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R-Series User Manual

1. Ensure the controller and speed setting potentiometers are electrically connected to the vehicle frame Do not leave connections unnecessarily exposed Chapter 6 Appendices 57 dynamic R series 6 8 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 Chapter 6 Appendices 58 dynamic R series 6 9 Contact Details Dynamic has a global network of sales and service centers Please contact your nearest Dynamic representative for Sales and or Service advice or contact us directly through our web site www daynamicmobility co nz Sales amp Service Dynamic Europe Limited Sales Dynamic Asia Service d Dynamic Controls New Zealand Head Office Dynamic Controls 15 Print Place Ph 64 3 962 2519 PO Box 1866 Fax 64 3 962 2966 Christchurch New Zealand E mail info dynamic controls co nz Europe Sales amp Service Dynamic Europe Ltd Stonebridge Cross Business Park Ph 44 1905 772 321 Fax 44 1905 827 520 Droitwich Worcestershire WR9 OLW United Kingdom E mail sales dynamic eu com North America Sales amp Service Dynamic North America 31335 Industrial Pkwy Ph 1440 979 0657 S
2. 7 Example of Charger Socket wiring for wiring shown using Charger Programmer an Off board charger shown using the tiller connector connector Chapter 2 Installation and Testing 12 dynamic R series The inhibit pin is a Multi function input and can be used for an alternative function if a charger is not plugged into this pin The function is fully programmable using the Wizard See Section 2 7 1 for further details about Multi function Input pins A suitable fuse must be installed in the Battery Positive wire to protect the scooter wiring Fuse to be connected as close as practical to the scooter connector to minimize the length of unprotected wiring To prevent driving while charging an appropriate inhibit pin in either the Charge Program or Tiller connector must be connected so that a connection between Battery Negative and Inhibit is made while charging 2 6 2 Programmer Connections There are two options for connecting a programmer either through the Charger Programmer connector or through any correctly configured charger socket The R series programming adapter will plug directly into an off board charger socket or into the 4 pin Molex Mini Fit Junior connector with the use of the AMP programming adapter If an on board charger is installed it will be necessary to disconnect it prior to programming through this connector Either of the Pin 14 or Prog Inh Multi function Inputs may be used for programming Char
3. LED i light array Light Output B Pin3 or 11 Diode AVY ddl 24V relay Light Output ji 24V relay Pin3 or 11 Pins 3 and 11 can be set to one of Beeper Brake Light Reversing Light or Status Chapter 2 Installation and Testing 27 dynamic R series 2 9 Testing To ensure that each scooter meets a minimum level of safety the following procedure should be undertaken This procedure should be carried out in a spacious environment and with due regard to any possible unexpected scooter movement in the event of faulty installation l 14 Lo ke 17 Raise the wheels off the ground using blocks under the scooter frame so that the wheels can turn freely Recheck all wiring paying particular attention to polarities of batteries motor and park brake Make the final connection to the Battery Positive terminal open the key switch and close the circuit breakers Turn the key switch to turn the R series on Ensure it turns on correctly Turn the key switch again to turn the R series off Ensure it turns off correctly Turn the key switch again to turn the R series back on Ensure all installed hardware is functioning correctly by activating appropriate buttons switches etc Turn each drive wheel by hand to check that the park brakes are engaged The wheels should not move Move the throttle slightly out of neutral and listen for the click as the park brakes disengage Move
4. Zick M lifunction INOUTS srsacesteunececconnsdesoasanceestinnsctbtotsuredacsenassctecteasestteteaeadeens 14 DID ACUE OOS serce serran EE EA EAA NE AE oS 16 DT NOW TO E EA 17 PTB NEON CNC EE E E E E nies 17 ZO AONE ONG MOM OUTOUTS sisesrsiinanisernniaseiicrnderrenn n E raaa 18 2 8 MEC OS CONS cots sete a A E RA 19 20 1 Tirone Connec hiol sdumaceecss tests tacscuesnuntencsaceassaseoncasucsnabesaecutearaeposnteaeice 20 2 8 2 Speed Limit Pot Connections ssessseesssssseesessserrsssseeressseessssseersssseee 22 2 8 3 Alternative Speed Reduction Options ssssssssessessseessssseersssseerrssseee 23 2 8 4 Tiller Battery SUPPlY seeeesseenseesseessssssensssseessssssesssssseessssseresssseessssssersssseee 24 209 Key CIA NOUT sessies e a ai i 25 296 STAW WICC CON OUVIDO esnan aa ea Nie 25 28 7 Beeper QUT UT raceassnccssecsactcaendcaasenchacaesaasaqesemicntudasteneonesansacaateasascosontaestte 26 2 8 8 Battery Gauge OUTOUT vaiciectisdinssdsteasadseedienaeahdvioesadiqdeessscancteysssbiedhadeadorss 26 2 8 9 Brake and Reversing Lights eeeeeeesseeeseesesrrserreeessssereessessreerereeseseeeee 27 2 9 TR STING a E N A E EE E AAA 28 3 Programming the R SETICS cccccceccsscsscssccescesee LP 3 1 AOAC ON aec A E R 29 E BDA a E A E AE E S 30 e ERANTO ANE E E A AE E EEA 30 3 2 R series Programmable Parameter DESCTIIDTIONS cccccccccesseseececeseeeeeeseeeeceeees 31 3 2 1 ProgramldentilicatiOrN sss inccosadsnatncss
5. an option is grayed out the function does not support this option Sets the function of Pin 6 on the tiller connector It may be configured as one of drive profile swap Slow Reverse Drive Release Brake Slow Stop Active defines the circuit state at which the function will be active Slows to defines the soeed when a Slow function is active Setting the Latching option to Yes will require the active state to be cleared and the controller turned off and then back on again If an option is greyed out the function does not support this option Sets the function of Pin 12 on the tiller connector It may be configured as one of Charger Inhibit drive profile swap Slow Reverse Drive Release Brake Slow Stop Active defines the circuit state at which the function will be active Slows to defines the soeed when a Slow function is active Setting the Latching option to Yes will require the active state to be cleared and the controller turned off and then back on again If an option is greyed out the function does not support this option Sets the function of Pin 14 on the tiller connector It may be configured as one of drive profile swap Slow or Slow Stop Active defines the circuit state at which the function will be active Slows to defines the speed when a Slow function Is active Setting the Latching option to Yes will require the active state to be cleared and the controller turned off and then bac
6. damage by securing them in optimum positions A warning must be conveyed to the operator that the controller could cause the vehicle to come to a sudden stop In situations where this might affect the safety of the operator the fitting and wearing of a seat belt is required Performance adjustments should only be made by professionals in the health care field or by persons fully conversant with the adjustment process and the operator s capabilities Incorrect settings or programming in an unsafe location could cause injury to the operator or bystanders or damage to the vehicle or surrounding property Performance adjustments should only be made indoors or outdoors in dry conditions The dealer therapist or other agent supplying the scooter to the end user should ensure it is appropriately configured for the needs of that user This should be confirmed by the user drive testing the scooter in a safe area accompanied by their agent The system should be turned off when not in use The user should turn the system off before getting in and out of the vehicle Do not operate the vehicle if it behaves erratically or shows abnormal response heating smoke or arcing Turn the system off at once and consult your service agent If the scooter drives without demand turn the key switch to the off position to halt the scooter lf while driving the speed limiting pot or speed reduction switch has no influence on the scooter speed the throttle
7. driving in reverse 7 oree Sets the rate of acceleration when driving in reverse cae Acceleration Bevel i Sets the rate of deceleration when driving in reverse e Deceleration Sets the maximum speed when driving forwards and O 100 Lowest Forward Gp the soeed pot is set to its lowest minimum soeed speed position Sets the maximum speed when driving in reverse and O 100 Lowest Reverse the soeed pot is set to its lowest minimum soeed PSE Zs position Sets the amount of time taken to achieve full O 2550 i acceleration or deceleration i e the take off Soft Start Period ae ms characteristics as you accelerate or decelerate from rest Higher values give a softer more relaxed take off while lower values give a more aggressive take off Sets the acceleration characteristics as you reach the O 100 demanded speed A higher value will give a softer and Soft Finish 7 more relaxed transition from acceleration to the demanded speed A lower value will give a more direct and aggressive transition O Emergency Sets an emergency rate of deceleration when a Stop 100 Deceleration input is active or if a non critical fault occurs Sets a rate of deceleration to be used when the user O 100 has activated the Slam Braking feature Slam Braking is Slam Braking activated when the throttle is moved significantly in the opposite direction to that currently moving or if the key switch is r
