rhino installation manual iss6 (1)

RHINO

DS52K, DS72K(A), DS112K, DS162K

Installation manual

GBK51140 Issue 6, August 2009

The Trusted Force in Scooter Control

About this manual

This manual can help you understand and install the Dynamic Controls (DYNAMIC) RHINO scooter controller. It describes the general principles, but it gives no guidelines for specific applications. If there is a specific requirement for your application, please contact Dynamic Controls or one of the sales and service agents to assist you. This manual must be read together with all other relevant scooter component manuals.

In this manual, a few symbols will help you identify the purpose of the paragraph that follows:

Notes & Precautions:

Notes provide supporting information in order to install, configure, and use the product. Not following the instructions given in notes or precautions can lead to equipment failure.

Warnings:

Warnings provide important information that must be followed in order to install, configure, and use the product safely and efficiently. Not following the instructions given in a warning can potentially lead to equipment failure, damage to surrounding property, injury or death.

The term ‘programming’ used in this manual refers to adjusting parameters and configuring options to suit an application. ‘Programming’ does not change or alter any software within the controller and is performed using a controlled programming tool available only to authorised personnel.

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 ensure reliable and safe use of the product.

Due to continuous product improvement, DYNAMIC reserves the right to update this manual. This manual supersedes all previous issues, which must no longer be used.

DYNAMIC reserves the right to change the product without notification.

Any attempt to gain access to or in any way abuse the electronic components and associated assemblies that make up the scooter system renders the manufacturer’s warranty void and the manufacturer free from liability.

DYNAMIC, the DYNAMIC logo, the RHINO logo and the R-series logo are trademarks of Dynamic Controls. All other brand and product names, fonts, and company names and logos are trademarks or registered trademarks of their respective companies.

DYNAMIC owns and will retain all trademark rights and DYNAMIC or its licensors own and will retain all copyright, trade secret and other proprietary rights, in and to the documentation.

All materials contained within this manual, in hardcopy or electronic format, are protected by copyright laws and other intellectual property laws.

© Copyright 2009 Dynamic Controls. All rights reserved.

GBK51140: Issue 6 - August 2009 4

Contents

1 Introduction to the Rhino........................................7

2 Features of the RHINO..............................................8

3 Specifications..........................................................9 3.1 Electrical Specifications ............................................................ 9 3.2 Mechanical Specifications..................................................... 10 3.3 DC Connector Material Specifications ................................ 11

4 Installation .............................................................12 4.1 Mounting ................................................................................... 12 4.2 Connections and wiring.......................................................... 14

4.2.1 General wiring recommendations ............................. 15 4.2.2 Connector pinouts........................................................ 16 4.2.3 Wiring diagram for DS52K, DS72K, DS112K ................ 18 4.2.4 Wiring diagram for DS72KA (Actuators) .................... 18 4.2.5 Wiring diagram for DS162K .......................................... 19 4.2.6 Motor and Parkbrake Connector Wiring................... 20

4.2.6.1 Motor protection ............................................................. 21 4.2.6.2 Manual parkbrake release ............................................ 21

4.2.7 Battery and Battery Charger Connections Wiring... 22 4.2.7.1 On-Board Charger wiring............................................... 23

4.2.8 Throttle / Wig-Wag Wiring ............................................ 24 4.2.9 Speed Limit Pot / Reduce Speed Switch Wiring....... 25

4.2.9.1 Reduce Speed Switch.................................................... 25 4.2.9.2 Analog Speed Limit Pot.................................................. 26 4.2.9.3 Reduce Speed Switch & Analog Speed Limit Pot ..... 26

4.2.10 Key Switch and Status Light Wiring............................. 27 4.2.11 Horn / Buzzer wiring....................................................... 28 4.2.12 Brake / Reversing lights wiring ..................................... 28 4.2.13 Actuator / Seat Lift Wiring (DS72KA only) .................. 29

5 Programming ........................................................31 5.1 The hand held programmer................................................... 32

5.1.1 Fault menu ..................................................................... 33 5.1.2 Read Menu (DS2K-PI only) ........................................... 33 5.1.3 Setup Menu.................................................................... 34 5.1.4 Options Menu ................................................................ 35 5.1.5 Profiles Menu (DS2K-PI only)......................................... 36

5.1.5.1 Upload a Profile from the RHINO .................................... 36 5.1.5.2 Download a Profile to the RHINO ................................... 37 5.1.5.3 Edit a Profile that is stored in the RHINO Programmer. 38

5.1.6 Speed Lever In Neutral Menu ..................................... 39 5.1.7 Controller Version Menu............................................... 39

5.2 Wizard Parameter List .............................................................. 40


5.3 Parameter Descriptions ........................................................... 42 5.3.1 Software revisions.......................................................... 42 5.3.2 Drive Performance........................................................ 43

5.3.2.1 Forward Speed ................................................................ 43 5.3.2.2 Reverse Speed................................................................. 43 5.3.2.3 Maximum Speed ............................................................. 43 5.3.2.4 Acceleration .................................................................... 44 5.3.2.5 Deceleration .................................................................... 44 5.3.2.6 Soft Start Damping .......................................................... 45 5.3.2.7 Slam Brake........................................................................ 45

5.3.3 Throttle Options ............................................................. 46 5.3.3.1 Single Ended Pot ............................................................. 46 5.3.3.2 Pot Reverse....................................................................... 46 5.3.3.3 Demand Curve................................................................ 47 5.3.3.4 Creep Speed ................................................................... 47 5.3.3.5 Speed Pot Neutral ........................................................... 48 5.3.3.6 Speed Pot Fault Threshold.............................................. 48 5.3.3.7 Standard Speed Pot ....................................................... 49 5.3.3.8 Speed Pot Full Scale Deflection (FSD).......................... 49 5.3.3.9 Speed Pot Dead-Band................................................... 49

5.3.4 Speed Reduction Options ........................................... 50 5.3.4.1 Speed Limit Pot Minimum............................................... 50 5.3.4.2 Speed Derating (Enable Mode 2) ................................ 50 5.3.4.3 Reduce Speed (Mode 2) ............................................... 51 5.3.4.4 Scale Turn Speed (Mode 2) ........................................... 51 5.3.4.5 Invert Turn Input (Mode 2).............................................. 51

5.3.5 General Options............................................................ 52 5.3.5.1 Buzzer Reverse ................................................................. 52 5.3.5.2 Sound Faults ..................................................................... 52 5.3.5.3 Sleep Beep ....................................................................... 52 5.3.5.4 Sleep Mode...................................................................... 53 5.3.5.5 Enable Brake Lights ......................................................... 53 5.3.5.6 Enable Reverse Lights ..................................................... 53

5.3.6 Motor Options................................................................ 54 5.3.6.1 Maximum Current ........................................................... 54 5.3.6.2 Current Limit Time............................................................ 54 5.3.6.3 Boost Current (DS162K/KD only).................................... 55 5.3.6.4 Load Compensation / Motor Resistance .................... 56 5.3.6.5 Motor Reverse.................................................................. 58 5.3.6.6 I2T / Motor Derating ........................................................ 58 5.3.6.7 I2T Parameters (Rev. D and Rev. F) .............................. 59 5.3.6.8 I2T Parameters (Rev. B and Rev. C).............................. 60

5.3.7 Battery Options.............................................................. 61 5.3.7.1 Battery Derating (Battery Saver)................................... 61 5.3.7.2 Battery Saver Threshold .................................................. 61 5.3.7.3 Battery Circuit Resistance .............................................. 62 5.3.7.4 BDI Threshold .................................................................... 62

5.3.8 Parkbrake Options ........................................................ 62 5.3.8.1 Brake Checking ............................................................... 62 5.3.8.2 PB Open Circuit Drive Test ............................................. 62 5.3.8.3 Parkbrake Delay.............................................................. 63 5.3.8.4 Check For Slope / Slope Current .................................. 63 5.3.8.5 Enable PB Release 1 ....................................................... 64 5.3.8.6 Enable PB Release 2 ....................................................... 64 5.3.8.7 Push Speed....................................................................... 64 5.3.8.8 Rollaway Speed............................................................... 64


6 Diagnostics............................................................65 6.1 Diagnostic tools ........................................................................ 65

6.1.1 The Status Light .............................................................. 65 6.1.2 RHINO Programmer ........................................................ 65 6.1.3 The PC-based Wizard program .................................. 65

6.2 Out Of Neutral At Power Up (OONAPU)............................... 66 6.3 Diagnosing RHINO Faults........................................................... 66

6.3.1 Status Light ON, but scooter does not move............ 67 6.3.2 Status Light OFF ............................................................. 68 6.3.3 Status Light Flashing ...................................................... 68 6.3.4 Can't achieve full speed ............................................. 69

6.4 Flash Codes............................................................................... 70 6.5 RHINO Fault Log & Run-Time Log............................................. 71

7 Appendices ..........................................................73 7.1 Programming Accessories ...................................................... 73 7.2 Intended Use and Regulatory Statement ............................ 74 7.3 Maintenance ............................................................................ 75 7.4 Warranty .................................................................................... 75 7.5 Safety and Misuse Warnings................................................... 76 7.6 Electromagnetic Compatibility (EMC) ................................. 78 7.7 Environmental statement........................................................ 78


1 Introduction to the Rhino

The RHINO family of scooter controllers provides a reliable, smooth, cost-effective control solution for most mobility scooters and includes:

DS52K - RHINO 50 A Controller*

DS72K - RHINO 70 A Controller

DS72KB - RHINO 70 A Controller with lights

DS72KA - RHINO 70 A Controller with seat lift

DS112K - RHINO 110 A Controller

DS112KB - RHINO 110 A Controller with lights

DS162K(D) - RHINO 160 A Controller with lights**

The brains of RHINO is a microcontroller, which gives it all the digital safety, programming and feature benefits demanded by the scooter industry, yet RHINO drives with the smoothness of an analog controller. New circuitry gives RHINO more sustained power capability than many equivalent controllers, as well as exceptional load compensation to provide excellent speed stability over various driving terrains.

For maximum performance, protection and convenience, RHINO is housed in a solid die-cast aluminium case. For maximum versatility, RHINO is fully programmable by the manufacturer to optimise matching the RHINO to the scooter.

Notes:

Unless otherwise specified, all references in this manual apply to the DS52K, DS72K, DS72KA, DS112K, and DS162K.

*The DS52K is no longer available. It has been replaced by the R-series DR50.

**The DS162K is no longer available. It has been replaced by the DS162KD. Unless otherwise noted, everything that applies to the DS162K applies to the DS162KD as well.

Sample RHINO Installation


2 Features of the RHINO

RHINO has a number of safety features and performance enhancements including:

• Increased Safety RHINO has incorporated additional safety features including: a programmable Wig-wag Fault Threshold parameter and an Analog Reduce Speed Input.

• Protection from Motor Burn-Out A motor protection algorithm calculates when the controller needs to ease back to protect the motor.

• Smooth driving RHINO’s special “S-curve” drive algorithm gives the scooter smooth take-off and braking.

• Best range per charge RHINO’s electronics return energy to the battery during braking, giving maximum range for each battery charge.

• Self-protection RHINO automatically senses when it is being pushed too hard and eases back control to protect the controller.

• “Ever Test” keeps the driver safe RHINO’s Ever Test software regularly checks the electronics to ensure scooter safety.

• Soft stop If the RHINO detects a fault, it brings the scooter to a controlled, safe stop.

• Battery saver RHINO has sophisticated software that helps prevent battery damage.

• Safety on slopes The RHINO-equipped scooter automatically detects roll-away down a slope and limits roll speed to a safe programmable value – even when the parkbrake is off.

• Sleep mode RHINO can automatically turn the scooter off after a programmable time period.

• Flexible throttle The throttle (wig-wag, engager, or speed input) can be programmed for left hand, right hand, or single ended operation.

• Diagnostic indication If the Status Light is installed, the controller tells the driver which scooter component needs attention. This may also be indicated by the reversing beeper.

• Fully programmable The scooter can be programmed to suit the needs of each user.

• Innovative new S3-TEC technology This algorithm gives RHINO its smooth driving performance and power.

• Optimised case design The case has been mechanically designed to optimise performance.

• Electromagnetically compatible See the appendices on Electromagnetic Compatibility (EMC) and Safety and Misuse Warnings.

• Fault Log A Fault Log is available for approved service personal to view up to the last 16 faults generated, improving diagnostics and product servicing.

• Run-Time Log The Run-Time Log provides information on the total time RHINO has been driven.


3 Specifications

3.1 Electrical Specifications

Parameter Value Battery Min Nom Max Units Battery Voltage 17.5 24 32 V Battery Saver High threshold (programmable) Low threshold

17.1

19.5 16.5

22

V V

Quiescent Current Key Off Sleep Mode On (Neutral)

1.5 2

50

mA mA mA

Battery Connector 6 x 1/4" Quick Connect Tabs Throttle Throttle potentiometer 3-wire 5 kΩ + 20% linear Forward/Reverse control Bi-directional wig-wag, or

Single direction throttle with reverse switch Speed Limit potentiometer DS52K, DS162K DS72KB, DS112KB, DS162KD

3-wire 10 kΩ logarithmic 3-wire 4.7 kΩ logarithmic

Logic connector AMP 8-way MiniMate-N-Lock (MnL) Motor Output Min Nom Max Units Motor Type (permanent magnet) 24V DC Motor Armature Resistance 5 mΩ Maximum output voltage 23.5 V Continuous motor current (@ 25˚C ambient temperature) DS52K DS72K(A) DS112K DS162K

10 25 43 50

A A A A

Peak motor current DS52K DS72K(A) DS112K DS162K *Boost current, 10 s max

50 70 110 160

180*

A A A A

Nominal braking current DS52K DS72K(A) DS112K DS162K

50 70 110 160

A A A A

Stall timer (programmable) 5 15 50 s Motor/Parkbrake Connectors 4 x 1/4" Quick Connect Tabs

Molex 2-way Mini-fit (DS162K only) Parkbrake Output Min Nom Max Units Output voltage Vbat -1.1 Vbat V Output current 1.3 A Actuator Output (DS72KA only) Min Nom Max Units Voltage 17 24 32 V Peak current 10 12.5 A


3.2 Mechanical Specifications

Parameter Min Nom Max Units Material: Case top: Die-cast aluminium

Base plate: Nylon 66 Weight 650 g Operating Temperature Range -25

(-13) 60

(140) C

(°F) Operating Humidity Range (non-condensing) 0 85 %RH Protection rating IPx4 Battery Connector Cycles 10 cycles Motor/Parkbrake/Logic Connector Cycles 10 cycles Electromagnetic Compatibility (EMC) ISO7176-21 Performance and Safety ISO7176-14

Warning:

To achieve the specified IPx4 rating, mount the RHINO as shown in section 4.1 and fit a boot over the logic connector. If necessary, add a water shielding cover to protect the RHINO from water entry as appropriate to the environment that the vehicle will be used in.

