Dynamic Service Agent Hall Overtemp ADC Fault Cause Internal Fault Action Replace SLM Consult an approved Dynamic Service Agent Relay Precharge Fault Cause 1 Short between a motor terminal and Battery 2 Internal Fault Action Repair fault if found Consult an approved Dynamic Service Agent Port Feedback Fault Cause Internal Fault Act...

Page 59: ...it 2 The Position Sense Pot Wiper may be shorted to a battery terminal an end terminal on the pot the clutch switch or a motor terminal 3 Faulty Pot Action Check for the above and repair if necessary Check voltage on Position Sense Pot end terminal Pot Res Fault Cause 1 A Position Sense Pot end terminal may be open circuit 2 Any Position Sense Pot terminal may be shorted to a battery terminal anot...

Page 60: ...arged fully discharged or worn out Lighting SMPS Fault Cause 1 A short circuit between the 13 4 V regulated supply if fitted and battery or 2 There is no power supplied to the lighting Action Check all lighting circuitry Check wiring as per section 5 4 3 and 5 4 4 Head Light Fault Cause The circuitry for the Side Lights front and rear is faulty Action Check for an open circuit or a short circuit f...

Page 61: ...l DX system components should be kept free of dust dirt and liquids If necessary wipe with a cloth dampened with warm water or alcohol Do not use solvents or abrasive cleaners 4 Where any doubt exists consult your nearest Service Centre or Agent 5 There are no user serviceable parts in any DX System component do not attempt to open any case Warning If any DX component is damaged in any way or if i...

Page 62: ...afety Do not operate the wheelchair unless you have full control Ensure that the chair is correctly programmed for your needs and environment and ask your dealer to adjust if necessary Always choose a Drive Program that you feel safe with and that is compatible with your environment Do not operate the DX System if it behaves erratically or shows abnormal response heating smoke or arcing Turn the s...

Page 63: ...quipment without charge for materials and labour The Warranty is subject to the provisions that the equipment Has been correctly installed Has been used solely in accordance with this manual Has been properly connected to a suitable power supply in accordance with this manual Has not been subjected to misuse or accident or been modified or repaired by any person other than someone authorised by Dy...

Page 64: ...ronic Mobile Service EMS Telephone Int 61 2 887 2824 46 Berripa Close 24 hours Int 61 2 963 1778 North Ryde Sydney Fax Int 61 2 887 2114 NSW Australia 2113 North America Rosstron Inc Telephone Int 1 310 539 6293 1521 W 259th St Fax Int 1 310 539 4078 Harbor City CA 90710 USA Europe Controls Dynamic Ltd Telephone Int 44 1562 820 055 Lisle Avenue Fax Int 44 1562 742 720 Kidderminster DY11 7DL United...

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