8. lead to water ingress which could result in system malfunctions and long term damage to the unit e For peak performance locate the controller so that air can flow over and around the case particularly if mounting in the Tiller e A position close to the batteries and motor is recommended to reduce the length of high current wires e Use both screw positions to attach the controller Socket cap screws are recommended Select a screw length that protrudes between 4 and 6mm through the case Do not over tighten the mounting screws Regardless of mounting orientation protect scooter wiring connectors and components including those of the tillerhead 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 Do not mount the R series in a position where the user can come into contact with the unit The case temperature can exceed 41 C Chapter 2 Installation and Testing 2 dynamic R series 2 2 2 2 1 Connections and Wiring General Wiring Notes and Recommendations The following notes apply to all wiring on the scooter Notes specific to particular component wiring can be found under each component s designated sub section e g battery connections It is the installer s responsibility to ensure the finished wiring package Is safe and fit for purpose l Before making any connectio
9. speed The scooter manufacturers are provided with all the integration set up operating environment test and maintenance information needed in order to ensure reliable and safe use of the controller Device Classification Europe The R Series Controller is a component of a Class medical device as detailed in the Council Directive 93 42 EEC concerning Medical Devices USA The R Series Controller is a component of a Class Il medical device Powered Wheelchair as detailed in 21 CFR 890 3860 Compliance and Conformance with Standards In accordance with the device classification the R Series scooter controller is designed to comply with the requirements of the European Medical Device Directive 93 42 EEC and 21 CFR 820 30 The R Series scooter controller has been designed such that the combination of the scooter and controller along with accessories as applicable complies with the requirements of the MDD Harmonized standards EN12184 and EN12182 and the FDA Consensus standard ANSI RESNA 7176 for performance However final compliance of the complete scooter system with international and national standards is the responsibility of the scooter manufacturer or installer Programming Adapter The programming adapter is intended to allow the R Series scooter controllers the ability to communicate with the Wizard and the DX Hand Held Programmer The adapter is not intended to alter the controller in any way but simply passes
10. this manual Most electronic equipment is influenced by radio frequency interference RFI Caution should be exercised with regard to the use of portable communications equipment in the area around such equipment While Dynamic Controls has made every effort to ensure that RFI does not cause problems very strong signals could still cause a problem It is the responsibility of the vehicle manufacturer to ensure that the vehicle is tested in accordance with local EMC regulations If RFI causes erratic behavior turn the vehicle off immediately Turn the vehicle off before using cell phones or portable communications devices In the event of the fault indicator flashing while driving the operator must ensure that the system is behaving normally If not the system must be turned off and a service agent contacted Report any malfunctions immediately to your service agent 6 6 Service and Configuration Warnings The following warnings are applicable to the installation technician only After the vehicle has been configured check to make sure 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 intended operation cannot be achieved contact your service agent The completed installation must be thoroughly checked and all programmable options correctly adjusted for safe ope
11. 0 will cause the controller to decelerate using the programmed forward or reverse deceleration rate 2 7 4 Latched The Latched parameter sets whether the function will become latched once active If a function is latched the active condition will have to be removed and the controller turned off and then on again before the function will be turned off Chapter 2 Installation and Testing 17 dynamic R series 2 7 5 Multi function Outputs The Multi function Outputs will output signals dependant on the condition of the controller or batteries As with the Multi function Inputs the Multi function Output pins have been designed to offer maximum flexibility in the implementation of the scooter feature set and are programmable using the Wizard With the exception of the status output on Pin 10 these functions are not configurable as to their active state or have the ability to be latched The specific functionality of each output will be explained in a further section The table below shows the supported functionality for each input pin Beeper Brake Light Reversing Light Status Status High Status Low 5V Battery Gauge 12V Battery Gauge Other Figure 9 Multi function Output Pins Chapter 2 Installation and Testing 8 dynamic R series 2 8 Tiller Connections The tiller connector provides all the connections necessary to power and control all the functions contained in the tillernead This connecto
12. 100 travel Setting this to 100 will have no effect on soeed no SRW Forward matter the SRW position Setting this to 50 will cause Speed Scale the speed to be scaled by half when the SRW is at 100 travel This feature is useful for an Anti tip type application whereby the soeed can be automatically reduced the further the tiller is turned in order to stop Push Speed tipping Sets the reverse soeed limit when the Speed Reduction O 100 Wiper SRW is active and the wiper is at 100 travel SRW Reverse Setting this to 100 will have no effect on soeed no Speed Limit matter the SRW position When the SRW is at 100 travel setting this to 50 will cause the soeed to be limited to 50 of the maximum reverse speed Chapter 3 Programming the R series 35 dynamic R series Parameter Description Sets the scaling factor to be used on the programmed Maximum Reverse Soeed when the Speed Reduction Wiper SRW is active and the wiper is at 100 travel Setting this to 100 will have no effect on soeed no SRW Reverse matter the SRW position Setting this to 50 will cause Speed Scale the speed to be scaled by half when the SRW is at 100 travel This feature is useful for an Anti tip type application whereby the soeed can be automatically reduced the further the tiller is turned in order to stop Tipping 3 2 5 OEM Drive Limits Sets maximum values for certain drive performance parameters Paramet
13. Hand Held Programmer Plugging a hand held programmer into the R series when an abnormal condition exists will cause the fault to be displayed on the screen A 4 digit code will be disolayed which indicates the condition The first two digits provide the flash code number The second two digits provide more specific diagnostics information that is suitable for repair technicians While there are alternative flash code sequences that may be flashed on the status LED the hand held programmer will only display the appropriate Scooter Flash Code information For instance if the Shark Flash Codes are used the Status LED will disolay an 8 Flash code for an internal error When the hand held programmer is plugged in it will disolay a flash code 9 on the screen DYNAMIC Wizard Wizard is the preferred diagnostics tool in the workshop environment providing a full fault history last 16 and verbal descriptions of each flash and associated servicing code If after analyzing the data the condition cannot be diagnosed it is possible to print or save a Status Report for further analysis or distribution through fax or email to a service center Chapter 4 Diagnostics 47 dynamic R series 4 4 Advanced Diagnostics Logs In addition to the standard diagnostics reports additional diagnostic information is available from the controller using the Wizard or HHP This additional information is extremely useful for identifying the root cause of any fa
14. Negative IsQ TEST RESISTOR 330o0hm PT Throttle Wiper Joke Pin 1 PT ISO TEST RESISTOR 3300hm This will decrease the susceptibility of the throttle circuit to leakage OAS The configurable options for the speed limit pot when wired in parallel through Pin 9 are for specific details about each of these options please refer to the programming section Option Description Lowest Forward Speed Sets the forward speed of the scooter when the speed limit pot is turned to its lowest value with the throttle at maximum deflection Lowest Reverse Soeed Sets the reverse soeed of the scooter when the speed limit pot is turned to its lowest value with the throttle at maximum deflection Speed Limit Pot If a Soeed Limit Pot is wired to the dedicated Speed Limit Pot wiper Pin 9 this parameter should be enabled If the Soeed Limit Pot is wired in series this parameter should be disabled otherwise the speed of the scooter will be limited to the Lowest Forward and Lowest Reverse Speed settings and or Soeed Limit Pot faults generated Chapter 2 Installation and Testing 22 dynamic R series 2 8 3 Alternative Speed Reduction Options In addition to the throttle and speed limit pot the R series has other soeed reduction options to allow for further flexibility in the way soeed reduction Is applied For soecific details about each of these options please refer to the programming section Option Descript