IPx4 rating does not imply RHINO is suitable for use in wet or damp conditions.

44 m

m1.

73”

155 mm / 6.1”10

0 m

m /

3.9”

DS162K only

DS162K only

DS162K only

3 Holes

4.1 mm

Bottom View

Front View

Top View

Side View

Isometric View


3.3 DC Connector Material Specifications

Parameter Value DC Part Number GCN51315 Material Type Zytel nylon resin Flammability Rating V-2

DS162K - Motor Terminals:2 x AMP series Receptacle

w/o latch 14-12 AWG

DS112K - Park Brake Terminals:2 x AMP series Receptacle

w/o latch 22-20 AWG

Motor Terminals:2 x AMPINNERGY Connector

or


4 Installation

4.1 Mounting

Mount RHINO in a well-ventilated and free-draining location with orientations as shown in the first two drawings.

The position and orientation should give maximum mechanical protection to RHINO.

Mount RHINO out of the path of water splashes from wheels or cowling. A location such as midway between the rear wheels might be suitable.

Regardless of mounting orientation, protect scooter wiring and connectors from the risk of damage, water splashes and/or water ingress, and route the cabling so that water will not run down into the connector system. The use of cable boots is highly recommended.

Failure to adhere to the mounting orientations specified might lead to water ingress.

For peak performance, locate RHINO so that air can flow over and around the case.

A position close to the batteries and motor is recommended to reduce the length of high current wires.

Warning:

Do not mount the controller in a position where the user can come into contact with the unit. The case temperature can exceed 41°C.

If desired, allow easy access to the RHINO programming socket. After programming, replace the sealing bung securely or fit a replacement label (GLA51612).

Protect the tiller head circuitry, wiring and components from water splashes.

α

15˚ ≤ ≤ 75˚


Use all three screw positions to mount the RHINO. M4 x 30mm socket cap screws are recommended.

The model below shows a highly recommended mounting configuration. Note that:

• The RHINO is mounted at an angle to drain the connector area, as shown in Figure 2 on the previous page.

• The RHINO is mounted onto a plate covering the entire area of the base.

• The RHINO is mounted away from water splashes and a mudguard installed to prevent water from the wheels splashing over the controller.

• The motor and battery wiring is as short as possible.

• All cabling is secured in such a way that water cannot run down into the rear of the connector.

155 mm / 6.1"

145 mm / 5.71"

72.5 mm / 2.85"

100

mm

/ 3

.9"

90 m

m /

3.5

"

Use (3) M4 screws

Short wiring

Mounted on slope andaway from water splashes

No water travel into connector

Base plate


4.2 Connections and wiring

RHINO connections are located along the front of the case as shown. The illustration below indicates the different connectors and gives a section reference for specific installation instructions. When all wiring has been completed, it must be securely fastened to the scooter frame to ensure there is no strain on the connectors or any chance of snagging.

Notes:

Ensure that all wiring is suitably routed and restrained to prevent snagging.

Connector housings must be fitted to prevent incorrect connections.

Warning:

Before making any connections to RHINO, disable the scooter by one of the following means to prevent accidental movement or arcing:

1) place the battery circuit breaker in the open position, or 2) disconnect the batteries

Programming Connector (Chapter 5)

Motor Connector

(4.2.6)

Battery Connector

(4.2.7)

Parkbrake Connector

(4.2.6)

Logic Connector (4.2.7, 4.2.8, 4.2.9, 4.2.10, 4.2.11, 4.2.12,

4.2.13)


4.2.1 General wiring recommendations

To minimise EMC emissions, maximise EMC and ESD immunity, and to keep the cabling of the scooter safe and tidy, please observe the following guidelines. • Keep all cables as short as possible.

• Try to run wires in pairs or bunches. Bind wires together and fix them to the chassis.

• Do not route the motor cable near the motor case, where possible.

• Avoid wire loops, especially loops of single wires instead of wire pairs.

• Fasten cables to the scooter frame to prevent strain on the connectors.

• Do not leave electrical connections unnecessarily exposed.

• 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 are electrically connected to the vehicle frame.

• Do not use the vehicle frame as the earth return. Any electrical low-resistance connection to the frame is a safety risk and is not allowed by international safety standards.

• To minimise electromagnetic emissions by the motor brushes, it may be necessary to fit capacitors between the brush holders and the motor case. Make sure that the leads are kept as short as possible. A suitable capacitor is 4n7, 2kV Ceramic.

• For low-current signals, do not use wire sizes smaller than 0.5 mm2/AWG20, because smaller wires are physically not strong enough for this application.

• For best electrical performance, the wire size must be as large as possible. Recommended minimum wire sizes are shown in the wiring sections.

• Do not use damaged or abused cables. A damaged cable can potentially produce localised heat, sparks or arcing and as such it can cause a fire.

• Protect all cables against possible contact with flammable material.

• Where possible, the installation must prevent and/or discourage the user to access any cable.

Warning:

1. Route the cables and fasten all scooter components in a position so that the cables, the connectors and the connector sockets of the RHINO do not allow water 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 from 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 schedule and the service instructions of the powerchair must include the appropriate inspection and maintenance requirements for the connectors and the cables.


4.2.2 Connector pinouts

This table shows pinouts for the battery, motor and logic connectors. The table on the following page shows the recommended mating connector information.

Note:

If the controller is used in a scooter system that is fitted with lighting, the lighting should be independently fused. [Reference EN12184 - Section 9.4]

Warning:

Connecting a DS72K to a scooter wired for a DS72KA will cause the seat actuator to drive on connection to the battery terminals and may result in injury. Connecting a DS72KA to a scooter wired for a standard RHINO will result in damage to the controller.

Battery Connector Pinout Pin Function

1 Battery Positive / Actuator (DS72KA)

2 Battery Positive 3 Battery Positive

4 Battery Negative / Actuator (DS72KA)

5 Battery Negative 6 Battery Negative Motor Connector Pinout Pin Function

1 Parkbrake Negative / Motor Positive (DS162K)

2 Parkbrake Positive / Motor Negative (DS162K)

3 Motor Positive 4 Motor Negative Parkbrake Connector Pinout (DS162K only) Pin Function 1 Parkbrake Positive 2 Parkbrake Negative Logic Connector Pinout Pin Function 1 Key Switch 2 Throttle – 3 Throttle Wiper 4 Throttle + 5 Buzzer – / Brake lights – 6 Reduce Speed/Analog Speed Pot

7 Forward/Reverse / Drive/Actuator select (DS72KA)

8 Inhibit

1 2

4 5

3

6

Battery Connector

87654321

Logic Connector

1 2

3 4

Motor/Parkbrake Connector

21

Parkbrake Connector (DS162K only)


The following connector kits are available from DYNAMIC:

RHINO Model No. Connector Kit Part No. DS52K, DS72K, DS72KA DSLOOM-72K DS112K DSLOOM-112K DS162K DSLOOM-162K

Warning:

Do not use the frame of a wheelchair or scooter as the earth return for any lights or actuators. Making any low resistance connection to the frame is regarded as a possible safety hazard and is not allowed by international performance and safety standards for wheelchairs and scooters.

Recommended Battery Mating Connector Part Description Supplier/Part # Housing AMP 6-way 250 series Plug Housing AMP 171898-1 Battery Pins AMP 250 series Receptacle w/o latch 14-12 AWG AMP 170258-2

Battery: DS52K 2 x 2mm² or 1 x 3mm² per circuit DS72K(A) 2 x 2mm² or 1 x 3mm² per circuit DS112K 2 x 3mm² per circuit DS162K 2 x 3mm² & 1 x 2mm² per circuit

Wire Gauge

Tillerhead/Charger: 1mm² AMP 170032-2 Battery Boot RHINO Battery/Motor Connector Boot DC GCN0787 Recommended Motor Mating Connector Housing DS52K: AMP 4-way 250 series Plug Housing AMP 172134-1 DS72K(A): AMP 4-way 250 series Plug Housing AMP 172134-1 DS112K: DYNAMIC Connector DC GCN51315 DS162K: DYNAMIC Connector DC GCN51315

Motor Pins DS52K: (2) AMP 250 series Receptacle w/o latch 14-12 AWG AMP 170258-2

DS72K(A): (2) AMP 250 series Receptacle w/o latch 14-12 AWG AMP 170258-2

DS112K: (2) AMPINNERGY Connector Contact, dual-beam, 10-12 AWG AMP 556880-2

DS162K: (2) AMPINNERGY Connector Contact, dual-beam, 10-12 AWG AMP 556880-2

(2) AMP 250 series Receptacle w/o latch 14-12 AWG AMP 170258-2

Parkbrake Pins (2) AMP 250 series Receptacle w/o latch 22-20 AWG AMP 170384-2 Wire Gauge Motor: DS52K: 2.5mm² DS72K(A): 4.0mm² DS112K: 5.0mm² DS162K: 1 x 5mm² & 1 x 3mm² / circuit Parkbrake: 0.5mm²

Motor Boot RHINO Battery/Motor Connector Boot DC GCN0787 Recommended Parkbrake Connector (DS162K Only) Housing Mini-Fit Jr. 2-Way Molex 39-01-3028 Pins Molex Mini-Fit Receptacles, 18-24 AWG Molex 39-00-0039 Recommended Logic Mating Connector Housing AMP 8-way Mini Mate’N’Lok Plug Housing AMP 770579-1 Logic Pins AMP Mini Universal Mate’N’Lok Socket Contact AMP 170365-1 Wire Gauge 0.2mm² Logic Boot RHINO Logic Connector Boot DC GCN0786


4.2.3 Wiring diagram for DS52K, DS72K, DS112K

4.2.4 Wiring diagram for DS72KA (Actuators)

TILLER HEAD

R

HIN

O D

S72K

A M

RHINO 70: 35-40A

Circuit Breaker

24VSupply

Battery +

Actuator 2Battery -Motor –

PB+PB –

Motor +

Battery –

8-12A Fuse

Park Brake

ManualPark BrakeRelease

Battery +

Battery –

Inhibit

Motor

5kΩThrottle +

Throttle –Throttle Wiper

Key SwitchThrottle –Throttle WiperThrottle +

Inhibit

Buzzer –Reduce Speed or Analog Speed Pot Wiper

Drive/Actuator

ExternalStatusLight

KeySwitch

ReverseBuzzer

Programmer Drive/Actuator AD

Reduce Speed

_ +

+ +

12

3

ChargerSocket

HornSwitch

– –

10k-100kResistor

Ω

Battery +

8-12A Fuse

M

RHINO 50: 30 40A70: 35-40A

110: 50-75ACircuit Breaker

–

24VSupply

Battery +

Battery +

Battery –

Motor –

PB+PB –

Motor +

Battery –

8-12AFuses

Park Brake


Battery +

Battery –Inhibit

Motor

5kΩThrottle +



Inhibit


Forward/Reverse

ExternalStatusLight

KeySwitch

ReverseBuzzer

Programmer

Analog Speed Pot

Forward/ReverseReduce Speed

TILLER HEAD

_ +

+ +

12

3

ChargerSocket

HornSwitch

– –

10k-100kResistor

Ω

RH

INO

DS5

2K, D

S72K

, DS1

12K


4.2.5 Wiring diagram for DS162K

TILLER HEAD

M

RHINO 160: 80-100ACircuit Breaker

or Fuse

24VSupply

Battery +

Battery +

Battery –

Motor –

PB+PB –

Motor +

Battery –

8-12AFuses


Battery +

Battery –Inhibit

Motor

5kΩThrottle +



Inhibit


Forward/Reverse

ExternalStatusLight

KeySwitch

ReverseBuzzer

Programmer

Analog Speed Pot

Forward/ReverseReduce Speed

_ +

+ +

12

3

ChargerSocket

HornSwitch

– –

10k-100kResistor

Ω

R

HIN

O D

S162

K


4.2.6 Motor and Parkbrake Connector Wiring

For RHINO DS52K, DS72K(A), and DS112K, the motor and parkbrake terminals are located on the same connector. The motor is connected to Quick Connect (QC) Pins 3 (Motor +) and 4 (Motor –). The parkbrake is connected to QC Pins 1 (PB –) and 2 (PB +).

For RHINO DS162K, the motor and parkbrake terminals are located on separate connectors.

Note:

The Motor Reverse parameter (5.3.6.5) reverses the polarity of Pin 3 and 4. If this parameter is set to 'Yes', the motor turns in the opposite direction. However, do not use this parameter for left-handed use, set the Pot Reverse parameter (5.3.3.2) to 'Yes' instead.

Warning:

Motor and battery connectors must not be accessible without the use of tools.

Parkbrake Connections RHINO Model Recommended

Wire Gauge All RHINO Models 0.5mm2 / 20 AWG Motor Connections RHINO Model Recommended

Wire Gauge DS52K 2.5mm2 / 14 AWG DS72K(A) 4.0mm2 / 12 AWG DS112K 5.0mm2 / 10 AWG DS162K 5.0mm2 & 3.0mm2 /

10 + 12 AWG

Normally open switchclosed when mechanicalbrake released

[8] Inhibit

Battery -Park Brake –Park Brake +

M

Mot

or +

Mot

or -

Normally open switchclosed when mechanical

brake released

[8] Inhibit

ParkBrake

Battery -

Park Brake – [1][2] Park Brake +

MMotor + [3]

[4] Motor –


4.2.6.1 Motor protection

In the event of an overheated motor, the motor protection algorithm on all DS52K, DS162K will reduce the performance of the scooter before shutting it down. Cycling the power will clear the fault.

For the DS52K, three standard variants for motor burnout protection are available from DYNAMIC. Please contact us to have RHINO optimized for your scooter.

4.2.6.2 Manual parkbrake release

Some scooters can be fitted with a manual parkbrake release lever to allow the scooter to be pushed when RHINO is turned off. If this lever is fitted, it is recommended that a normally open micro switch be placed across Pin 8 (Inhibit) of the logic connector and Battery Negative (–) of the battery connector, as shown on the previous page. The switch should be wired such that the switch is open when the manual-release lever is disengaged. This creates a safety interlock that inhibits driving when the parkbrake is disengaged.

An alternative is to place a normally closed micro switch in series with the parkbrake, as shown below. When wiring the parkbrake like this, note the following: For scooters with a Status LED, disengaging the manual-release lever of the parkbrake causes a fault (Flash Code 5), and the scooter will not be able to drive. Engage the parkbrake and turn the power off and then on again to clear the fault. For scooters without a Status LED, the fault exists but is not displayed to the operator.