15. allation and Testing 1 dynamic R series 2 6 1 Battery Charger Connections There are two options for connecting a battery charger either on board OBC or off board If an on board charger is installed it is recommended it be plugged directly into the Charge Program connector For either charging solution a battery charger with a maximum rating of 8 Amps RMS should be used A suitable fuse must be installed in the Battery Positive wire to protect the scooter wiring For off board chargers an XLR type socket can be connected either through the Charge Program connector or through the tiller by using the Battery and Battery connections on the tiller connector To prevent driving while charging an appropriate inhibit pin in either the Charge Program or Tiller connector must be connected so that a connection between Battery and Inhibit is made when charging Configure the appropriate pin to be used as the charge inhibit by setting either the Pin 14 Configuration or Prog Inh Pin Configuration parameter to Charger Inhibit When the Charger Inhibit function is enabled it is always active when the circuit state is low switched to Battery Negative Alternatively any of the Multi function Input pins that support the Slow function may be used If used Slows to must be set to 0 and Latches set to Yes Inhibit Charger Socket On board for Off board Charger OBC Charger Figure 6 Example of On board charger Figure
16. anedcacasneseansqscesecactnenewseeeseseeas OU 5 1 R series Electrical Soecifications esseessssseeessscersessscessssesressssersssssceessserrsssseeees 50 5 2 FV SIC Cl SIO I COM ONG cccueteaeeseccu seni aseyccccisanscaoctagenedeeodssecasemeetcanssscensocsauteced ssec lt tancocees yo of 1 g e od aan eee ene eee ee A ene 6 1 PCC EGOS SONGS WISE serari penikon oinar nor NEARE OEE REEERE 52 6 2 Intended Use and Regulatory STATEMENT cccsssscccssssssscceeessessecscnsescssseensess 53 6 3 POM EE OE A I E A E E E E E N TA 54 6 4 WT ora E SAE EAA A N EAE E E E 54 6 5 Safety and Misuse VV GINA OS su censasactiinideutes stecencauuadesanincetacubedadeavcimadsesteiusatsnetiannaael 55 6 6 Service and Configuration WOMINOS wisicessccissrscensadicsecccnsosseninaznataceesdicresiencenactasias 56 6 7 Electromagnetic Compatibility EMC sssesesesssssessesssccressesssrrseressesrserereesesseeeresss 57 6 8 Environmental StatemeNi assisen enei EE 58 6 9 COC ST OIG e E EEEE EE 59 Table of Contents dynamic R series 1 Introducing the R series Where the requirement is for quality value and simplicity Dynamic has the answer The new R series means a refined drive experience blending innovative performance improvements with an unprecedented balance of power and size 50 and 90 Amp models provide the power you want when you need it New programmable acceleration curves zero rollback on slopes improved motor matching algo
17. as described in Section 2 2 1 If necessary the motor polarity can be swapped when programming Chapter 2 Installation and Testing 7 dynamic R series 2 4 1 Motor Protection Levels The R series offers multiple pre set levels of motor protection simply by selecting the appropriate value of Motor Protection Level in the Wizard and entering the motors power rating A guide to selection of Motor Protection would be to choose a value appropriate to the size quality of motor considering higher levels of protection may affect the performance of the controller Changing the Motor Power Rating parameter to a higher value while leaving the Motor Protection Level at the same value will scale the level of protection to match the larger motor If further customization of the Motor Protection is required advanced parameters are available in Advanced mode If any of the advanced parameters are changed Motor Protection Level will change to Custom By changing the Motor Protection Level parameter in the Wizard a range of parameters will be changed to optimize the protection to the selected level In the event of an overheated motor the motor protection algorithm will reduce the performance of the scooter before shutting it down In order to provide adequate protection the R series will remember the condition of the motor when it has been turned off 2 4 2 Motor Testing The R series has 4 different modes for test
18. ation rate Available on Tiller Connector Pins 6 12 and 14 and Charger Programmer Connector Pin 4 2 8 4 Tiller Battery Supply Pin 7 provides the 24V supply to the tiller while Pin 13 provides the OV return These pins have current ratings of 6 Amps and can be used for wiring an XLR socket for an off board battery charger An external fuse should be installed into the Battery Positive circuit Refer to Section 2 6 1 for further details about battery charging The Battery Positive and Battery Negative supplies must not be connected either directly or through switches to the same input connector A suitable fuse must be installed in the Battery Positive wire to protect the scooter wiring Fuse to be connected as close as practicable to the scooter connector to minimize the length of unprotected wiring In connecting switches between an input pin and either Battery Positive or Battery Negative the installer must ensure that there is no possibility of the switch es connecting Battery Positive to Battery Negative Chapter 2 Installation and Testing 24 dynamic R series 2 8 5 Key Switch Input Pin 5 of the analog connector provides the key switch power circuit A high quality key switch gt 50 000 operations should be used Up to 2 status LEDs up to 10mA each may be wired in line with this output as an alternative to using one of the Status output pins Key Switch Key Switch with 1 Key Switch with 2 in line Stat
19. ccess to the same information as the DX HHP plus a wider range of programmable parameters based on the users access level Chapter 3 Programming the R series 30 dynamic R series 3 2 R series Programmable Parameter Descriptions 3 2 1 Program Identification Parameter Description Range Program Name Enter a name for the program Program Enter a brief description about the program and or its N A Identification intended use 3 2 2 User Personalisation Parameter Description Sets the period of inactivity before the controller will Sleep Timer min put itself to sleep A value of Off means the controller will not go to sleep Off 5 10 15 20 25 30 Sets how the controller will wake up from sleep If set to Key Only the key switch will wake the controller up by turning the key off and then on again If set to Key Throttle Key Throttle either the key switch or the throttle will Key Only wake the controller from sleep Note that if the Sleep Timer is set to Off this setting will have no effect Swap Throttle Set this to a value matching the handedness of the Nis Vas Direction user No is the typical setting for right handed use Sets whether the beeper will operate If Yes the Flash Code Sleep and Reversing Beepers may then be turned off separately If No none of the beeper outputs will operate ash Ode Set to Yes if you would like audible flash codes Beeper Sleep Beeper Set to Yes if you woul
20. d like the controller to beep sis Yas when it goes to sleep Set to Yes if you would like the controller to beep Reversing Beeper ae aes l No Yes when it drives in reverse Wakeup Style Enable Beeper Chapter 3 Programming the R series 3 dynamic R series 3 2 3 Throttle Configuration Parameter Description Sets the throttle type being used Set to wig wag for a bi directional throttle that provides soeed and direction uni polar for a bi Wig wag Throttle directional throttle that provides soeed only direction is chosen by Single Type the forward reverse switch or single ended for a single directional ended Uni throttle that provides soeed only direction is chosen by the forward polar reverse switch Throttle Sets the type of throttle being used Set to single for all throttles with a Single Input single wiper Dual If a Soeed Limit Pot is wired to the dedicated Speed Limit Pot wiper Pin 9 this parameter should be enabled f the Speed Limit Pot is wired in series this parameter should be disabled otherwise the No Yes speed of the scooter will be limited to the Lowest Forward and Reverse Speed settings and or Speed Limit Pot faults generated Speed Limit Pot Set this to account for any slight mechanical offset between the throttle neutral position and the centre position of the throttle wiper The offset is an absolute voltage above or below neutral Reverse Forward speed limit 2V soee