Normally closed switchopened when mechanical

brake released

Park Brake –Park Brake +

Normally closed switchopened when mechanical

brake released

ParkBrake

Park Brake [1]– [2] Park Brake +

Alternative Parkbrake Connections for DS52K, DS72K(A), DS112K

Alternative Parkbrake Connections for

DS162K


4.2.7 Battery and Battery Charger Connections Wiring

On all RHINOs except the DS72KA* (refer section 4.2.4), the battery connector provides three Battery Positive (+) and three Battery Negative (–) pins. These pins are also used for a battery charger connection and to provide power to the tiller head and logic functions. An example of battery charger and tiller head wiring is illustrated here, but refer to the appropriate sections for further details.

A thermal circuit breaker or fuse must be installed in the battery wiring, as illustrated, to protect the batteries and wiring loom from external short circuits.

Recommended circuit breaker ratings are: DS52K: 30-40A DS72K(A): 35-40A DS112K: 50-75A DS162K: 80-100A

An acceptable alternative is for the manufacturer to use two separate circuit breakers, one in each battery circuit (Battery + and Battery –). Battery wire gauge should match that of the motors (refer to section 4.2.6).

A battery charger socket may be connected between any of Pins 1-3* (Battery +) and Pins 4-6* (Battery –) of the battery connector. To prevent driving while the charger is plugged in, an inhibit wire must be connected to Pin 8 (Inhibit) of the logic connector. The charger plug should provide a connection from Inhibit to Battery – when the charger is plugged in.

An in-line 8–12A fuse must be installed in the Battery Positive (+) and Battery Negative (-) wires connecting to the battery charger socket and should be as close to RHINO as possible.

For the DS112K and DS162K, two of the three Battery Positive terminals and two of the three Battery Negative terminals MUST be used for battery connections.

Notes:

*On the DS72KA, battery connector pins 1 and 4 are used for the actuator output. Connecting the battery across these two pins will result in damage to the controller.

Warning:

Make sure that the battery wiring cannot touch the opposite battery terminal.

[8] Inhibit

Circuit Breaker

24VSupply

Charger Socket(viewed from front)

[4*-6] Battery –

[1*-3] Battery +8-12AFuses

+ +1

3

2


4.2.7.1 On-Board Charger wiring

When an on-board battery charger is used, make sure that the charger has a Battery Charge/Run switch. When the switch is in the Charge position, the Inhibit should connect to Battery – as shown.

Use a minimum of 1 mm2 wire gauge for battery chargers that supply 8 A or less. For battery chargers that supply more than 8 A, 1.5 - 2 mm2 wire gauge is recommended.

[8] Inhibit

Circuit Breaker

24VSupply

On-board Charger

Battery -

Battery +8-12AFuses

+ +


4.2.8 Throttle / Wig-Wag Wiring

RHINO supports a short travel (60°) 5kΩ linear potentiometer for speed control. We recommend the use of a high-quality, long-life (greater than 10 million cycles) potentiometer, such as a conductive plastic type. The use of carbon or wire-wound potentiometers is not recommended.

Connect the throttle to the logic connector as illustrated. For neutral, set the impedance between Throttle – and Throttle Wiper to half the potentiometer rating (typically 2.5kΩ). Alternatively, set the wiper to 2.5v when in neutral, measured to Battery –.

Connect the Throttle – and Throttle + terminals to the potentiometer such that when the user gives a normal forward signal, the resistance between Throttle Wiper and Throttle + decreases, while the resistance between Throttle Wiper and Throttle – increases.

We recommend fitting 330Ω ISO resistors directly to the throttle potentiometer for improved fault detection (see section 5.3.3.6 - Speed Pot Fault Threshold). Make sure that the connections between the ISO resistors and the throttle terminals are insulated. If ISO resistors are fitted, it may be necessary to decrease the Speed Pot Full Scale Deflection (FSD) parameter (5.3.3.8).

For left-handed driving operation, set the Pot Reverse parameter (5.3.3.2) to 'Yes'. This reverses the polarity of Pins 2 and 4 so the scooter drives in the opposite direction.

For single-ended (unipolar) throttle operation, connect a switch between Pin 7 (Forward/Reverse) of the logic connector and any of the Battery Negative (–) pins of the battery connector and set the Single Ended Pot parameter (5.3.3.1) to 'Yes'. This option is not available on the DS72KA.

In single-ended mode, the Pot Reverse parameter determines the direction of the Forward/Reverse switch. If this parameter is set to 'No', the scooter drives reverse when the switch is closed. If this parameter is set to 'Yes', the scooter drives forward when the switch is closed.

Warning:

Connecting a speed reducing potentiometer in series with the main speed control wiper terminal may result in a loss of ability of the system to detect wiring faults. Under certain fault conditions, such an arrangement may lead to erratic operation of the scooter. If speed reduction is desired, adopt one of the recommended solutions.

Battery –

5kΩ

[4] Throttle +[3] Throttle Wiper

Throttle – [2]

Forward/Reverse [7]

5k ThrottleΩ

Forward/Reverse Switch

330Ω

330Ω

Battery –

5kΩ

[4] Throttle +[3] Throttle Wiper

Throttle – [2]

Forward/Reverse [7]

5k ThrottleΩ

Forward/Reverse Switch

Throttle Connection with ISO Resistors for Improved Fault Detection

Standard Throttle Connection


4.2.9 Speed Limit Pot / Reduce Speed Switch Wiring

4.2.9.1 Reduce Speed Switch

RHINO offers a slow speed driving mode that is activated when the Reduce Speed Switch is closed. If the switch is closed, the maximum forward and reverse speed of the scooter will be limited to the value set with the Reduce Speed parameter (5.3.4.3).

Use this feature to, for example: • Create a 'slow speed' switch for the user,

useful for driving indoors or in a busy shopping area • Limit the speed when the scooter is turning • Limit the speed when the seat of the scooter is raised to a height at which it

becomes unsafe to drive at full speed. Connect the potentiometer as a variable resistor between Pin 6 and Battery –.

Parameters

Speed Derating = Yes Reduce Speed = 1-10 (as required) Speed Limit Pot Minimum = 100%

Notes:

To enable the reduce speed mode, set the Speed Derating (Enable Mode 2) parameter (see 5.3.4.2) to 'Yes'.

The Invert Turn Input parameter (5.3.4.5) decides if the Reduce Speed Switch must be normally open or normally closed.

Battery –

Reduce Speed [6]

Reduce Speed Switch


4.2.9.2 Analog Speed Limit Pot

In addition to a reduce speed switch, RHINO also supports the use of an analog Speed Limit Potentiometer to limit the maximum speed of the scooter. If the potentiometer is fully turned to the minimum position, the maximum speed of the scooter limited to the Speed Limit Pot Minimum parameter (5.3.4.1).

Connect the potentiometer as a variable resistor between Pin 6 and Battery –.

Parameters

Speed Derating = No Reduce Speed = ignored Speed Limit Pot Minimum = 0-100% (as required)

Dependent on the model of the RHINO, use either a 4.7 kΩ or a 10 kΩ logarithmic potentiometer.

We recommend the use of a high-quality, long-life (greater than 10 million cycles) potentiometer, such as a conductive plastic type. The use of carbon or wire-wound potentiometers is not recommended.

Notes:

The Invert Turn Input parameter (5.3.4.5) reverses the direction in which the pot decreases speed. No: 0Ω = min speed, Yes: max Ω = min speed.

4.2.9.3 Reduce Speed Switch & Analog Speed Limit Pot

The Speed Limit Pot can be connected in parallel with the reduce speed switch. This results in a Speed Pot that can be implemented as either a digital input or an analog input.

Parameters

Speed Derating = Yes Reduce Speed = 1-10 (as required) Speed Limit Pot Minimum = 0-100% (as required)

Potentiometer RHINO models 4.7 kΩ Log DS72KB

DS112KB DS162KD

10 kΩ Log DS52K DS162K

Not supported All other models

Analog Speed Pot Wiper [6]

Analog Speed Pot

Battery –

Reduce Speed or Analog Speed Pot Wiper [6]

Reduce Speed Switch

Analog Speed Pot

Battery –


4.2.10 Key Switch and Status Light Wiring

Connect the Key Switch between Pin 1 (Key Switch) of the logic connector and any of the Battery + pins of the battery connector.

We recommend a Key Switch type with fast switching action that is rated for at least 1 million cycles of operation and at least 350 mA DC continuous.

Connect a fuse or circuit breaker in series with the Key Switch as close to RHINO as possible in the Battery + lead. The fuse or circuit breaker should be rated to protect associated wiring, nominally 200 mA.

RHINO supports a Status Light (LED) to tell the user the status of the scooter system. This indicator that for example can be installed in the tiller head, tells the user at a glance • if the scooter is on or off, • if the battery voltage is too high or too low, or • if there is currently a fault somewhere in the system. If there is a fault, a flash code (a

rhythmic flashing of the indicator) is shown. See the Diagnostics section (6.4) for more details about flash codes.

Connect the Status LED in series with the Key Switch circuit, as shown. Be sure the polarity is correct. If the LED is connected the wrong way, the RHINO will not turn on.

RHINO will limit the current through the Status LED to 10 mA, therefore, no series resistor is required.

Note:

The voltage drop across the LED should be less than 5 V at 10 mA. If more brightness is desired, two LEDs may be connected in series.

LEDs with voltage ratings, for example 12V or 24V, have internally fitted resistors and must not be used.

Battery +

Key Switch [1]

External Status Light

Key Switch

To buzzer

8-12

A Fu

se

200 mA Fuse

Other wiring


4.2.11 Horn / Buzzer wiring

RHINO provides an output for an external horn or buzzer. The buzzer output is limited to 10 mA.

Connect the Horn/Buzzer between Pin 5 (Horn/Buzzer) and Pin 1 (Key Switch) of the logic connector. Place a 10k–100kΩ resistor in parallel across the Buzzer if wired as in section 4.2.3. To use the buzzer as a horn, add a switch between Pin 5 and Battery –. Wiring the buzzer to the battery and the fuse side of the key switch enables the horn to be used even when the key switch is off.

If Buzzer Reverse (Wizard) is set to 'Yes' or Buzzer Volume (HHP) is set higher than 1, the buzzer beeps when the scooter drives reverse. For more information on the difference between the Wizard and the HHP for this parameter, see section 5.3.5.1.

If Sound Faults (5.3.5.2) is set to 'Yes', the buzzer beeps the same number of beeps as the flash code number when a flash code is shown on the Status LED.

If Sleep Beep (5.3.5.3) is set to "Yes", the buzzer beeps three times when the controller goes to sleep.

4.2.12 Brake / Reversing lights wiring

The RHINO Brake/Reversing Light feature is enabled with the Enable Brake Lights parameter (5.3.5.5) and the Enable Reverse Lights parameter (5.3.5.6). Lighting functionality is only available on DS72KB, DS112KB and DS162KD.

The Brake/Reversing light functions use the buzzer output of the RHINO as a Light output. This output can be used as either a buzzer output or a light output, but not both. Therefore, in order to use the lighting functions, all buzzer parameters must be set to 'Off'.

The light output can sink 10 mA in total and is shared between the brake light and the reverse light functions. If both light functions are set to 'Yes', the same light is used for both functions.

To use the lighting functions, Buzzer Reverse, Sound Faults and Sleep Beep must all be set to 'Off'. If any of these parameters is set to 'On', lighting functions are disabled the buzzer output is used as an audible output.

Horn Switch

[1] Key SwitchExternal Status Light

[5] Buzzer –

ReverseBuzzer

Battery +

_

+

Battery –

10-100kResistor

Key Switch

[5] Buzzer –

Battery +

Battery –

2K21N4148

1N4148

1N4148RELAY - SPST

BC807

(10 mA max)


4.2.13 Actuator / Seat Lift Wiring (DS72KA only)

RHINO with Seat Lift (DS72KA) has an identical wiring layout to the standard DS72K, except for the following actuator details.

The DS72KA offers an output for one actuator. This output can be used for any actuator function, for example a seat lift.

Actuator Output

Power is supplied to the actuator through Pin 1 (Seat Output 1) and Pin 4 (Seat Output 2) of the battery connector. Actuator wiring should be a minimum of 0.8mm2 (18AWG). The maximum output current of the actuator output is 12.5 A.

Drive Seat Select Switch

When Pin 7 (Seat/Drive Select) on the logic connector is connected to Battery +, the throttle controls driving as normal. When Pin 7 is not connected, the throttle controls the actuator. Wiring the drive select switch through the key switch reduces battery drain when 'drive' is selected and the scooter is off.

Note:

Set Single Ended Pot (5.3.3.1) to 'No', otherwise the actuator function is not available.

Warning:

If a standard RHINO (DS72K) is used on a scooter wired for a RHINO with Seat Lift (DS72KA), the seat actuator will start to move as soon as the battery is connected to the pins of the battery connector.

Using a DS72KA on a scooter wired for a standard RHINO will result in damage to the controller.

Battery connector Pin DS72K DS72KA (with actuator) 1 Battery Positive Actuator Output 1 4 Battery Negative Actuator Output 2 Logic connector Pin DS72K DS72KA (with actuator) 7 Forward / Reverse Actuator / Drive Select

[4] Seat Output 2[1] Seat Output 1

Seat/DriveSelect [7]

Seat/Drive Select Switch

Actuator

Drive

Seat

[2] Battery +

Key Switch


5 Programming

Warning:

Performance adjustments must only be made by healthcare professionals, or by persons who completely understand the adjustment process and the capabilities of the operator.

Wrong settings, or programming in a location that is not safe, can cause injury to the operator or bystanders, or damage to the vehicle or surrounding property.

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.

Ensure that the deceleration parameters are always higher than the acceleration 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.

RHINO is programmed during manufacture with default settings that should suit most scooter end-users. Using a programmer, these settings can be modified to suit a specific scooter model or end user.

The RHINO can be programmed with two different programming tools:

• A hand held programmer (see 5.1 for a parameter list)

• The PC-based Wizard programmer (see 5.2 for a parameter list)

After programming, put the rubber protection plug back into the programming socket.

Note:

The scooter does not drive while a programmer is plugged into the RHINO.

Plug in the programmer while the controller is turned on, otherwise the new settings will be lost.

If the scooter is turned off during programming, any changed settings are not saved and RHINO defaults back to the previously programmed settings.

Programming Socket


5.1 The hand held programmer

The hand held RHINO programmer is a tool that allows modification of RHINO driving and system settings. Two versions of the programmer offer different levels of access to modify settings.

DS2K-PD - The dealer programmer gives access to drive parameters, such as speed and acceleration.

DS2K-PI - The installation (OEM) programmer additionally gives access to system settings such as motor resistance and motor reverse, and can read extensive system diagnostics such as motor voltage. The installation programmer is only meant for scooter manufacturers and repair centres.