21. d limit 0 63 0 62 Default Neutral neutral offset Scaled to Scaled to Set the percentage of total throttle movement that will result in full speed For instance if a mechanical stop restricts the throttle from moving more than 80 of its full electrical travel setting this to 75 will ensure maximum speed can still be reached Mechanical Mechanical stopper 2 5V stopper Throttle Full Full Scale Scale OV 5V Deflection Deflection set to 50 eee Detauit Neutral neutral offset Deadband 0 100 0 100 Deadband 100 100 Chapter 3 Programming the R series 39 dynamic R series Parameter Description Range Sets the controller response to throttle movement Setting to O will give a linear soeed response to throttle movement i e moving the throttle half of its travel will result in 50 speed Higher settings will 0 100 give an increasingly non linear resoonse and greater resolution at lower speeds i e moving the throttle half of its travel will result in 25 speed Sets how far the throttle must be moved out of neutral before the controller will begin to drive The dead band around neutral is set as a percentage of the total travel Also commonly referred to as Neutral Window Default gt P nena Throttle Dead band set to neutral I offset Throttle 20 O 100 Enable this test to have the controller check the throttle and its associated wiring for electrical faults or fa
22. dynamic R series DR50 and DR90 Scooter Controllers Installation Manual GBK52040 Issue 2 January 2006 dynamic R series About this Manual This manual has been designed to help you install and configure a Dynamic Controls Dynamic R series Scooter Controller for use with a generic brand mobility scooter For this reason there are no guidelines for specific applications If there is a specific requirement for your application please contact Dynamic or one of the sales and service agents as we can assist you to configure the controller for this application Throughout this manual there are a few symbols that will help you quickly identify the purpose of the paragraph that follows Notes amp Precautions Notes provide supporting information for the previous paragraph or section that should be followed in order to install configure and use a R series Scooter Controller safely and efficiently Warnings Warnings provide important information for the previous paragraph or section that must be followed in order to install configure and use a R series Scooter Controller safely and efficiently Programming notes This icon denotes that the paragraph refers to the programming of an R series Scooter Controller The term programming used throughout this manual refers to adjusting parameters and configuring options to suit an application Programming does not change or alter any softwa
23. e company will repair the equipment or at its discretion replace the equioment without charge for materials and labor This Warranty is subject to the provisions that the equipment e has been thoroughly checked upon completion of installation and all programmable options correctly adjusted for safe operation prior to use e has been correctly installed e has been used solely in accordance with this manual e has been properly connected to a suitable power supply in accordance with this manual e has not been subjected to misuse or accident or been modified or repaired by any person other than someone authorized by Dynamic Controls e has been used solely for the driving of electrically powered scooters in accordance with the scooter manufacturer s recommendations Chapter 6 Appendices 54 dynamic R series 6 5 Safety and Misuse Warnings Warnings to be included in the User Manual The following warnings are applicable to the installer and must be passed on to the end user before use of the product Do not install maintain or operate this equipment without reading understanding and following the proper instructions and manuals otherwise injury or damage can result No user serviceable parts inside A warning must be conveyed to the operator that he or she has the responsibility to ensure that the vehicle is kept in a good safe operating condition and to ensure that components such as cables are protected from
24. e proximity to the motors This does not apply to park brake wiring Chapter 2 Installation and Testing 3 dynamic R series 2 2 2 Typical R Series Wiring Installation circuit breaker i 24V Supply p Reduce Speed amp As status Light Key Switch Park Brake Park Brake Release Switch Battery Charger socket Figure 2 Typical Wiring Installation Note Unless otherwise specified all the information in this manual applies to both the DR50 and the DR90 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 To meet ISO requirements the Battery and Motor connectors must be fixed in such a way they cannot be swapped or transposed Alternatively these may be protected by a cover that cannot be removed without the use of tools Chapter 2 Installation and Testing 4 dynamic R series 2 3 Battery Connections Battery Connections Minimum Wire Gauge Function see notes below Battery Positive R50 2 5mm 13 AWG 2 Battery Negative RIO 4 0mm 11 AWG Mating Connector Industry standard 4 6 35mm Quick Connect QC female receptacles available from many manufacturers Use only high q
25. ect positions Throttle OONAPU The Throttle is out of neutral when turning the controller on e Ensure the throttle is in neutral when turning the controller on e The Throttle may require re calibration Speed Pot Fault The throttle soeed limit pot SRW or their associated wiring may be faulty e Check the throttle and soeed pot and associated connections and wiring Motor Voltage Fault The motor or its associated wiring Is faulty e Check the motor and associated connections and wiring Other error The controller may have an internal fault e Check all connections amp wiring Push Rollaway Fault The scooter has exceeded the Push or Rollaway speed limits e Turn the controller off and then on again Chapter 4 Diagnostics 44 dynamic R series 4 2 2 SHARK Flash Codes Flash Description Meaning User Fault Possible stall timeout or user error e Turn the controller off and then on again 2 Battery Fault The batteries may have run out of charge or be too high e Either recharge the batteries or if traveling down a slope reduce your speed e Check the battery and associated connections and wiring 3 Motor Fault The motor has been exceeding its maximum current rating for too long or may be faulty e Turn the controller off leave for a few minutes and turn back on again e Check the motor and associated connections and wiring Pa mer SC sSS SSS 5 Park Brake Fault Either a park brake release s
26. eds this value the status LED will flash slowly 3 times every time the scooter is turned on to indicate the service is due Chapter 4 Diagnostics 48 dynamic R series The Service Scheduler can be enabled and disabled by both the dealer and the OEM by setting the Service Period to 0 hours The OEM can disable the Service Scheduler by setting the Service Scheduler to No The Dealer cannot change this parameter Chapter 4 Diagnostics 49 dynamic R series 5 Specifications 5 1 R series Electrical Specifications Parameter Description 24V supply 2 x 12V in series circuit breaker protected For the DR50 recommended minimum capacity 15 Amp hours For the DR90 recommended minimum capacity 20 Amp hours Compatible Battery Supply Compatible Motor 24V DC permanent magnet type typically rated 100 300 watts Reverse Supply Voltage Volts Current Rating R50 e Continuous 20 C ambient Amps Peak lt 60 secs 20 C initial po 40 a Amps e Boosted Current Amps NO e Boost Time Current Rating R90 e Continuous 20 C ambient e Peak lt 60 secs 20 C initial O y Amps e Boost Current Amps e Boosted Current Amps NO e Boost Time Seconds Park Brake Output e Voltage 24 Volts e Current Quiescent Current idle Charging Current Throttle Resistance Pin 1 to Pin 5 Speed Limit Pot Pin 9 linear Speed Reduction Wiper Pin 4 log Chap
27. emoved while driving Chapter 3 Programming the R series 34 dynamic R series Parameter Description Range This feature will stop the vehicle rolling away on a slope when being pushed Set the maximum speed the vehicle can be pushed by an external force when the controller is on and the park brakes have been electrically released If this speed is exceeded the controller will execute a controlled stop and display a Push Rollaway Fault Turn the controller off and then on again to clear this O 100 fault This feature stops the vehicle from rolling away on a O 100 slope if the controller is turned off and the park brakes are released Roll away Speed Set the maximum speed the vehicle can move when the controller is turned off lf this soeed is exceeded the controller will power on and execute a controlled stop and display a Push Rollaway Fault Turn the controller off and then on again to clear this fault Sets the forward soeed limit when the Speed Reduction O 100 Wiper SRW is active and the wiper is at 100 travel SRW Forward Setting this to 100 will have no effect on soeed no Speed Limit matter the SRW position When the SRW is at 100 travel setting this to 50 will cause the soeed to be limited to 50 of the maximum forward speed Sets the scaling factor to be used on the programmed O 100 Maximum Forward Speed when the Soeed Reduction Wiper SRW is active and the wiper is at
28. encooaeadiniensosanbosdeniesaisipanrcohextohincetnetanise 31 322 User Perondi aloi esnean aE EEI a 31 323 INOMe Congal seenen AE cai caeseaaaeeseciacse 32 324 Dive SOMA GIAC C easevaearttnsescrcdatnareuanvaaciaaacdicncisapnaniessectecttantiaruenvenanets 34 329 QOEM Dive AIP occa caceaetsccatencettssade ssckaceoncataane OR 36 3 2 6 Motor Management siscchecccndssdsnnsdateasadsuedisnssahboieddondstoassesanctenesabiedeadsscoies 37 3 2 7 Park Brake MANAgeMent esssssecesereessserressrrreressssressseeresssrseeesssereessseee 37 3 2 8 Battery MANAQeEMEnt eeeseeecssseeesesereessrsrressrsreeesssreessseeresssssseesssereessseee 39 e STEM OO ee E E AEE E EAA 40 3 2 10 Multi Function Inputs Configuration eeessssssessesssrrcrreseeessrrcereeesseeeeee 4 3 2 11 Multi Function Outputs Configuration eeeesssesseessrsrrreseeessrreereeeesereee 42 Table of Contents dynamic R series 4 DICICINGSING Serene EE E EE E a 4 1 O O a EE E E E TE 43 4 2 FIST OCIS DEO oca E E a 43 4 2 1 Scooter Flash Codes sseeccssseeessssresseserressrrreeesssreesssesressssseeesssereessseee 44 A22 SHARK 1S 8 COO en ai ee eee A5 A23 OS FCS OS eesosa tera teas O EAEE EE 46 A24 Iye SFIS SO OCS escremire E E EAE 46 4 3 DIAGNOSES TOOS oranda ctantgotactasactnaieavadswsadtecanuonse a S aN 47 4 4 Advanced Diagnostics LOGS ecerernsiroieoridirriiis dii in Eea EEA TANE NAN ARE 48 4 5 SE S aa E e E E E E E N E Ore eer 48 SSC ING COINS wricecc retiree ccics