• Turn on the scooter before you connect the programmer to the RHINO. • To save all changes, disconnect the programmer from the RHINO while the scooter is

still on and wait until the status light of the scooter lights up (around 2 seconds). • To cancel all changes, turn off the scooter before you disconnect the programmer

from the RHINO. All the changes will be lost.

Note:

The obsolete DZ-DS-PD and DZ-DS-PM hand held programmers require an adapter cable (DSADAPT72K) to connect to the RHINO, and they cannot access all current RHINO parameters. For this reason, only use a DS2K-PD/PI hand held programmer to program the RHINO.

The following sections describe the menus of the hand held programmers and give a parameter listing if applicable. Some listed parameters are only available on specific RHINO variants.

Read Menu (DS2K-PI only), 5.1.2

Setup Menu, 5.1.3

Fault menu, 5.1.1

Options Menu, 5.1.4

Profiles Menu (DS2K-PI only), 5.1.5

Speed Lever In Neutral Menu, 5.1.6

Controller Version Menu, 5.1.7

Press ENTER to go to SETUP MENU MENU ENTER

Go to the next Main Menu Option

Enter this menu

Programmer Main Menu Screen


5.1.1 Fault menu

If a fault has occurred, the fault menu comes up as the first option. The fault menu gives a description of the fault and the value of the parameter that has caused the fault.

If no fault condition is present, the fault menu is not shown.

5.1.2 Read Menu (DS2K-PI only)

The read menu gives access to a number of diagnostic parameters, which are read and shown in real time.

Parameter Possible Values Typical PD PI

Controller Software Version - 2.93

Motor Current 0 - 180 A

Speed Pot (Throttle) Voltage 0 - 255 (FS = 5V) 128 (2.5 V)

NTC Voltage 0 - 255 67 (@20 C)

A Motor Voltage 0 - 255 (FS = 34V)

B Motor Voltage 0 - 255 (FS = 34V)

Bus Voltage 0 - 255 (FS = 34V) 178

Battery Voltage 0 - 255 (FS = 34V) 185

15 V Rail Voltage 0 - 255 (FS = 34V) 116

Speed Limit Pot Voltage 0 - 255 (FS = 5V) 255 (no pot)

Some listed parameters are only available on specific RHINO variants.

Press ENTER to go to FAULT MENU MENU ENTER

FAULT Speed Pot Error MENU 44 0

Go to the next Main Menu Option

Go to the Fault Menu

Go back to Main Menu

Parameter Value

Press ENTER to go to READ MENU MENU ENTER

READ Controller S/Ware Version:2.93 MENU NEXT PREV

Go to the next Menu Option

Go to the Read Menu


Next Parameter

Previous Parameter


5.1.3 Setup Menu

The setup menu contains all analog programmable parameters (not On/Off values).

Parameter Section Possible Values Default PD PI Acceleration 5.3.2.4 1 - 10 7

Deceleration 5.3.2.5 1 - 10 7

Maximum Speed 5.3.2.3 127 - 255 255 (100 %)

Forward Speed 5.3.2.1 1 - 10 10

Reverse Speed 5.3.2.2 1 - 10 6

Reduce Speed (Mode 2) 5.3.4.3 1 - 10 5

Buzzer Reverse Volume 5.3.5.1 1 - 10 10

Motor Resistance 5.3.6.4 0 - 225 mΩ 60 mΩ

Sleep Time 5.3.5.4 5 - 60 min 30 min

Maximum Current 5.3.6.1 10 - Unit Rating (A) Unit Rating

Boost Current* 5.3.6.3 10 - 180 A 180 A

Boost Time* 5.3.6.3 0 - 100 (x 0.1 s) 10 (1 s)

Soft Start Period 5.3.2.6 0 - 200 (x16 ms) 50

Parkbrake Delay 5.3.8.3 1 - 30 (x 0.05 s) 6

Current Limit Time* 5.3.6.2 25 - 250 (x 0.2 s) 75

Slope Current* 5.3.8.4 5 - 100 A 20 A

BDI Threshold* 5.3.7.4 157 - 195 (x 2/15 V) 175

Battery Saver Threshold* 5.3.7.2 128 - 165 146

Battery Circuit Resistance* 5.3.7.3 0 - 50 mΩ 0 mΩ

Speed Limit Pot Minimum* 5.3.4.1 51 - 255 255 (100 %) Creep Speed* 5.3.3.4 0 - 20 (0 - 8 %) 0

Push Speed* 5.3.8.7 51 - 255 255 (100 %)

Rollaway Speed* 5.3.8.8 73 - 255 255 (100 %)

Demand Curve* 5.3.3.3 0 - 255 204 (80 %)

Motor I2T Continuous Current* 5.3.6.7 5 - 100 A 20 A

Motor I2T Brush Time* 5.3.6.7 5 - 250 128 (256 s)

Motor I2T Case Time* 5.3.6.7 25 - 250 128 (34 min)

Motor I2T Brush/Case Ratio* 5.3.6.7 25 - 250 85 (33 %)

Speed Pot Neutral 5.3.3.5 102 - 180 128 (2.5 V)

Std Speed Pot FSD 5.3.3.8 15 - 127 40 (0.78 V)

Std Speed Pot Dead-band 5.3.3.9 5 - 63 10 (0.2 V)

Alt Speed Pot FSD 5.3.3.8 30 - 127 72 (1.4 V)

Alt Speed Pot Dead-band 5.3.3.9 5 - 63 20 (0.4 V)

Speed Pot Fault Threshold* 5.3.3.6 10- 63 10 (0.2 V)

* Only available on specific RHINO variants or newer software versions. For a detailed description see the section that is shown after the parameter name.

Press ENTER to go to SETUP MENU MENU ENTER

SETUP Acceleration: 3 MENU NEXT PREV VARY


Go to the Setup Menu

Main Menu

Next Parameter

Previous Parameter

Adjust this Parameter

SETUP Acceleration: 3 MENU UP DOWN ENTER


Confirm the new value

Back to Setup Menu

Main Menu Parameter Adjustment Setup Menu


5.1.4 Options Menu

The options menu contains all digital (On/Off) programmable parameters.

Parameter Section Possible Values Default PD PI Single Ended Pot 5.3.3.1 On / Off Off

Standard Speed Pot 5.3.3.7 On / Off Off

Motor Reverse 5.3.6.5 On / Off Off

Pot Reverse 5.3.3.2 On / Off Off

Speed Derating (Enable Mode 2)

5.3.4.2 On / Off On

Brake Checking 5.3.8.1 On / Off On

Battery Derating (Battery Saver)*

5.3.7.1 On / Off On

Load Compensation 5.3.6.4 On / Off On

Motor Derating (Enable I2T) 5.3.6.6 On / Off Off

Enable Sleep* 5.3.5.4 On / Off On

Check For Slope 5.3.8.4 On / Off Off

Current Limit Timer 5.3.6.2 On / Off On

Enable Soft Start 5.3.2.6 On / Off On

Sleep Beep 5.3.5.3 On / Off On

Sound Faults* 5.3.5.2 On / Off On

Enable PB Release 2* 5.3.8.6 On / Off Off

Enable PB Release 1* 5.3.8.5 On / Off Off

Invert Turn Input (Mode 2)* 5.3.4.5 On / Off Off

Enable Slam Brake* 5.3.2.7 On / Off On PB Open Circuit Drive Test* 5.3.8.2 On / Off On

Key-off Slam Brake* 5.3.2.7 On / Off On

Scale Turn Speed (Mode 2)* 5.3.4.4 On / Off On

Enable Brake Lights* 5.3.5.5 On / Off Off

Enable Reverse Lights* 5.3.5.6 On / Off Off

*Only available on specific RHINO variants or newer software versions.

For a detailed description of each parameter see the section that is shown after the parameter name.

Press ENTER to go to OPTIONS MENU MENU ENTER

OPTIONS Single-ended Pot: OFF MENU NEXT PREV VARY


Go to the Options Menu

Main Menu

Next Parameter

Previous Parameter


OPTIONS Single-ended Pot: OFF MENU VARY ENTER

Change value


Back to Options Menu

Main Menu Parameter Adjustment Options Menu


5.1.5 Profiles Menu (DS2K-PI only)

A profile is a set of all the scooter parameters as they are listed in the Setup and Options menu. These parameters together define the behaviour of the scooter.

The programmer has three profiles stored in its permanent memory:

• 1 and 2 can be edited by the programmer, read from and written to the RHINO. • DEFAULT is a profile with DYNAMIC factory default settings. This profile cannot be edited

by the programmer or overwritten by a profile from a connected RHINO controller. This makes sure that it is always possible to go back to the default factory settings as they have been set by DYNAMIC.

The profiles can be used by manufacturers and servicing agents to reprogram controllers quickly and efficiently with their custom performance settings.

The profiles menu has three options:

• Upload a profile from the RHINO to the programmer. • Download a profile from the programmer to the RHINO. • Edit the parameters in one of the three stored profiles. It is possible to edit the

parameters of the DEFAULT profile, however this must then be saved as profile 1 or 2.

5.1.5.1 Upload a Profile from the RHINO

1. In the Main Menu screen, press MENU until the Profiles menu is shown. Press ENTER.

2. Press NEXT until the Upload option is selected. Press ENTER.

3. Press VARY to select the profile number inside the programmer that the RHINO profile will be stored in (1 or 2).

4. Press ENTER to upload the profile from the RHINO to the chosen profile inside the programmer.

5. Press MENU twice to return to the Main Menu.

Press ENTER to go to PROFILES MENU MENU ENTER

PROFILES Press ENTER To Up- Load Profile MENU NEXT ENTER


Go to the Profiles Menu

Main Menu

Next Option (Upload, Download, Edit)

Choose this Option

UPLOAD PROFILE Store As Profile #: 1 MENU VARY ENTER

Choose Profile

Write to chosen Profile

Back to Profiles Menu

Main Menu Upload Profile Profiles Menu


5.1.5.2 Download a Profile to the RHINO

1. In the Main Menu screen, press MENU until the Profile menu is shown. Press ENTER.

2. Press NEXT until the Download option is selected. Press ENTER.

3. Press VARY to select the profile that you want to write to the RHINO (1, 2 or DEFAULT).

4. Press ENTER to download the chosen profile from the programmer to the RHINO.

5. After downloading, the programmer shows the 'Check Profile' screen. Press NEXT to check all the parameters that have been written. When you are satisfied with the parameter values, press MENU.

6. The programmer now shows the ' Speed Lever in Neutral' screen. Check if the buzzer sounds. If the buzzer does not sound, the throttle is not in the zero-speed position. Adjust the throttle potentiometer until the buzzer sounds. Press MENU to return to the Download Profile screen.

Note:

If the programmer is unplugged while the Download Profile screen is shown, the programmer automatically returns to this same screen when it is plugged into another RHINO controller. This way, the same profile can be downloaded to multiple RHINO controllers with a minimum of time spent.

To prevent downloading of the wrong profile during manufacturing, use the LOCK function to restrict access to a single profile. To lock or unlock the programmer, press the LOCK key in the Download Profile screen and enter the password. For further details, contact Dynamic Controls or a Sales and Service Agent.


PROFILES Press ENTER To Down-Load Profile MENU NEXT ENTER



Main Menu


Choose this Option

DOWNLOAD PROFILE Profile #: 1 MENU LOCK VARY ENTER

Choose Profile

Write to Rhino


Main Menu Download Profile Profiles Menu

PLEASE WAIT... Profile #: 1 MENU LOCK VARY ENTER

CHECK PROFILE Acceleration: 3 MENU NEXT

Continue Check next parameter

SPEED LEVER NEUTRAL Buzzer Will Sound When Lever Centered MENU

Back to Download Profile screen

Downloading Check Throttle Check Profile


5.1.5.3 Edit a Profile that is stored in the RHINO Programmer

1. In the Main Menu screen, press MENU until the Profile menu is shown. Press ENTER.

2. Press NEXT until the Edit option is selected. Press ENTER.

3. Press VARY to select the profile that you want to edit (1, 2 or DEFAULT). If you choose DEFAULT, you must save the changes to profile 1 or 2 in step 11.

4. Press ENTER to edit the chosen profile.

5. Press NEXT / PREV to view the parameter values of this profile.

6. Press VARY to select the parameter you want to adjust.

7. Press UP / DOWN to change the value of the selected parameter.

8. Press ENTER to confirm the new value (to cancel, press MENU).

9. Press MENU to go back to the 'Edit Profile' screen.

10. After you have edited all the parameters, press MENU in the 'Edit Profile' screen to save the profile.

11. Press VARY to select the profile you want to save the new settings to (1 or 2).

12. Press ENTER to save the settings to the chosen profile. You can now download this profile to the RHINO, if desired. See 5.1.5.2.


PROFILES Press ENTER To Edit Programmer Profile MENU NEXT ENTER



Main Menu


Choose this Option

EDIT PROFILE Profile #: 1 MENU VARY ENTER

Choose Profile

Edit chosen Profile


Main Menu Profile Selection Profiles Menu

Edit Profile Edit Parameter

Next Parameter

Previous Parameter


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5.1.6 Speed Lever In Neutral Menu

This menu allows you check if the physical neutral position of the throttle produces a voltage at the throttle wiper input (pin 3 of the logic connector) that the RHINO sees as zero speed.

In this menu, the buzzer will sound and the status light will light up* as long as the RHINO thinks that the throttle is in the neutral position.

• Mechanically disconnect the throttle potentiometer from the throttle. • Rotate the potentiometer slowly until the buzzer sounds. • Lock the potentiometer body in this position to the throttle. • Check that the buzzer sounds when the throttle is in neutral,

and for small deflections to either side of neutral.

Notes:

The zero speed input voltage is normally 2.5 V, but this can be changed with the Speed Pot Neutral parameter (5.3.3.5).

*RHINO controllers with a software versions lower than 2.46 use only the buzzer and not the status light for this function.

5.1.7 Controller Version Menu

This menu shows the software version of the controller. The DS2K-PI also shows the run time (the time that the throttle has been deflected).

Notes:

In the DS2K-PI, the software version is also shown in the Read Menu.

Press ENTER to go to SPEED LEVER IN NEUTRAL MENU MENU ENTER

SPEED LEVER NEUTRAL Buzzer Will Sound When Lever Centered MENU


Go to the Neutral Menu


Press ENTER to go to CONTROLLER VERSION MENU MENU ENTER

CONTROLLER VERSION Version: 2.93 Run Time: 7.38Hr MENU


Go to the Version Menu



5.2 Wizard Parameter List

Key: Editable at this level

Viewable at this level

Section 5.3 describes the parameters listed below in detail. Some listed parameters are only available on specific RHINO controllers.

Parameter Possible Values Default Lite Std AdvDrive Performance (5.3.2)

Forward Speed 1 - 10 10

Reverse Speed 1 - 10 6

Maximum Speed 50 - 100 % 100 %

Acceleration 1 - 10 7

Deceleration 1 - 10 7

Enable Soft Start No/Yes Yes

Soft Start Period 0 - 3200 ms 800 ms

Enable Slam Brake* No/Yes Yes

Key-off Slam Brake* No/Yes No

Throttle Options (5.3.3)

Single Ended Pot No (Wig-Wag) Yes (Throttle) No

Pot Reverse No / Yes No

Demand Curve* 0 - 100 % 80 %

Creep Speed* 0 - 8 % 0 %

Speed Pot Neutral 2.0 - 3.5 V 2.5 V

Speed Pot Fault Threshold* 0.2 - 1.25 V 0.2 V

Standard Speed Pot No / Yes No

Std Speed Pot FSD 0.3 - 2.48 V 0.78 V

Std Speed Pot Dead-band 0.10 - 1.24 V 0.20 V

Alt Speed Pot FSD 0.58 - 2.48 V 1.4 V

Alt Speed Pot Dead-band 0.10 - 1.24 V 0.40 V

Speed Reduction Options (5.3.4) Speed Limit Pot Minimum* 20 - 100 % 100 %

Speed Derating (Enable Mode 2) No / Yes No

Reduce Speed (Mode 2) 1 - 10 5

Scale Turn Speed (Mode 2)* No (Limit) Yes (Scale) No

Invert Turn Input (Mode 2)* No / Yes No

General Options (5.3.5) Buzzer Reverse Off / On On

Sound Faults* No / Yes No

Sleep Beep No / Yes Yes

Sleep Time Off, 5 - 60 min 5 min

Enable Brake Lights* No / Yes No

Enable Reverse Lights* No / Yes No

*Only available on specific RHINO variants or newer software versions.


Parameter Possible Values Default Lite Std AdvMotor Options (5.3.6)

Maximum Current 30 - Unit rating Unit rating

Current Limit Time Off, 5 - 50 s 15 s

Boost Current* 0 - 180 A 0

Boost Time* 0 - 10 s 1 s

Load Compensation No / Yes Yes

Motor Resistance 5 - 225 mΩ 50 mΩ

Motor Reverse No / Yes No

Motor Derating (Enable I2T) No / Yes No

Motor I2T Continuous Current* 5 - 100 A 20 A

Motor I2T Brush Time* 10 - 510 s 256 s

Motor I2T Case Time* 7 - 68 min 34 min

Motor I2T Brush/Case Ratio* 10 - 98 % 33 %

Motor Capacity* 1024 - 645122 A2s 30720 A2s

Motor Ramp Down Rate* 1 - 30 s 4 s

Motor Recovery Rate* 5 - 100 60

Motor Continuous Current* 5 - 105 A 20 A

Battery Options (5.3.7) Battery Derating (Battery Saver)* No / Yes No

Battery Saver Threshold* 17.1 - 22.0 V 19.5 V

Battery Circuit Resistance* 0 - 50 mΩ 0 mΩ

BDI Threshold* 20.9 - 26.0 V 23.3 V

Parkbrake Options (5.3.8) Brake Checking No/Yes Yes

PB Open Circuit Drive Test* No/Yes Yes

Parkbrake Delay 0.05 - 1.5 s 0.3 s

Check For Slope On / Off Off

Slope Current* 5 - 100 A 20 A

Enable PB Release 1* No/Yes No

Enable PB Release 2* No/Yes No

Push Speed* 20 - 100 % 100 %

Rollaway Speed* 30 - 100 % 100 %

* Only available on specific RHINO variants or newer software versions.

For a detailed description of each parameter see the section that is shown after the parameter group name.


5.3 Parameter Descriptions

This section describes each parameter in detail. If the values that are shown in the Wizard are different from the values that are shown in the hand held programmers (DS2K-PI and DS2K-PD), the values of the hand held programmers will be shown on the second line of the parameter table. If the parameter table has only one line, it means that the values in the Wizard and in the hand held programmers are the same.

For example:

Parameter Possible Values Default Lite Std Adv PD PI

BDI Threshold 20.9 - 26.0 V 157 - 195

23.3 V 175


Acceleration 1 - 10 7

5.3.1 Software revisions

Some parameters are only available to specific software revisions. A list of software revisions and which controller they refer to is given below.

Software Revision

Software version*

Controller

Rev B Lower than 2.79

Original Rhino

Rev C 2.79 DS72K, DS72KA, DS72KSP, DS112K Rev D 2.88 Not released Rev E 2.90 DS52K, DS72KB, DS112KB Rev F 2.92

and higher DS162K, DS162KD

*You can check the software version of your controller with

• the Controller Version Menu of the DS2K programmer (see 5.1.7), or • the Wizard: Tools Change Module Version.

WizardHHP

Wiz &HHP


5.3.2 Drive Performance

5.3.2.1 Forward Speed


Forward Speed 1 - 10 10 Sets the maximum speed in the forward direction when the throttle is fully deflected forward. Dealers can adjust this parameter to the preference of an individual user or to the terrain that a specific scooter will be used in.

Note:

The overall maximum speed of the scooter is limited by the Maximum Speed parameter (5.3.2.3) that has been set by the scooter manufacturer.

5.3.2.2 Reverse Speed


Reverse Speed 1 - 10 6 Sets the maximum speed in the reverse direction when the throttle is fully deflected reverse. Dealers can adjust this parameter to the preference of an individual user or to the terrain that a specific scooter will be used in. Normally this is set much lower than the Forward Speed.

Note:

Anti-tip wheels may be required if high Reverse Speed settings are used.

5.3.2.3 Maximum Speed


Maximum Speed 50 - 100 % 127 - 255

100 % 255

The Maximum Speed parameter scales all other speed demands to the maximum physical achievable speed of the scooter. For example, if Maximum Speed is set at 50% and the Forward Speed parameter is set to 8 (of 10), the scooter will drive at 50% x 80% = 40% of its maximum achievable speed when the throttle is fully deflected forward. This parameter is set by the scooter manufacturer to suit a particular scooter model with a specific motor and a specific wheel diameter. For the speed preferences of individual customers, use the Forward Speed and Reverse Speed parameters instead.

Note:

If local regulations require that the scooter speed is limited to a specific value, use this parameter to set the speed limit for a particular scooter model.


5.3.2.4 Acceleration


Acceleration 1 - 10 7 Sets the rate at which the speed increases after the throttle has been deflected. 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.

5.3.2.5 Deceleration


Deceleration 1 - 10 7 Sets the rate at which the speed decreases after the throttle has been released to neutral.

Low deceleration values produce a gentle stop, but increase the braking distance. High deceleration values produce a more aggressive stop, but can be uncomfortable. Adjust this parameter to the preference of the user.

Warning:

Setting the Deceleration too low or too high can result in a scooter that is unsafe. Test thoroughly after programming to make sure that the scooter complies with local regulatory requirements for maximum allowable braking distance.

SPEED

TIME

Too high • Too sensitive • Jerky

Too low • Unresponsive • Long delays

Good • Smooth • Dependent on user

and environment

SPEED

Too low • Unresponsive • Braking distance

too long

Too high • Rough • The user can

fall out of the scooter

Good • Smooth • Dependent on user

and environment


5.3.2.6 Soft Start Damping


Enable Soft Start No/Yes Yes

Soft Start Period 0 - 3200 ms 0 - 200 (x16 ms)

800 ms 50

Soft Start temporary reduces the acceleration or deceleration rate when the user moves the throttle to go faster or slower, during the time that is set with Soft Start Period. This makes the speed change smoother, especially with high acceleration/deceleration rates or high motor resistance settings. The default setting generally gives the best performance.

Notes:

1. If Enable Soft Start is set to 'No', the value of Soft Start Period is ignored.

2. Soft Start damping is not only applied from standstill, but also during driving, whenever the speed demand changes.

3. Soft Start damping is applied while starting and stopping, except during an emergency stop or slam stop.

Warning:

If Soft Start Period is set to a very high value, test thoroughly after programming to make sure that the scooter still complies with local regulatory requirements for maximum allowable braking distance.

5.3.2.7 Slam Brake


Enable Slam Brake No/Yes Yes

Key-off Slam Brake No/Yes No If, while driving forward, the throttle is instantly moved more than 30% in the reverse direction, a slam brake will occur. During a slam brake, the scooter will decelerate immediately at approximately twice the deceleration rate that is set with the Deceleration parameter (5.3.2.5).

The resulting deceleration rate will never be more than the maximum value 10, so if the Deceleration parameter already has a high value, the effect of a slam brake will be limited.

If Key-off Slam Brake is set to 'Yes', a slam brake will also be applied when the scooter is switched off while driving. Otherwise, normal deceleration is applied when the scooter is switched off while driving.

Notes:

Slam Braking is not applied while driving reverse, or when Enable Slam Brake is set to 'No'.

Soft Start Damping (5.3.2.6) is not applied during a Slam Brake.


5.3.3 Throttle Options

5.3.3.1 Single Ended Pot


Single Ended Pot No (Wig-Wag) Yes (Throttle) No

Yes - The throttle controls speed only.

The direction of the scooter is selected with a Forward/Reverse switch that is connected between pin 7 of the logic connector and Battery Negative.

No - The throttle controls speed and direction. No Forward/Reverse switch is required. In the DS72KA (with actuator), pin 7 now acts as a Drive / Actuator Selector. In the other RHINO models, pin 7 can now act as a parkbrake release switch if Enable PB Release 2 (5.3.8.6) is set to 'Yes', otherwise pin 7 is ignored.

Notes:

If Single Ended Pot is set to 'Yes', the neutral position is still halfway the pot at 2.5 kΩ. If the throttle is moved out of the centre position in either direction, the scooter starts to move in the direction that has been selected with the Forward/Reverse switch. This allows left-handed and right-handed operation of the same wigwag without reprogramming the scooter.

For the DS72KA, set Single Ended Pot to 'No' otherwise the actuator function is not available.

5.3.3.2 Pot Reverse


Pot Reverse No / Yes No Yes - The polarity of the throttle is reversed. Moving the throttle in the direction that

normally causes forward movement now results in reverse movement while the reverse buzzer beeps. Typically used for left-handed operation.

No - The polarity of the throttle is normal. Typically used for right-handed operation.

If Single Ended Pot is set to 'Yes', this parameter reverses the directions of the Forward/Reverse switch.

Notes:

The Motor Reverse parameter 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 Reverse Speed parameter. For this reason, do not use Motor Reverse for left-handed operation. Use Pot Reverse instead.


5.3.3.3 Demand Curve


Demand Curve 0 - 100 % 0 - 255

80 % 204

Defines the scooter response to movement of the throttle.

0% - The response to the throttle is linear. If the throttle is held halfway, the scooter will drive at half its programmed speed.

100% - The response to the throttle is curved. If the throttle is held halfway, the scooter will drive at around 25% of its programmed speed. This gives the user finer control at low speed. The curve does not change the maximum speed, so the scooter will still drive at full maximum speed when the throttle is fully deflected.

5.3.3.4 Creep Speed


Creep Speed 0 - 8 % 0 - 20 0 %

If the speed demand of the throttle is below the creep speed, it will be treated as zero demand and the parkbrakes will stay engaged. Once the speed demand exceeds the creep speed, the scooter will start to drive at the requested speed demand (so if Creep Speed is set at 8%, the speed demand will jump from zero to 8%).

This prevents crawlaway, rollback on slopes, or heating up of the motor because the speed demand is low enough to stall the motor without reaching the current limit.

Note:

The Speed Pot Neutral and Speed Pot Dead-band parameters increase the dead-band of the throttle itself, this parameter increases the dead-band of the speed demand after all speed processing is done (Demand Curve, Forward Speed, Reverse Speed, Reduced Speed and Speed Limit Pot processing).

Spee

d

Movement

100%

100% 50%

0% 100%


5.3.3.5 Speed Pot Neutral


Speed Pot Neutral 2.0 - 3.5 V 102-180

2.5 V 128

Defines the throttle wiper position that RHINO interprets as "neutral" (zero speed). Normally this is at 2.5V (50% of the throttle wiper range).

Warning:

If the throttle wiper is not connected, the wiper input reads 2.5 V by default. For this reason, if Speed Pot Neutral is set away from 2.5 V by more than the Speed Pot Dead-Band parameter (see 5.3.3.9), the scooter can start to drive by itself if the throttle wiper becomes disconnected.

5.3.3.6 Speed Pot Fault Threshold


Speed Pot Fault Threshold 0.2 - 1.25 V 10 - 63

0.2 V 10

Defines how close the voltage of the speed pot (throttle) wiper can get to 0 or 5 Volt without generating a fault. If the voltage at the wiper terminal is lower than the threshold value, or higher than 5V minus the threshold value, a Speed Pot Fault (see 6.4 for flash codes) is generated. This usually happens when a short circuit exists between the throttle wiper and either terminal of the throttle potentiometer.

Increase this parameter if • ISO resistors are fitted to the wig-wag potentiometer, or • a speed reduction pot is connected in series with the speed pot wiper. In this case,

shorts between the wiper input and either wig-wag potentiometer end may not be detected and will result in a full speed runaway. Reducing the valid voltage range results in a Speed Pot Fault if such a short is present.

Note:

A speed reduction pot in series with the speed pot wiper is not recommended. If speed reduction is required, please consider one of the recommended options described in section 4.2.8 and 4.2.9 instead.


5.3.3.7 Standard Speed Pot


Standard Speed Pot No / Yes No The RHINO gives the possibility to use two different software presets (standard and alternative) for speed pot settings. For both presets, it is possible to enter a separate length of travel (FSD, Full Scale Deflection) and dead band, as shown below. Choose with this parameter which preset (standard or alternative) you want to use.

5.3.3.8 Speed Pot Full Scale Deflection (FSD)


Std Speed Pot FSD 0.3 - 2.48 V 15 - 127

0.78 V 40

Alt Speed Pot FSD 0.58 - 2.48 V 30 - 127

1.4 V 72

Sets the amount of throttle wiper movement between zero speed (as set with the Speed Pot Dead-Band parameter, see below) and maximum speed.

If set too high, the scooter will not achieve maximum speed no matter how much the throttle is deflected. If set too low, the scooter will reach maximum speed with only a small deflection of the throttle.

If ISO resistors are fitted, it may be necessary to decrease this parameter.

5.3.3.9 Speed Pot Dead-Band


Std Speed Pot Dead-band 0.10 - 1.24 V 5 - 63

0.20 V 10

Alt Speed Pot Dead-band 0.10 - 1.24 V 5 - 63

0.40 V 20

Sets the amount of throttle wiper movement away from the zero-speed position (as set with the Speed Pot Neutral parameter, see 5.3.3.5) at which the scooter starts to drive.

This defines the size of the dead-band at the start of the throttle range, at the zero speed position.