29. er Description Range Pma Sets the maximum value that can be set by a dealer ie Forward Speed ok for Maximum Forward Speed Set to 100 for no effect Limit moxie Sets the maximum value that can be set by a dealer alee Reverse Speed Limit for Maximum Reverse Speed Set to 100 for no effect Lowest Forward Sets the maximum value that can be set by a dealer O 100 Speed Limit for Lowest Forward Speed Set to 100 for no effect Lowest Reverse Sets the maximum value that can be set by a dealer O 100 Speed Limit for Lowest Reverse Speed Set to 100 for no effect a Sets the maximum value that can be set by a dealer O 100 Acceleration Limit l 7 for Forward and Reverse Acceleration Set to 100 for no effect A _ Sets the maximum value that can be set by a dealer O 100 Deceleration Limit for Forward and Reverse Deceleration Set to 100 for no effect Chapter 3 Programming the R series 36 dynamic R series 3 2 6 Motor Management Parameter Description Sets the level of protection applied to the motor Set Off Very Low Motor Protection this depending on the size and quality of your Low Medium Level installed motor If custom the motor set up has been High Very High manually changed in Advanced Mode Custom This parameter automatically sets Motor Protection Motor Continuous Current Motor Case Time Motor Brush Time and Motor Brush Case Ratio Set the power rating of your installed moto
30. for further details about Active States Park Brake Park Brake Release Switch Figure 5 Electronic Park Brake release wiring If the park brake has been electrically released the speed at which the scooter can be pushed is limited by the Push Speed parameter This is to prevent the scooter from rolling away down a slope while the park brakes are electrically released Chapter 2 Installation and Testing 10 dynamic R series 2 5 1 Park Brake Testing The R series has 3 different modes for testing the park brake circuitry These are configured in the Wizard None will disable all park brake testing Pre Drive will test the park brake every time the throttle is moved out of neutral Driving will test the park brake every time the throttle is moved out of neutral and will test the park brake periodically while driving This test may result in some audible noise during driving Park Brake Testing must not be turned off unless there are no park brakes installed 2 6 Battery Charging and Programming Connections Charger Programmer Connections th Fonction re Gauge Mating Connector Part Numbers Dynamic E l Part Part Description Supplier Part GCNO0886 Molex Mini Fit Jr 4 socket housing 39 01 3048 Molex Mini Fit J Receptacles GCNOO8S 16 AWG 0 8 1 3 mm wire PE Molex Mini Fit J Receptacles GCNO 1 18 24 AWG 0 2 0 8 mm wire 97 00 0037 Chapter 2 Inst
31. ging and programming cannot occur using the same inhibit pin at the same time Chapter 2 Installation and Testing 13 dynamic R series 2 7 Multi function Pins The Multi function Pins are a new concept maximizing flexibility in both scooter design and installation Allowing the ability to be configured as one of multiple functions scooter variations typically implemented through wiring changes can now be implemented through programming The R series offers both Multi function Inout and Output pins 2 7 1 Multi function Inputs The Multi function Inputs are activated by an input external to the controller causing it to function in a different way Most functions are fully configurable as to the circuit state in which they are active or operating as well as the ability to become latched where the controller must be turned off and then on again to cancel the function In addition the soeed to which a Slow input decelerates is fully customizable The table below shows the supported functionality for each input pin The specific functionality of each input will be explained in a further section Pin 4 Pin 6 Pin 12 Pin 14 Prog Inh SRW kevesse a reecio rake wwen fT Figure 8 Multi function Input Pins Chapter 2 Installation and Testing 14 dynamic R series The configurable options for each input pin are Active this defines the circuit state at which the function operates Sl
32. ilures Use caution when No Yes disabling throttle testing as throttle faults may not be detected If Throttle Checking is enabled this sets the maximum expected Maximum throttle voltage If exceeded the controller will generate a fault Throttle ne ae l 0 00 5 00 Voltage V indicating an error may have occurred with the throttle or its associated wiring ai If Throttle Checking is enabled this sets the minimum expected Minimum throttle voltage If exceeded the controller will generate a fault Throttle a 0 00 5 00 indicating an error may have occurred with the throttle or its Voltage V associated wiring Enable this test to have the controller check the throttle is in the neutral position when turned on If the throttle is out of neutral the None controller will either cause a latching fault the controller must be Non turned off and then on again or non latching fault release the latching throttle to neutral and the fault will clear OONAPU stands for Out Of Latching Neutral At Power Up Chapter 3 Programming the R series 33 dynamic R series 3 2 4 Drive Performance Parameter Description Maximum O Forward Speed Sets the maximum speed when driving forwards 7 Forai f Sets the rate of acceleration when driving forwards Acceleration TONNAG Sets the rate of deceleration when driving forwards os Deceleration Maximum O 100 Reverse Speed Sets the maximum speed when
33. information to and from the controller The information passed may alter the controller performance The intended power source is a 24V battery supply from the controller The intended environment is indoors or outdoors in dry conditions Chapter 6 Appendices 53 dynamic R series 6 3 Maintenance 1 All vehicle components should be regularly checked for loose damaged or corroded connectors terminals or cabling All cables should be restrained to protect them from damage Damaged components should be replaced 2 All switchable functions on the Dynamic electronics system should be regularly tested to ensure they function correctly 3 All Dynamic electronic components should be kept free of dust dirt and liquids If necessary wipe with a cloth dampened with warm water Do not use solvents or abrasive cleaners 4 There are no user serviceable parts in any Dynamic electronic component Do not attempt to open any case or undertake any repairs or warranty claims will be affected 5 Where any doubt exists consulf your nearest service center 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 6 4 Warranty All equioment supplied by Dynamic Controls is warranted by the company to be free from faulty materials or workmanship If any defect is found within the warranty period th
34. ing the motor circuitry These are configured in the Wizard None will disable all motor testing Open will enable testing of the motors for open circuits Short will enable testing of the motors for short circuits All will enable testing of the motors for both open and short circuits It is highly recommended motor testing is not turned off Chapter 2 Installation and Testing Q dynamic R series 2 5 Park Brake Connections Park Brake Connections pn Foncion WreGause Park Brake Positive R50 0 5mm Park Brake Negative RYO 0 5mm Mating Connector Part Numbers Dynamic Part GCN0884 Molex Mini Fit Jr 2 socket housing 39 01 3028 Molex Mini Fit J Receptacles 18 GCNO771 24 AWG 39 00 0039 The R series supports a 24V park brake which is wired directly through the park brake connector A manual park brake release lever can be fitted so the scooter can be pushed when the controller is turned off To meet ISO requirements if a manual park brake release lever is fitted a micro switch should be connected in such a way that it inhibits driving when the park brake is disengaged Part Description Supplier Part An alternative method of meeting ISO requirements is to wire a micro switch to any multi function input which is configured to inhibit driving and mechanically couple this switch to the park brake release lever Micro Switch oy Inhibits when Park Brake Nor
35. ion Profile 2 When this function is active the drive performance and characteristics as defined in Profile 2 will be used The primary use of this function is to set a Reduce Speed mode Available on Tiller Connector Pins 4 6 and 12 Speed Reduction Wiper Provides variable soeed reduction dependant on the position SRW of a soeed pot 10k log As a conventional User Control potentiometer the SRW Pin 4 supports the use of a 10k logarithmic pot wired as a variable resistor between Pin 4 and Battery of the tiller Pin 13 Alternatively this function can be used as an Anti tio feature to stop the scooter tipping while turning at a high speed the soeed being reduced dependant on how far the tiller is turned Available on Tiller Connector Pin 4 5 If SRW is set to 50 i H 50 speed 100 50 speed M a A B C Slow Slows the scooter to a set speed limit a percentage of the maximum speed Has no effect on scooter acceleration or deceleration Available on Tiller Connector Pins 6 12 and 14 and Charger Programmer Connector Pin 4 Chapter 2 Installation and Testing 23 dynamic R series Slow Stop This function has three states Inactive Slow and Stop When Slow is active the scooter will slow to a programmed speed limit a percentage of the maximum speed Has no effect on scooter acceleration or deceleration When Stop is active the scooter will stop at the programmed Emergency Deceler
36. ion Outputs Configuration Parameter Description Set the type of flash code indication required See Scooter Shark Flash Code Type Diagnostics Section for details about the different Type 3 Type 4 flash code types Sets the function of Pin 3 on the tiller connector It None Brake Light Pin 3 Function may be configured as one of Brake Light Reverse Reverse Light Light Beeper or Status Beeper Status Sets the function of Pin 10 on the tiller connector It None Status High may be configured as one of Status High Status Low Status Low 5V Pin 10 Function 5V Gauge 12V Gauge or other Choose Other Gauge 12V setting when using a custom multi bar LED display for Gauge Other flash codes and battery gauge display Sets the function of Pin 11 on the tiller connector It None Brake Light Pin 11 Function may be configured as one of Brake Light Reverse Reverse Light Light Beeper or Status Beeper Status Chapter 3 Programming the R series 42 dynamic R series 4 Diagnostics Y The R series is not user serviceable Specialized tools are necessary for the repair of any R series component 4 1 Introduction An abnormal condition may be indicated by a flash code on the Status output A Flash Code is a sequence of flashes separated by a pause followed by a repetition of the sequence Additionally Flash Codes may be sounded by connecting a beeper to a suitably programmed output and enabling the BeepO
37. ity algorithm and can output this to either a 5V or 12V voltmeter battery gauge display shown left Alternatively a digital LED display is supported by using the Other setting wiring shown right The algorithm used Is the same as the Dynamic Shark powerchair controller and has built in filters to adjust for voltage dips under load and floating voltages after periods of idling This function is available on Pin 10 of the Tiller Connector and is rated for 1 OMA source Voltmeter Battery Gauge LED Battery Gauge FOOL mamo SV or 12W Analog Voltmeter The battery gauge output can be configured as either a 5V Gauge or 12V gauge Chapter 2 Installation and Testing 26 dynamic R series 2 8 9 Brake and Reversing Lights Pins 3 and Pin 11 on the tiller connector can be configured as either a brake light or reversing light Either light output may be connected to an LED array 500mA or relay driven incandescent or halogen bulb If an LED array is used it must be a 24V array and have its own internal current limiting system An LED array will also need to incorporate reverse polarity protection such as a series diode The brake light will operate whenever the controller decelerates The reversing light will operate whenever the controller is driving in reverse LED Lighting Output Incandescent or Halogen bulb output 24V Relay lt 100mMA 24V Relay with fly back and series diode lt 500mA u B 500mA
38. k on again If an option is greyed out the function does not support this option Chapter 3 Programming the R series Sets the function of Pin 4 on the tiller connector Multi Function Inputs Configuration Function Active Slows to Latches Low High Open None Low or High SRW Low or Profile 2 Open High or Open None Profile 2 Slow Reverse Drive Release Brake Slow Stop Low High Open Low or High Low or Open High or Open O 100 No Yes Low High Open Low or High Low or Open High or Open None Profile 2 Slow Reverse Drive Release Brake Slow Stop O 100 No Yes Low High Open Low or High Low or Open High or Open None Charger Inhibit Slow Slow Stop O 100 No Yes 4 dynamic R series Sets the function of the Program Inhibit pin Pin 14 on the OBC connector It may be configured as one of drive profile swap Slow or Slow Stop Low High Active defines the circuit state at which the None Open function will be active Slows to defines the Charger speed when a Slow function is active Setting Inhibit Slow Low or 0 100 No Yes Low or High the Latching option to Yes will require the Slow Stop Open active state to be cleared and the controller High or turned off and then back on again Open If an option is greyed out the function does not support this option 3 2 11 Multi Funct
39. m s Load Compensation feature the actual voltage output may be up to 10V higher than this setting Maximum Motor Voltage V Chapter 3 Programming the R series 38 dynamic R series 3 2 7 Park Brake Management Parameter Description Set as required to test the park brake In most instances this should be set to Driving which does both a pre drive and driving Park Brake test In some cases the driving test may be excessively noisy in Testing which case set this to Pre drive This will only test the park brake prior to driving It is recommended this test not be disabled for safety reasons None Pre drive Driving Sets the delay between the scooter stopping and the park brakes being applied Park Brake Neutral Delay ms 0 0 25 500 Throttle returned to neutral While stopped sets the delay between throttle movement and the park brakes being disengaged Park Brake _ a Release scree 0 0 25 500 Delay ms Throttle deflected 3 2 8 Battery Management Parameter Description Battery Capacity Setthe capacity of the installed batteries to ensure A hr the most accurate calculation of battery charge Sets the voltage at which the controller will begin slowing the scooter to protect the batteries from an under voltage condition Undervoltage Rollback Start V Sets the voltage at which the controller will stop driving the scooter to protect the batteries from an under voltage co
40. mally Closed Park park brake is Park Brake Brake released Release Switch Figure 3 Recommended Park Brake Wiring Figure 4 Alternative Park Brake Wiring using a mechanical release lever using a mechanical release lever Alternatively a normally closed micro switch can be placed in series with the park brake This will cause a Flash Code 5 to be displayed and the scooter will be Unable to drive To clear the fault engage the park brake and turn the power off and then on again If the park brake is disengaged scooter motion will still be detected in order to limit soeed when freewheeling Chapter 2 Installation and Testing 9 dynamic R series Electronic The scooter must not be driven with the park brake release operated The park brake release should not be operated while on a slope To meet ISO requirements the scooter must not be able to drive when the park brake is disengaged If the controller is turned off and the park brakes are disengaged the Rollaway Speed parameter sets the percentage of maximum scooter speed at which the controller will turn on and decelerate the scooter The park brake may also be released electrically by activating a switch in the tiller If this is required enable this feature on either Pin 6 or Pin 12 of the tiller connector using the Wizard and connect a switch to the appropriate pin The switch can be configured to be active in any of six states Refer to Section 2 7 2
41. nFault feature Depending on the condition the scooter may or may not allow driving In some cases driving may be allowed but in a reduced speed limp mode 4 2 Flash Code Display To make the most of your existing industry knowledge of products the R series has the ability to display a variety of different flash code types These may be one of Scooter Shark Type 3 or Type 4 The Diagnostics Report lists the Flash Code type that the controller is currently set to display See the following sections for each set of flash code details Chapter 4 Diagnostics 43 dynamic R series 4 2 1 Scooter Flash Codes Flash Description Meaning Del a the batteries Dee mea O Recharge the batteries High Battery Fault Battery voltage is too high This may occur if overcharged amp or traveling down a long slope e f traveling down a slope reduce your speed to minimize the amount of regenerative charging Check the battery and associated connections and wiring Current Limit Time out The motor has been exceeding its maximum current rating for too long This may be due to a faulty motor e Check the motor and associated connections and wiring e Turn the controller off leave for a few minutes and turn back on again Park Brake Fault Either a park brake release switch is active or the park brake is faulty e Check the park brake and associated connections and wiring Ensure any associated switches are in their corr