Zero Speed

Zero Speed

5 V0 V 2.5 V

Throttle Range REV

Full Speed Fault

0.2 V 0.7 V 2.1 V 2.9 V

Throttle Range FWD

Full Speed

4.8 V4.3 V

Fault

SP Neutral(2.5V)

SP DeadBand (0.4V)

SP DeadBand (0.4V)

SP FSD

(1.4V)

SP FSD

(1.4V)

Fault Threshold

(0.2V)

SP Fault Threshold

(0.2V)

Para

met

er

Thro

ttle

Typical throttle parameter setup


5.3.4 Speed Reduction Options

5.3.4.1 Speed Limit Pot Minimum


Speed Limit Pot Minimum 20 - 100 % 51 - 255

100 % 255

This parameter is meant for an optional Analog Speed Limit Pot (see 4.2.9.2) that is connected between pin 6 of the logic connector and battery negative. It is not meant for the throttle/wig-wag Speed Pot.

Speed Limit Pot Minimum sets the maximum speed of the scooter when the speed limit potentiometer is turned fully to the minimum position. The speed is given as a percentage of the Forward Speed and Reverse Speed parameters (5.3.2.1).

Note:

Set to 100% if no speed limit pot is connected to pin 6 of the logic connector, otherwise a speed limit pot error may occur.

If this parameter is not listed in the parameter list, your Rhino does not support the use of an Analog Speed Limit Pot, only the use of a Reduce Speed switch.

5.3.4.2 Speed Derating (Enable Mode 2)


Speed Derating (Enable Mode 2) No / Yes No

The Speed Derating feature allows a second driving mode that limits the speed of the scooter when a Reduce Speed Switch (see 4.2.9.1) is activated.

Use this feature to, for example: • Create a 'slow speed' switch for the user • Limit the speed when the scooter is turning • Limit the speed when the seat of the scooter is raised to a height at which it

becomes unsafe to drive at full speed. The switch must be connected between pin 6 of the logic connector and battery negative. Pin 6 can be called the "Reduce Speed" input or the "Turn" input, dependent on the application. If the switch is activated, the speed of the scooter will be limited to the value set with the Reduce Speed parameter (5.3.4.3). The Invert Turn Input parameter (5.3.4.5) decides if the input on pin 6 is high active or low active.

Note:

If Speed Derating is set to 'No' , an analog speed limit pot between pin 6 and battery negative can still limit the speed of the scooter. See the Speed Limit Pot Minimum parameter description (5.3.4.1) for details.


5.3.4.3 Reduce Speed (Mode 2)


Reduce Speed (Mode 2) 1 - 10 5 This parameter is only used when Speed Derating (5.3.4.2) is set to 'Yes'.

When pin 6 of the logic connector is connected to battery negative, the controller will automatically limit the forward and reverse speed to the value set by Reduce Speed. For example, if Reduce Speed is set to 7, Forward Speed to 10 and Reverse Speed to 6, the maximum forward speed will reduce to 7, but the maximum reverse speed will stay at 6, as it is already lower than Reduce Speed.

The speed reduction method is dependent on the setting of the Scale Turn Speed parameter.

5.3.4.4 Scale Turn Speed (Mode 2)


Scale Turn Speed (Mode 2) No (Limit) Yes (Scale) No

This parameter is only used when Speed Derating (5.3.4.2) is set to 'Yes'.

This parameter defines the speed reduction method that is used when the maximum speed of the scooter is limited to the value of the Reduce Speed parameter.

No (Limit) - Limits the speed in both directions to the Reduce Speed value. This means that the throttle may have a dead zone. For example, if the Reduce Speed parameter is set to half the Forward Speed value, the upper half of the throttle range will not increase the forward speed of the scooter any further.

Yes (Scale) - Scales the maximum speed in both directions to the Reduce Speed value. The throttle will not have a dead zone, to reach the reduced maximum speed the throttle must be fully deflected.

Set to 'No' if the input is from an automatic speed limit switch such as a steering sensor, slope sensor or seat position switch. This makes sure that the speed of the scooter does not change while driving if the switch becomes activated when the speed is already below the Reduced Speed limit.

Set to 'Yes' if the input is from a 'slow speed mode' switch that is operated by the user.

5.3.4.5 Invert Turn Input (Mode 2)


Invert Turn Input (Mode 2) No / Yes No Yes - The switch between pin 6 and battery negative is normally closed. An open circuit

between pin 6 and battery negative activates the reduced speed mode.

No - The switch between pin 6 and battery negative is normally open. A short circuit between pin 6 and battery negative activates the reduced speed mode.

This parameter also affects the direction of the Analog Speed Limit Pot (4.2.9.2).


5.3.5 General Options

5.3.5.1 Buzzer Reverse


Buzzer Reverse Buzzer Volume

Off / On 1 - 10

On 10

Wizard:

On - The buzzer beeps if the RHINO drives reverse.

Off - The buzzer does not beep if the RHINO drives reverse.

HHP:

2-10 - The buzzer beeps on full volume if the RHINO drives reverse. The volume of the buzzer is not dependent on the value of this parameter. Any value other than 1 activates the reverse buzzer with full volume.

1 - The buzzer does not beep if the RHINO drives reverse. This value does not affect the functionality of Sound Faults or Sleep Beep. If these are set to 'Yes' they will cause beeps even if Buzzer Volume is set to '1'.

Note:

The buzzer output is located on pin 5 of the logic connector.

5.3.5.2 Sound Faults


Sound Faults No / Yes No Yes - If a flash code is shown on the Status LED, the buzzer beeps the same number

of beeps as the flash code number.

No - The buzzer does not beep during a fault.

5.3.5.3 Sleep Beep


Sleep Beep No / Yes Yes Yes - When the controller goes to sleep, the buzzer beeps three times.

No - When the controller goes to sleep, the buzzer does not beep.


5.3.5.4 Sleep Mode


Enable Sleep On / Off On

Sleep Time Off, 5 - 60 min 5 - 60

5 min 30

If Enable Sleep is set to 'On', the RHINO automatically "goes to sleep" if no throttle activity is detected for Sleep Time minutes. When the RHINO is in Sleep Mode, the Status Light is OFF and the scooter does not respond to commands. To wake up the RHINO, turn the power off and then on again.

The Wizard does not have an Enable Sleep parameter. To turn off Sleep Mode, set Sleep Time to 'Off'.

5.3.5.5 Enable Brake Lights


Enable Brake Lights No / Yes No Yes - The light output will be turned on when the scooter decelerates.

No - The light output is not used when the scooter decelerates.

The brake light must be connected to the buzzer output of the RHINO. This output can be used as either a buzzer output or a light output, but not both. Therefore, in order to use the lighting functions, all buzzer parameters (Buzzer Reverse, Sound Faults and Sleep Beep) must be set to 'Off'. If any of the buzzer parameters is set to 'Yes', the value of Enable Brake Light is ignored and the buzzer output is used as an audible output.

The light output can sink 10 mA in total and is shared between the brake light and the reverse light functions. If both functions are set to 'Yes', the same light will be used for both functions. Lighting functionality is only available on DS72KB, DS112KB and DS162K(D).

5.3.5.6 Enable Reverse Lights


Enable Reverse Lights No / Yes No Yes - The light output will be turned on when the scooter drives reverse.

No - The light output is not used when the scooter drives reverse.

The reverse light must be connected to the buzzer output of the RHINO. This output can be used as either a buzzer output or a light output, but not both. Therefore, in order to use the lighting functions, all buzzer parameters (Buzzer Reverse, Sound Faults and Sleep Beep) must be set to 'Off'. If any of the buzzer parameters is set to 'Yes', the value of Enable Reverse Lights is ignored and the buzzer output is used as an audible output.

The light output can sink 10 mA in total and is shared between the brake light and the reverse light functions. If both light functions are set to 'Yes', the same light will be used for both functions.

Lighting functionality is only available on DS72KB, DS112KB and DS162K(D).


5.3.6 Motor Options

5.3.6.1 Maximum Current


Maximum Current 30 - Unit rating 10 - Unit rating

Unit rating Unit rating

Sets the maximum output current in Ampere that RHINO will deliver to a motor. A low value can affect the performance of the scooter, for example when the scooter tries to climb up a curb.

The maximum useable setting corresponds with the current rating for the controller type, for example 50A for the DS52K. Higher settings than the controller rating have no effect on the controller.

5.3.6.2 Current Limit Time


Current Limit Timer No / Yes Yes

Current Limit Time Off, 5 - 50 s 25 - 250 (x 0.2)

15 s 75

If the throttle is deflected but the scooter can not drive because

• It is on a slope that is too steep, • It tries to climb up a curb that is too high, or • It is trapped,

the maximum current (as set by the Maximum Current parameter) will flow through the motor continuously, because the motor is still trying to drive. This can cause motor damage when the motor becomes too hot. To prevent motor damage, the RHINO disables drive after Current Limit Time* seconds of maximum continuous current.

If a current limit timeout has occurred, the scooter will not drive and the Status Indicator LED shows Flash Code 4 (see section 6.4 for flash code descriptions). To reset the fault, turn the scooter off and turn it back on again.

Notes:

Some safety standards specify a particular current limit time (also referred to as stall time or stalling timeout). See the regulations of the country in which the scooter is to be used to determine what the correct Current Limit Time value is.

If Current Limit Time is set to 'Off', the RHINO 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.

*Rev. B models use a fixed value of 15 s, and use the Current Limit Timer parameter to turn the option on or off.


5.3.6.3 Boost Current (DS162K/KD only)


Boost Current 0 - 180 A 10 - 180

0 A 180

Boost Time 0 - 10 s 0 - 100 (x 0.1)

1 s 10

Boost Current provides a short boost of additional power for climbing a curb or starting on a hill. The maximum duration of the boost is set with Boost Time.

If the current drops below 75% of the Maximum Current value, the Boost Time will recover at 25% of the actual time. For example, if Boost Time is set to 10 seconds, and the current has been above Maximum Current for 7 seconds, the remaining boost time is 3 seconds. If the current now stays below 75% of Maximum Current for 8 seconds, the remaining boost time increases with 8 x ¼ = 2 seconds to 5 seconds.

A Boost Current value less than the value of Maximum Current has no effect.


5.3.6.4 Load Compensation / Motor Resistance


Load Compensation No / Yes Yes

Motor Resistance 5 - 225 mΩ 0 - 225

50 mΩ 60

Load Compensation automatically compensates for changes in motor speed when the scooter drives over loads such as sidewalks, curbs or slopes. Set Load Compensation to 'Yes' for normal operation. Load Compensation uses the Motor Resistance parameter to calculate the correct compensation value.

Note:

The Load Compensation and Motor Resistance parameters affect the performance of all other speed and acceleration parameters, and it is importantto set these parameters correctly before you program anything else. If the Load Compensation or Motor Resistance parameter is changed after the scooter has been set up, the complete speed/acceleration programming and testing procedure must be repeated.

Set Motor Resistance to the resistance of the motor that is installed on the scooter.

Motor Resistance

Too low Correct Too high

Scooter behaviour

• Drives like it is

going through thick mud

• Slows down when it goes up a sidewalk edge or up a ramp

• Slows down with heavier users

• Rolls back significantly after stopping on a slope

• Drives smoothly • Keeps the speed

reasonably constant. Only slightly slows down on a slope

• Does not roll back after stopping on a slope

• Drives very rough • Hard to control,

vibrates or surges • May creep forward

after stopping on a slope

• Motor becomes hotter than normal very easily, decreased motor life

If the scooter gives poor performance on carpet or at low speeds, the most probable cause is a Motor Resistance value that is set too low.


Determining the correct motor resistance by looking at the scooter behaviour

Tools needed

1. A scooter with a RHINO controller fitted 2. A DS2K Hand Held Programmer or

a laptop with the Wizard Programmer 3. A slope that you can drive up to

Procedure

• Set Load Compensation to 'Yes' • Set Motor Resistance to 20. • Drive the scooter onto a slope and increase the Motor Resistance value until the

scooter does not roll back after it has stopped on the slope. To test if Motor Resistance has the correct value, perform a series of scooter tests (drive on a slope, up a sidewalk edge, and over thick carpet) and check if the scooter behaviour is similar to the correct behaviour described above.

Notes:

1. This test procedure causes the motor to become hot. For this reason, the resulting value for Motor Resistance is too high. Reduce Motor Resistance by 20% to make sure that the scooter is still comfortable to drive when the motor is cold.

2. A new motor usually has a higher motor resistance than a motor that has been used for some time, because the motor brushes that are inside the motor do not make optimal contact until they are "worn in". If possible, perform this procedure when the motor has been used for several hours.

Optimum Motor Resistance. Scooter responsive AND smooth

Nervous

Uncontrollable Aim for this point: 20% back

from the top of the hill

Unresponsive

Perfo

rman

ce

Motor Resistance parameter

1 2

3


5.3.6.5 Motor Reverse


Motor Reverse No / Yes No Yes - The polarity of the motor pins on the motor connector is reversed and the motor

turns in the opposite direction.

No - The polarity of the motor pins on the motor connector is as described in section 4.2.2.

Note:

Do not use Motor Reverse to setup the scooter for left-handed use, set the Pot Reverse parameter (see 5.3.3.2) 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 the scooter for left-handed use will result in the reversing beeper beeping while the scooter drives slowly forward.

5.3.6.6 I2T / Motor Derating


Motor Derating (Enable I2T) Motor Derating No / Yes No

I2T or Motor Derating is a function that calculates the approximate temperature of the motor by measuring the motor current over time. If the calculated motor temperature becomes too high, the current output of the RHINO is reduced to protect the motor from burning out.

When the power of the scooter is turned off, the calculation resets the motor temperature to the ambient temperature.

In RHINO software revision D, a new algorithm was introduced that is more accurate than the old algorithm. The new algorithm uses different parameters with a different name. For this reason, the parameters of the two versions are described in two different sections on the following pages.

Note:

The I2T algorithm assists in motor protection. However, it cannot completely prevent the motor from burning out. The motor may last longer, but specific conditions can still burn out a motor, even with I2T activated.


5.3.6.7 I2T Parameters (Rev. D and Rev. F)


Motor I2T Continuous Current 5 - 100 A 20 A

Motor I2T Brush Time 10 - 510 s 5 - 250

256 s 128

Motor I2T Case Time 7 - 68 min 25 - 250

34 min 128

Motor I2T Brush/Case Ratio 10 - 98 % 25 - 250

33 % 85

These parameters only have effect if Motor Derating (Enable I2T) is set to 'Yes'. Match these parameters to the thermal characteristics of the motor that is installed on the scooter.

Motor I2T Continuous Current defines the current that the motor can handle continuously without becoming too hot.

Motor I2T Brush Time / Motor I2T Case Time. The algorithm estimates the temperature of both the motor brush assembly and the motor case. A heating term and a cooling term are calculated for the motor brush assembly. This calculation updates at intervals proportional to Motor I2T Brush Time. A heating term and a cooling term are also calculated for the motor case. This calculation updates more slowly, at intervals proportional to Motor I2T Case Time.

Motor I2T Brush/Case Ratio specifies what fraction the motor case temperature rises compared to the brush temperature. This Ratio term will be used to multiply the case heating term, and the complement of the Ratio will be used to multiply the case cooling term. Thus a Ratio of 66% will cause the estimated case temperature to stabilise at two-thirds of the estimated brush temperature, while a Ratio of 25% will cause the estimated case temperature to stabilise at 1/4 of the estimated brush temperature. The Ratio term will also be used to scale the brush cooling term, but the actual multiplier will be (1/(1-Ratio)). Therefore the higher the Ratio value, the smaller the difference between brush and case temperatures for a given amount of brush cooling.


5.3.6.8 I2T Parameters (Rev. B and Rev. C)


Motor Capacity 1024 - 645122 A2s 100 - 65500* 30720 A2s

Motor Ramp Down Rate 1 - 30 s 4 s

Motor Recovery Rate 5 - 100 0 - 1*

60 0.6

Motor Continuous Current 5 - 105 A 20 A These parameters only have effect if Motor Derating (Enable I2T) is set to 'Yes'. Match these parameters to the thermal characteristics of the motor that is installed on the scooter.

Motor Capacity sets the thermal mass of the motor. A greater capacity increases both the reaction and recovery times from heating. Its units are in thousands of Amperes-Squared Seconds, but the current used for this calculation is the amount of current in excess of or below the Motor Continuous Current Parameter. For example, a value of 9kA2S with a 30A continuous current, corresponds to just under 2 seconds at 100 Amperes (100 Amperes-30 Amperes = 70A excess, squared is 4.9kA2, so a capacity of 9kA2S divided by 4.9kA2 = 1.8 seconds).

Motor Ramp Down Rate is a ramp time that determines the rate at which the current is limited from maximum current limit to Motor Continuous Current when the Motor Capacity is exhausted.

Motor Recovery Rate defines how quickly the motor cools down. The Motor Recovery Rate controls the rate at which the Motor Capacity is rejuvenated when the controller current is below the threshold Motor Continuous Current.

Motor Continuous Current is the current that the controller will be limited to if the Motor Capacity has been exhausted.

Note:

*The DS2K-PI hand held programmer does not support these parameters. Use the Wizard or the obsolete DS-DZ-PD hand held programmer to access these parameters.


5.3.7 Battery Options

5.3.7.1 Battery Derating (Battery Saver)


Battery Derating (Battery Saver) No / Yes No

If the battery Voltage falls below Battery Saver Threshold*, the RHINO 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 • gives the user a physical warning that the battery is almost empty before the battery

is damaged. The scooter will drive slower but should still be able to climb small obstacles such as curbs. If the battery voltage falls below 16.5 V, the scooter stops driving because the throttle is reduced to zero.

*Battery Saver Threshold is only available on Rev. F models (see Software revisions, 5.3.1). Older models use the fixed value of 19.5 Volt.

5.3.7.2 Battery Saver Threshold


Battery Saver Threshold 17.1 - 22.0 V 128 - 165

19.5 V 146

Sets the voltage at which the Battery Saver feature starts to work. A high value provides additional battery protection but limits the performance of the scooter, especially on slopes. A low value provides increased performance when the battery is low, but may shorten the life of the battery.

Max

imum

Thro

ttle

V 16.5 V Battery Saver

Threshold

Battery Empty

Battery Almost Empty


5.3.7.3 Battery Circuit Resistance


Battery Circuit Resistance 0 - 50 mΩ 0 mΩ If the resistance of the battery circuit is entered, the controller can calculate a more accurate battery voltage used in features such as the Battery Saver.

5.3.7.4 BDI Threshold


BDI Threshold 20.9 - 26.0 V 157 - 195

23.3 V 175

Sets the Voltage below which the Battery Discharge Indicator (BDI) indicates that the battery is almost empty.

5.3.8 Parkbrake Options

5.3.8.1 Brake Checking


Brake Checking No/Yes Yes Yes - The RHINO checks the parkbrake for open circuit and short circuit faults before

and during driving.

No - The RHINO does not check the parkbrake at all. This option allows the RHINO to be used without an electric parkbrake.

Always set this option to 'Yes' if the scooter has an electric parkbrake.

5.3.8.2 PB Open Circuit Drive Test


PB Open Circuit Drive Test No/Yes Yes The RHINO checks the parkbrakes for open circuits before and while driving. In some circumstances, the parkbrake checking during driving may result in audible noise and/or incorrectly generated faults. If this is the case, set this parameter to 'No'. In all other cases set this parameter to 'Yes'.

Note:

If Brake Checking is set to 'No', the value of this parameter is ignored.


5.3.8.3 Parkbrake Delay


Parkbrake Delay 0.05 - 1.5 s 1 - 30

0.3 s 6

The Parkbrake Delay parameter sets the delay between zero speed demand (after the scooter has decelerated and stopped) and the moment that the parkbrakes are engaged.

The correct value of this parameter is dependent on the mechanics of the parkbrake that is used on the scooter. The delay must be longer for fast acting parkbrakes.

If the value of Parkbrake Delay is set too high, there may be too much rollback when stopping on a slope. If the value is set too low, the scooter may stop too abruptly.

5.3.8.4 Check For Slope / Slope Current


Check For Slope On / Off Off

Slope Current 5 - 100 A 20 A On a slope, the motors need power to stand still, otherwise the scooter will roll away.

If Check For Slope is set to 'Yes', and the motor current is higher than Slope Current* after the scooter has stopped, the Parkbrake Delay (5.3.8.3) is skipped and the parkbrakes are applied immediately. This can reduce the amount of rollback on a slope.

*Slope Current is not available in Rev. B models. These models use the fixed value of 20A.

Note:

If this function makes the scooter stop too abruptly, check if Load Compensation and Motor Resistance (5.3.6.4) have been setup correctly. If that does not help, increase Slope Current or set Check For Slope to 'No'.


5.3.8.5 Enable PB Release 1


Enable PB Release 1 No/Yes No This function is reserved for future use. Leave at 'No'.

5.3.8.6 Enable PB Release 2


Enable PB Release 2 No/Yes No If set to 'Yes', the Forward/Reverse switch can be used as an electronic parkbrake release switch.

This parameter is not available on the DS72KA or on Rev. B models.

Note:

This function is only available if Single Ended Pot (5.3.3.1) is set to 'No(Wig-Wag)'.

5.3.8.7 Push Speed


Push Speed 20 - 100 % 51 - 255

100 % 255

The speed at which the scooter can be pushed when the scooter is switched on and the parkbrake is electrically released with a parkbrake release switch.

If the Push Speed is exceeded, the scooter will perform a controlled stop.

5.3.8.8 Rollaway Speed


Rollaway Speed 30 - 100 % 73 - 255

100 % 255

The speed at which the scooter can be pushed when the scooter is switched off and the parkbrake is manually released.

If the Rollaway Speed is exceeded, the scooter will perform a controlled stop.


Create Diagnostic Report

6 Diagnostics

RHINO provides diagnostics information to assist technicians with diagnosing and correcting faults within the scooter system. A fault in the scooter will cause the RHINO Status Light to flash and the Horn to sound in bursts, separated by a pause. The number of flashes or ‘beeps’ in each burst, also referred to as the flash code, indicates the nature of the fault.

Depending on the severity of the fault and its impact on user safety, RHINO will react differently. It can:

• Display the flash code as a warning but allow normal driving and operation. • Display the flash code as a warning but allow limited driving and operation. • Display the flash code, stop the scooter and prevent driving until the scooter has

been turned off and then back on again.

6.1 Diagnostic tools

6.1.1 The Status Light

The RHINO controls a Status Light to indicate the status of the controller.

If the scooter is on and there are no faults present, the Status Light is continuously on.

If the RHINO detects a fault, the Status Light shows a Flash Code that indicates the cause of the fault. See section 6.4 for a detailed description of the Flash Codes and the possible solutions to the faults.

6.1.2 RHINO Programmer

If you plug a RHINO Programmer into the RHINO when a fault condition exists, the programmer will display the detected fault on its screen.

6.1.3 The PC-based Wizard program

The Wizard provides a full fault history and shows a description of any current faults.

To create a diagnostic report, click on the icon with the wrench or click Tools Diagnose controller.

If the fault cannot be identified and assistance is required, please save the diagnostic report as a file on the computer (File Save as) and email it to one of our service centres, together with a detailed description of the fault and circumstances.


6.2 Out Of Neutral At Power Up (OONAPU)

An Out Of Neutral At Power Up (OONAPU) fault occurs if the throttle is not in the centre position when the scooter is switched on. This makes sure that the scooter does not suddenly start to drive.

If an OONAPU fault exists, the Status LED shows flash code 6. The scooter does not drive. Return the throttle to the centre. The fault goes away and the scooter drives normally.

If the throttle is not returned to the centre within 10 seconds, the OONAPU fault becomes a latching fault. To clear the fault, switch the scooter off and then on again.

If the fault does not go away after the scooter has been turned off and on, the throttle may be faulty or incorrectly calibrated. See section 5.1.6 for more information.

6.3 Diagnosing RHINO Faults

Use the following troubleshooting guide if the scooter fails to operate. The guide will help identify whether the fault exists within RHINO or another part of the scooter system.

Required equipment: Voltmeter, optionally a DS2K-PI hand held programmer.

Notes:

1. Elevate the drive wheels before carrying out the following tests.

2. Turn the key switch on before beginning any diagnostics.

3. The voltages shown are nominal values.

Warning:

Testing should only be carried out by qualified service personnel.


6.3.1 Status Light ON, but scooter does not move

If the External Indicator Light is PERMANENTLY ON, but the scooter does not move

Check that the relay and the parkbrake solenoid are working.

Move the throttle to the full-speed position and listen carefully for the operation of the parkbrake solenoid or the relay in the RHINO.

• If you can hear the solenoid or the relay operating, the problem is not with the throttle or the inhibit circuitry.

• If you can hear the solenoid but the motor does not turn, look for an open circuit in the motor wiring.

• If you can hear the relay operating but not the solenoid, check that you are not using a DS72KA in actuator mode.

Check the voltages on the Throttle terminals with the throttle in neutral.

Connect a voltmeter between Battery – and the following Throttle pins:

Battery – » Pin 2: Throttle – 0.5 ± 0.1 V Battery – » Pin 4: Throttle + 4.5 ± 0.1 V Battery – » Pin 3: Throttle Wiper 2.5 ± 0.1 V (128 on DS2K-PI programmer)

The DS2K-PI hand held programmer also shows the throttle wiper voltage in its Read Menu (see section 5.1.2). The centre value should be approximately 128.

When the Throttle is moved in the forward and reverse directions, the voltage on Throttle Wiper should increase and decrease by 2V (or + 102 on the programmer).

• If the throttle voltages are not correct, an incorrect throttle potentiometer is being used and/or it is not correctly calibrated.

• If the voltage swing does not occur, check the potentiometer and wiring for open circuits.

• If the voltage swing does occur but the relay and parkbrake solenoid do not operate, check the throttle programming settings (section 5.3.3).

Check the voltages on the Motor terminals.

Connect a voltmeter between Motor + and Motor –.

The voltmeter should measure 0V when the throttle is in neutral. The voltmeter should measure 24V as the throttle is moved out of neutral to full forward.

• If the voltage out of neutral is above 0V but the motor is not driving, check the motor, motor wiring, and connectors.

Check the voltages on the Parkbrake terminals.

Connect a voltmeter between Parkbrake + and Parkbrake –.

The voltmeter should measure 0V when the throttle is in neutral. The voltmeter should measure 24V when the throttle is out of neutral.

• If the voltages are incorrect, check the parkbrake and parkbrake wiring.

Check inhibit status.

Connect a voltmeter between Inhibit and Battery –.

The voltmeter should measure 5V.

• If the voltage is 0V, check that an inhibit switch is not engaged (for example, from a battery charger). When 0V is applied to this terminal, driving will be inhibited.


6.3.2 Status Light OFF

If the Status Light is OFF

Check whether the RHINO Programmer is plugged in.

The status light will be out, and driving is not enabled when a Programmer is plugged in to the RHINO.

Confirm that the battery supply voltage is present on the RHINO Battery +/– terminals.

Connect a voltmeter between Battery + and Battery –, negative probe on Battery –.

The voltmeter should measure between 23 and 27 volts.

• If the voltage is negative, check for correct battery wiring polarity. • If the voltage is 0V, check the circuit breaker and for open circuit wiring.

Confirm that the key switch is on and that its wiring and fuses are intact. Confirm that the Status LED, if present, is fitted correctly.

Connect a voltmeter between the Key Switch terminal and Battery –.

The voltmeter should read at least 20 volts.

• If the voltage is 0V, use the voltmeter to check the wiring from Battery + to the key switch itself and back to the Key Switch terminal.

6.3.3 Status Light Flashing

If the Status Light is FLASHING

Count the number of flashes and refer to the following section, Flash Codes.

Plug in the RHINO Hand Held Programmer to determine the cause of the fault.


6.3.4 Can't achieve full speed

If the scooter can't achieve full speed at full throttle

Check if the battery is low or overcharged

If the battery Voltage is below 19.5 V, the Battery Saver function (5.3.7.1) reduces the output of the RHINO to increase the range and protect the battery. If the scooter drives downhill with a battery that is completely full, the battery can become overcharged. To protect the battery, the RHINO reduces the current output.

Check if the controller or the motor is hot

If the RHINO is hot, the controller reduces the output current to protect itself. If the RHINO has calculated that the motor is hot, it may reduce the output current to protect the motor (see section 5.3.6.6).

Check the battery wiring and the motor wiring

• Check that the diameter of the wiring is at least the recommended size as shown in section 4.2.2, otherwise performance is reduced.

• Check that the wires are not loose. Especially on high power scooters where multiple battery wires and motor wires are used in parallel, the scooter will still drive but perform less when one of the wires is disconnected.

Check if the scooter is programmed correctly

• Check that Forward Speed (5.3.2.1) = 10 and Maximum Speed (5.3.2.3) = 100%. • Check that Maximum Current (5.3.6.1) and Motor Resistance (5.3.6.4) are correct.

Check if a speed reduction mechanism is active

If the scooter has a speed limit pot, check that it is in the maximum position. If the scooter has a speed reduction switch, check that it is not activated. To check if the speed reduction mode is activated, disable the mode: • To disable the speed limit pot, set Speed Limit Pot Minimum (5.3.4.1) to 100%. • To disable the speed reduction switch, set Speed Derating (5.3.4.2) to 'No'. If full speed can now be achieved, the speed reduction mechanism is the problem. • Check that the programming (5.3.4) matches the wiring (4.2.9) of the pot/switch.