42. ndition Undervoltage Rollback End V Fuel Gauge Sets the voltage at which the fuel gauge will indicate Minimum V an empty battery ae Fuel Gauge Sets the voltage at which the fuel gauge will indicate Maximum V a full battery 19 0 27 0 Chapter 3 Programming the R series 39 dynamic R series Parameter Description Range Fuel Gauge High Sets the voltage at which a high voltage condition 240 320 Warning V will be indicated l Fuel Gauge Low Sets the voltage at which a low voltage condition will 18 0 26 0 Warning V be indicated l PONEI Aar Allows tuning of the battery gauge to the batteries 0 5 Dead band V l 3 2 9 System Options Parameter Description Range If enabled the Status Indicator will flash to indicate Service Scheduler aka No Yes when a service Is due Sets the drive time between service schedules When this number of hours has been exceeded the status indicator will flash to indicate a service is due Service Period hours To reduce current drain this should be disabled if a status LED Is not wired in series with the key switch Key Switch Status LED Chapter 3 Programming the R series AO dynamic R series 3 2 10 Parameter Pin 4 Function Pin 6 Function Description It may be configured as one of Speed Reduction Wiper SRW or drive profile swap Active defines the circuit state at which the function will be active If
43. ns to the controller disable the scooter by one of the following means to prevent accidental movement e Place the battery circuit breaker in the open position e Disconnect the motor or batteries and or elevate the drive wheels For peak performance all wiring should be as short as possible to prevent voltage loss at high current The type of cable used must be appropriate for the mechanical and environmental abuse it is likely fo encounter Heavy gauge wire is mandatory for high current connections batteries and motors For lower current wiring a gauge heavier than required to meet the current carrying requirements is recommended for mechanical robustness All exposed connections should be insulated e g with sleeving to reduce the likelihood of short circuits exposure to water and connection stress Wiring should be suitably restrained to prevent snagging and securely fastened to the oowerchair frame to ensure there is no strain on the connectors Take particular care of the routing and securing of wiring on chairs with moving or movable structures such as seat raise etc Such moving structures have the potential to crush and shear wiring causing potential safety issues To minimize EMC Issues e Wiring should be kept as short as possible e To minimize EMC generating loops pairs of wires should be run together where possible e g run Motor Positive and Motor Negative leads together e Avoid running wires in clos
44. nsure that it provides the necessary degree of motor protection To comply with ISO requirements a red wire for the Battery Positive must be used This must be the only use of a red wire in the controller installation Chapter 2 Installation and Testing 5 dynamic R series Fuse or circuit breaker rating 30 40 Amps 40 50 Amps Fuse or circuit breaker _ S Chapter 2 Installation and Testing 6 dynamic R series 2 4 Motor Connections Motor Connections Minimum Wire Gauge see notes below R50 2 5mm 13 AWG RIO 4 0mm 11 AWG Function Motor Positive 2 Motor Negative Mating Connector Part Numbers Industry standard 1 4 6 35mm Quick Connect QC female receptacles available from many manufacturers Use only high quality parts from a reputable manufacturer The wire gauge recommendations above are the MINIMUM gauge and are generally suitable for runs up to 400 mm Longer runs will require heavier wire typically an extra 1 0 mm for each additional 200 mm run length The heavier the wire the better driving performance will be In particular the length and gauge of wire affects the wire resistance and hence the optimum Load Compensation setting Ensure the Load Compensation parameter is tuned to match the chair wiring to ensure best driving performance These notes are in addition to the General Wiring Notes and Recommendations
45. on mOhm Current Limit A Sets the nominal peak current provided to the motor O 255 Sets a maximum value of Load Compensation that cannot be exceeded by a Dealer O 1020 Chapter 3 Programming the R series 37 dynamic R series Parameter Description Used in conjunction with Boost Time Boost Current gives a brief boost of current greatly improving performance with transient loads such as starting on a hill overcoming castor lock climbing obstacles etc Boost Current A Used in conjunction with Boost Current Boost Time gives a brief boost of current greatly improving performance with transient loads such as starting on a hill overcoming castor lock climbing obstacles etc Boost Time s If the Current Limit is exceeded for this amount of time driving will be disabled and a Flash Code Stall Timeout s displayed Release the wig wag back to neutral and try again Use this feature to protect the motor from Undue stress Before and during driving the motors are tested to ensure they are OK Motors can be tested for open None Open circuits short circuits or both It is recommended this Short All test not be disabled for safety reasons Motor Testing Limits the soeed of the scooter by setting the maximum driving voltage that will be applied to the motor even if the battery voltage is higher If may also prevent the scooter from speeding up when descending a slope Note that due to the syste
46. ottle and its associated wiring for electrical faults or failures Use caution when disabling throttle testing as throttle faults may not be detected Throttle OONAPU Configure whether throttle and or OONAPU Testing testing is conducted and whether a latching fault is entered Throttle Response Sets the controller response to throttle No movement at different amounts of deflection Chapter 2 Installation and Testing 2 dynamic R series 2 8 2 Speed Limit Pot Connections A speed limit pot may be connected either in series with the throttle wiper or in parallel by using the dedicated input Pin 9 Soeed Limit Pot wiper Pin 2 Throttle Positive and Pin 8 Throttle Negative If wiring in series a 25kQ pot should be used If wiring in parallel a 100kQ pot is recommended To increase the likelinood of detecting faults in the throttle wiring and to comply with ISO7176 14 it is recommended an ISO Test resistor be placed into the throttle wiring when installing a soeed pot in series with the Throttle Wiper Speed Pot in Series Speed Pot in Series with ISO Speed Pot in Parallel Resistor Throttle Wiper Throttle Wiper Pin J Q Pin 1 ea Ty ISO TEST Pin9 18 RESISTOR 4k7 10k is POT LO Speed Pot in Series with 2 ISO Resistors As an alternative to wiring a single ISO Test Resistor in the Throttle Wiper an ISO Test Resistor may be wired in series with each of Throttle Positive and Throttle
47. ows to if a Slow function is active this is the soeed the scooter will be limited to Latched this defines whether the function is latching If a function is latched the active condition will have to be removed and the controller turned off and then on again before the function will be turned off Due to the nature of the different functions some functions do not support the complete range of configuration See the table below for further details Active Slows to Latched Profle2 2 Slow iene if Slows to is set to QO Reverse Drive 2 Drive Slow Stop Latches when stopped Chapter 2 Installation and Testing 15 dynamic R series 2 7 2 Active States The Multi function Input pins support multiple active states that is the state of the circuit at which the function operates The active state for each function is configurable using the Wizard There are three typical active states along with three options that combine two of the active states Active Low Active Low or High Chapter 2 Installation and Testing 6 dynamic R series 2 7 3 Slows to The Slows to parameter sets the soeed to which the controller slows down when a Slow function is active If set to 0 the controller will decelerate at the programmed Emergency Deceleration rate and apply the park brake If set to 100 the Slow function will have no effect Any values between 0 and 10
48. r This will scale the Motor Protection Level to suit the size of your O 2550 motor Motor Power Rating W Turn the motor protection feature on or off This will be automatically set by the Motor Performance Level parameter Motor Protection Part of the motor protection feature this will be et aa automatically set by the Motor Protection Level 0 255 parameter Please contact Dynamic before setting Current A this parameter Part of the motor protection feature this will be Motor Case automatically set by the Motor Protection Level Time parameter Please contact Dynamic before setting this parameter O 128 Part of the motor protection feature this will be Motor Brush automatically set by the Motor Protection Level Time parameter Please contact Dynamic before setting this parameter O 510 Part of the motor protection feature this will be ae ase automatically set by the Motor Protection Level 0 100 Ratio parameter Please contact Dynamic before setting this parameter Motor Reverse Reverses the polarity of the motor output No Yes Matches the controller to the motors Load Compensation ensures the controller will provide a Load oT ei Compensation constant soeed regardless of the driving conditions O 1020 mOhm for example when going over curbs and ramps The controller will not drive to its potential unless this is set correctly Maximum Load Compensati