Check that the polarity of the wiring is correct. The polarity can be swapped with the Invert Turn Input parameter (5.3.4.5).

• Check the Speed Limit Pot Voltage in the Read Menu of the DS2K-PI hand held programmer (see section 5.1.2). If you don't have a programmer, check the voltage on Pin 6 of the Logic connector. For full speed, it should be 5V or 0V (depending on Invert Turn Input).

Check that the throttle has been setup correctly

Connect a voltmeter between Battery – and the following Throttle pins: Battery – » Pin 2: Throttle – 0.5 ± 0.1 V Battery – » Pin 4: Throttle + 4.5 ± 0.1 V Battery – » Pin 3: Throttle Wiper 2.5 ± 0.1 V (128 on DS2K-PI programmer) The DS2K-PI hand held programmer also shows the throttle wiper voltage in its Read Menu (see section 5.1.2). The centre value should be approximately 128. When the Throttle is moved in the forward and reverse directions, the voltage on Throttle Wiper should increase and decrease by 2V (or + 102 on the programmer). • If the throttle voltages are not correct, an incorrect throttle potentiometer is being

used and/or it is not correctly calibrated. • If the voltage swing does occur but the scooter still does not achieve full speed,

check the throttle programming settings (section 5.3.3), especially the Full Scale Deflection parameter.


6.4 Flash Codes

Flash Code

Fault source

Meaning

1 Battery Low

The battery is almost empty. • Recharge the battery as soon as possible.

2 Battery Empty

The battery is completely empty. The scooter does not drive. • Recharge the battery immediately.

If the scooter is left off for a few minutes, the battery may recover enough to allow driving again for a short time. However, driving on an empty battery may cause damage to the battery.

3 Battery Too Full

The battery voltage is too high. The scooter does not drive. • Check the batteries and the cables. • Batteries may be overcharged:

if driving downhill, slow down and turn on the lights. • Batteries may be damaged: contact your dealer.

If this fault occurs during battery charging, the battery charger is defective or not adjusted correctly.

• Contact your dealer If this fault occurs during when you stop or when you travel down a slope, and the batteries are not full, the battery connector may make intermittent contact.

• Check the battery cables and connectors. 4 Route /

Temperature The motor current has been at the maximum value for too long. The scooter does not drive.

• The motor may not be strong enough for the chosen route (the route is too steep).

o Turn off the scooter, let it cool down, then turn it back on again and choose another route.

• The wheels may be rubbing on the frame. o Make sure that the wheels can turn freely.

• The motor may be faulty. o Have the motor checked by a service technician.

The RHINO is too hot. The scooter does not drive.

• Wait a few minutes and try again • If this happens often, contact DYNAMIC

5 Parkbrake The parkbrake has been released manually. • Enable the parkbrake, and then turn the scooter off and on.

The parkbrake is not connected to the RHINO, or there is a short-circuit in the parkbrake connection. The scooter does not drive.

• Check that the motor and parkbrake cables and connectors are not loose or damaged. If necessary, unplug the motor connector or parkbrake connector and check that all pins are in the correct position.

• If this flash code does not appear until the throttle has been moved out of neutral, check for a short in the parkbrake circuit.

• If this flash code appears at power-up, check for an open circuit in the parkbrake circuit.

• Contact your dealer. 6 OONAPU Out Of Neutral At Power Up. The throttle was not in the neutral position

when the scooter was turned on. The scooter does not drive. • Return the throttle to neutral, turn the power off, and back on again. • Throttle may need to be adjusted (see section 5.1.6). • Check throttle wiring.


Flash Code

Fault source

Meaning

7 Speed Pot (Throttle)

The throttle or speed limit pot may not be correctly set up. The scooter does not drive.

• If no speed limit pot is fitted, the Speed Limit Pot Minimum parameter (5.3.4.1) must be set to 100%/255.

The voltage throttle, speed limit pot or their wiring may be faulty. • Check for open or short circuits. • Contact your dealer.

8 Motor Volts The motor is not connected to the RHINO, or there is a short-circuit in the motor connection. The scooter does not drive.

• The motor brushes may have lost connection. Turn the wheels of the scooter to reconnect the motor brushes, and then turn the RHINO off and on. If this happens often, the motors may be faulty.

• Check that the motor cables are not loose or damaged. • Contact your dealer.

9 Internal fault An internal fault has occurred. The scooter does not drive. • Contact your dealer.

10 Pushed Too Fast

The scooter has been pushed faster than the programmed Rollaway Speed parameter (5.3.8.8) when the Parkbrake has been mechanically released, or the scooter has been pushed faster than the programmed Push Speed parameter (5.3.8.7) when the Parkbrake Release function has been operated.

• Turn the scooter off and then back on again.

6.5 RHINO Fault Log & Run-Time Log

The Fault Log is a useful diagnostic tool for use by approved service technicians. The log retains information on the last 16 faults.

The Run-Time Log records the total time the RHINO has been driven including time being “pushed” with the parkbrakes electronically released.

Both logs are accessible with the DS2K Scooter Programmer or the Wizard.

Notes:

Battery Low warnings (Flash Code 1) are not logged in the Fault Log.


7 Appendices

7.1 Programming Accessories

DYNAMIC RHINO Programming Accessories

Part Description DC Part # Qty/Unit

Wizard software Wizard Kit – Programming Kit Contains software and cables (no dongle)

DWIZ-KIT

1

Wizard – Software Only (CD) DWIZ-SW 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

Hand Held Programmers OEM/Installation version Dealer version

DS2K-PI DS2K-PD

1 1


7.2 Intended Use and Regulatory Statement

The RHINO scooter controller is intended to provide speed control for scooter systems that utilise a single DC motor fitted with an integrated parkbrake. The RHINO with Seat Lift (DS72KA) controller is also fitted with a seat actuator control that is used to adjust seat height through a DC motor driven seat actuator. The controller will respond to user input demand via an analog input, in terms of direction (forward and reverse), speed, seat extend and seat retract. The RHINO is designed with a specified input device and with the expectation that the input device, system and environment in which it operates are also correctly designed, tested and adequately maintained. The scooter system integrator as well as the end user are provided with all of the integration, set up, test and maintenance information that will be needed in order to ensure reliable and safe use of the controller.

The RHINO controller is designed for scooters fitted with:

• A battery level and flash code indicator installed and visible to the user

• A Buzzer with audible output to indicate the scooter is reversing

• Optional lighting circuits (DS72KB, DS112KB and DS162K/KD variants only), which are protected independently from the drive circuits such that failure of the lighting circuit will not effect the driving circuit.

Product Disclaimer

Dynamic Controls products are built to allow customers’ vehicles to conform to national and international requirements. In particular to:

ISO7176-9 Climatic Tests for Electric Wheelchairs and Scooters

ISO7176-14 Power and Control Systems for Electric Wheelchairs and Scooters

ISO7176-21 Requirements and Test Methods for Electromagnetic Compatibility of Electric Powered Wheelchairs and Scooters

The performance of controllers fitted to wheelchairs and scooters depends on the design of the particular wheelchair or scooter. Final compliance must be obtained by the vehicle manufacturer for each vehicle. No component certificate issued by Dynamic Controls relieves a wheelchair or scooter manufacturer from compliance testing for the particular vehicle.

If Dynamic Controls controllers are fitted to vehicles or applications other than wheelchairs and scooters, testing to appropriate standards for the particular application must be completed, as ISO7176 might be inappropriate.


7.3 Maintenance

1. Keep all DYNAMIC electronic components free of dust, dirt and liquids. For cleaning the product, use a cloth dampened with warm soapy water. Do not use chemicals, solvents or abrasive cleaners, as this may cause damage to the product.

2. Regularly check all vehicle components for loose, damaged or corroded components such as connectors, terminals, or cabling. Restrain all cables to protect them from damage. Replace damaged components.

3. Regularly test all switchable functions on the DYNAMIC electronics system to ensure they function correctly.

4. There are no user-serviceable parts in any DYNAMIC electronic component. Do not attempt to open any case or undertake any repairs, else warranty will be voided and the safety of the system may be compromised.

5. Where any doubt exists, consult your nearest service centre or agent.

Warning:

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.

7.4 Warranty

All equipment supplied by Dynamic Controls is warranted by the company to be free from faulty workmanship or materials. If any defect is found within the warranty period, the company will repair, or at its discretion replace, the equipment without charge for materials or labour.

This warranty is subject to the provisions that the equipment:

• has been correctly installed.

• has been thoroughly checked upon completion of installation, and all programmable options correctly adjusted for safe operation prior to use.

• has been used solely in accordance with this manual and all other manuals of the DYNAMIC electronic components that are used on the scooter.

• 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 unauthorised personnel.

• has been used solely for the driving of electrically powered mobility scooters in accordance with the intended use and the recommendations of the scooter manufacturer.

• Has not been connected to third party devices without the specific approval of Dynamic Controls.


7.5 Safety and Misuse Warnings

Warnings to be included in the User Manual

The following warnings must be passed on to the operator of the vehicle before use of the product.

• Do not install, maintain, or operate this equipment before you have read and understood all the instructions and all the manuals for this product and all the other products that you use or install together with this product. Follow the instructions of the manuals. If you do not follow all instructions, injury or damage can be the result.

• Do not try to open or disassemble any case - there are no user-serviceable parts inside.

• The operator has the responsibility to keep the vehicle in a good safe operating condition. To protect all the components (for example the cables) from damage, the operator must fasten them in optimum positions.

• Do not touch the connector pins. If you touch the pins, they can become dirty or they can be damaged by electrostatic discharge.

• Immediately turn the controller off and consult your service agent if the vehicle o Is damaged o Does not behave the same every time o Does not respond normally, the way you expect it to o Becomes hotter than normal o Smokes o Arcs o Does not change its speed when you adjust the speed reduction pot or the

speed reduction switch (if one is available on your vehicle) o Displays a fault on its fault indicator and the controller does not perform normally.

• Turn the controller off o When you do not use it o Before you get in or get out of the vehicle o Before you use a mobile phone or a portable communications device near the

vehicle o If your vehicle drives by itself or against your will. When you turn the controller off

the vehicle will halt. • In the case of an emergency while the vehicle is driving, press the On/Off button 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, possibly in dangerous locations such as the middle of the road.

• Make sure that the battery charger that is used with the vehicle has a drive inhibit function that is correctly connected for use with the controller. If you are not sure, ask your dealer or vehicle manufacturer.

• If operators of the vehicle are left with limited or no mobility for any reason (for example, because the vehicle loses electric power or breaks down), it is important that they can still call for assistance from wherever they may be.

• Advise the operator to go downhill slowly. When the vehicle drives downhill, the motors act as a dynamo and generate energy. The controller sends the generated energy from the motor to the battery. This charges the battery. However, if the battery is fully charged, it cannot accept the generated energy anymore. When this happens, there is a risk of damage to the battery or an explosion. To prevent this risk, the controller forces the vehicle to slow down until the battery can accept more energy. After this, it allows the vehicle to speed up again. The result of this will be sudden speed changes of the vehicle. To prevent these speed changes with fully charged batteries, the operator must decrease the speed of the vehicle when going downhill.


• Inform the operator that the controller can cause the vehicle to come to a sudden

stop. If this can be dangerous to the operator, the installer must install a seat belt, and the operator must wear this seat belt.

• Operation of a vehicle on steep slopes can be dangerous. Before you drive up or down a slope, make sure that the slope does not exceed the capability of the vehicle.

• Do not use the parkbrake release on a slope. • Make sure that the controller does not become colder or hotter than the minimum

and maximum temperatures specified in this manual. • Most electronic equipment is influenced by Radio Frequency Interference (RFI). Be

careful when portable communications equipment is used in the area around such equipment. Dynamic Controls has made every effort to make sure that RFI does not change the behaviour of the controller, but very strong signals can still cause a problem. The vehicle manufacturer has the responsibility to make sure that the vehicle is tested according to local EMC regulations.

• Performance adjustments must only be made by healthcare professionals, or by persons who completely understand the adjustment process and the capabilities of the operator. Wrong settings, or programming in a location that is not safe, can cause injury to the operator or bystanders, or damage to the vehicle or surrounding property.

• Performance adjustments must only be made indoors, or outdoors in dry conditions.

Service and configuration warnings

The following warnings are applicable to the installation technician, and the dealer or the therapist who supplies the vehicle to the end user.

• It is the responsibility of the installer to make sure that accessories that are connected to the wires of the vehicle do not interfere with the operation of the controller.

• Do not use the vehicle frame as the earth return. Any electrical low-resistance connection to the frame is a safety risk and is not allowed by international safety standards.

• If the vehicle loses electric power, it is important that an attendant is able to move the vehicle easily.

• After you have completed the installation, check it thoroughly. Correctly adjust all 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 maintenance or service of the vehicle, check the functional operation of all components that are externally connected to the controller, such as o lights o external switches o actuators o DCI/ACI/OBC resistor switch circuits

(including programmed slowdown behaviour) • The dealer, therapist or other agent who supplies the vehicle to the end user has the

responsibility to make sure that the vehicle is correctly configured for the needs of that user.


• For each individual user, the vehicle set up and configuration should take into

consideration his or her o technical knowledge, experience and education, and o medical and physical condition, including the level of

disability and capability (where applicable). • It is the responsibility of the OEM and installer to make sure that the maximum driving

speed of the vehicle is limited as appropriate when the vehicle is in a mechanically unstable position, for example when the seat is raised.

• It is the responsibility of the therapist/ installer to minimize any risk of use error, including those arising from ergonomic features and/or the environment in which the device is intended to be used.

• Prior to handing over the vehicle, make sure that users are fully able to operate the product by giving them appropriate training on functionality and safety features, and having them test-drive the vehicle in a safe area in the presence of their agent.

7.6 Electromagnetic Compatibility (EMC)

DYNAMIC Electronic Controllers have been tested on typical vehicles to confirm compliance with the following appropriate EMC standards:

USA: ANSI/RESNA WC/Vol:2 - 1998 Sec 21

Europe: EN12184: 1999 Sec 9.8.1-3

National and international directives require confirmation of compliance on particular vehicles. Since EMC is dependent on a particular installation, each variation must be tested.

The General wiring recommendations in section 4.2.1 are written to assist with meeting EMC requirements.

7.7 Environmental statement

This product has been supplied from an environmentally aware manufacturer.

Please be environmentally responsible and recycle this product at the end of its life through your local recycling facility.

This product may contain substances that could be harmful to the environment if disposed of into a landfill.

Do not dispose of this product in fire.

rhino installation manual iss6 (1)

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