49. r also supports the new Multi function pins that can be configured for alternative functionality depending on application requirements Where the multi function pins are listed below the bold text indicates the recommended default functions Tiller Connections a Multi function Output Status Low 0 2mm JALLE pogaca 10 11 Multi function Output none Multi function Input Reverse Drive Battery Negative 1 0mm Multi function Input Charger Inhibit 0 2mm Mating Connector Part Numbers Dynamic l Part Description Supplier Part GCN0887 Molex Mini Fit Jr 14 socket housing 39 01 2145 Molex Mini Fit Jr Receptacles GENOOBS 16 AWG 0 8 1 3 mm wire eae Molex Mini Fit Jr Receptacles GENO771 18 24 AWG 0 2 0 8mm wire a ern Chapter 2 Installation and Testing 19 dynamic R series 2 8 1 Throttle Connections The R series supports 5kQ wig wag uni polar and single ended throttles for soeed control These are connected to Pin 1 Throttle Wiper Pin 2 Throttle Positive and Pin 8 Throttle Negative The throttle type and set up is fully configurable using the Wizard Once the throttle type has been defined the Hand Held Programmer can be used to calibrate the controller for the throttle being used i e ou 3 Throttle j AO i Throttle Pot a Wig Wag and Unipolar Single Ended Throttle Type Wig Wag 5 Neutral Forward Rever
50. ration prior to use It is the responsibility of the installer to ensure that accessories connected to the scooter wiring do not interfere with operation of the controller Chapter 6 Appendices 56 dynamic R series 6 7 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 dependant on a particular installation each variation must be tested The guidelines in this section are written to assist with meeting EMC requirements Minimizing Emissions Motors Motor brushes generate electromagnetic emissions It may be necessary to fit capacitors between the brush holders and motor case Ensure the leads are kept as short as possible A suitable capacitor is 4n7 250V Polypropylene Wiring Keep wire lengths as short as practical for a tidy layout Minimize any wire loops particularly loops of single wires as opposed to wire pairs Endeavor to run wires in pairs or bunches Where practical tie cables to wheelchair frame Immunity to Radiated Fields Follow the wiring recommendations for minimizing emissions Immunity to ESD Follow the wiring recommendations for minimizing emissions Ensure all vehicle sub frames are electrically connected
51. re within the controller and is performed using a controlled programming tool available only to authorised personnel The R series Scooter Controller is not user serviceable Specialized tools are necessary for the repair of any R series 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 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 powerchair system or mobility scooter control system renders the manufacturer s warranty void and the manufacturer free from liability Dynamic and the Dynamic 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 About this Manual dynamic R series 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 hard copy or electronic format are protected b
52. rithms and speed reduction wiper SRW ensuring improved curb climbing and hill starting capabilities and a refined drive experience Intelligent motor and battery management providing automatic power flow optimization auto battery configuration 5V and 12V battery capacity outputs and in depth battery logging and analysis tools Drop in replacement with industry standard connections and mounting support for a range of battery types new multifunction pins and ultra flexible drive inhibits Advanced diagnostics and servicing tools including event and drive time logging and programmable servicing scheduler A host of new features including 2 drive profiles brake and reverse lights reversing beeper and electronic park brake release Chapter 1 Introducing the R series dynamic R series 2 Installation and Testing 2 1 Mounting A A oO 113 mm oO my 1925mm on JIN 3 J 925mm Figure 1 R series Mounting Configuration e The position and orientation should give maximum mechanical protection to the controller e Mount out of the path of water splashes from wheels or cowling and protect the connector panel from direct splashing e As drain holes are incorporated within the connector panel mounting on an inclined plane would facilitate drainage e The controller must be mounted so that water will drain away from the controller e Failure to adhere to the mounting conditions specified may
53. se A wig wag throttle has its neutral at its centre point and full forward and reverse soeeds at the opposite extents The direction of forward and reverse to suit the users handedness can be swapped by programming mow 5s aA I Neutral Forward Forward Forward Reverse switch A uni polar throttle has its neutral at its centre point and full soeed at the opposite extents The direction of movement is defined with the use of a switch Single Ended A ANNS Neutral Forward Forward Reverse switch A single ended throttle has its neutral at its minimum extent and full soeed at the opposite extent The direction of forward and reverse can be swapped Chapter 2 Installation and Testing 20 dynamic R series The configurable options for the throttle are for specific details about each of these options please refer to the programming section Option Description HHP Auto configured Throttle Type One of Wig Wag Uni polar or Single ended a Swap Throttle Sets the throttle direction that gives forward Direction movement when using a wig wag throttle Throttle Neutral Offset Sets an offset from the expected neutral to allow for mechanical variance in throttles Throttle Full Scale Sets the amount of throttle movement required Deflection to achieve 100 soeed demand Throttle Dead band Sets how far the throttle must be moved before the controller will drive Throttle Testing Enable this test to have the controller check the thr
54. should be released Turn the system off at once and consult your service agent The scooter must not be driven with the park brake release operated The park brake release should not be operated while on a slope Ensure that the battery charger is installed with a drive inhibit Consult your dealer or vehicle manufacturer The scooter should not be driven if it is indicating a low battery Chapter 6 Appendices 55 dynamic R series If the vehicle speed surges when going down hill the common reason is the operation of an over voltage protective device When running down hill the braking energy from the motor is sent to the battery which charges it However if the battery is fully charged it cannot accept the generated energy without dramatically increasing its voltage If this over voltage condition were allowed to continue there would be a risk of damage to the battery or an explosion To prevent these risks the controller forces the vehicle to slow down until the battery voltage drops to a safe level after which it allows the vehicle to speed up again To prevent speed surging with charged batteries we advise operators to descend hills slowly Operation of a scooter on steep slopes could be hazardous No connector pins should be touched because contamination or damage due to electrostatic discharge might result The controller should not be stored or operated outside of the minimum or maximum temperature ranges specified in
55. ter 5 Specifications 50 dynamic R series 5 2 Physical Specifications Parameter N EEEF eum 131 5 mm s ee a For Mounting Hole dimensions refer to Section 2 1 Chapter 5 Specifications 5 dynamic R series 6 Appendices 6 1 Accessories Parts List Dynamic R Series Installation Manuals Part Description DCL Part Qty Unit Dynamic kR series Installation Manual GBK52040 1 Dynamic R Series Connectors Part Description DCL Part Qty Unit R50 Connector Set DR CONSETA Dynamic R Series Programming Accessories Part Description DCL Part Qty Unit release Dynamic DR Programming Adapter DR_ADAPT l Molex Programming Adapter DR PRGLMO2 l Wizard 5 Kit Programming Kit Contains DWIZ5 KIT software cables and adapter no dongle Wizard 5 Software Only CD DWIZ5 SW Wizard Dongle OEM or Dealer version DWD OEM or Parallel Port DWD DLR Wizard Dongle OEM or Dealer version USB DWD OEM U or l DWD DLR U DX Hand Held Programmer DX HHP 1 Chapter 6 Appendices 52 dynamic R series 6 2 Intended Use and Regulatory Statement Intended Use The R Series scooter controller is intended to provide soeed control for small or medium sized scooters that utilize a single 24V DC brushed motor and integrated park brake The controller will resoond to user input demand via an analog input in terms of direction forward and reverse and
56. th the Wizard and DX Hand Held Programmer DX HHP can be used to program kR series to provide superb performance for a wide variety of scooter configurations and users Scooters fitted with a standard 3 pin XLR type Battery Charger socket can be programmed by connecting the Wizard or DX HHP into that socket via a DR ADAPT Programming Adaptor Scooters without an XLR style battery charger socket can be programmed by connecting the Wizard or DX HHP into the R Series Charger Programmer socket using a combination of the DR ADAPT Programming Adapter and a DR PRGLMO2 Connector Adaptor DR ADAPT Programming Adaptor Charger Socket eT m a for Off board _ Charger Charger Programmer Socket DR PRGLMO2 Connector Adaptor Chapter 3 Programming the R series 29 dynamic R series 3 1 1 DX HHP R Series is programmed during manufacturing with default settings to suit many scooter users Using the DX HHP programmer allows for field adjustments to many programmable settings R Series has 2 programmable profiles which may be accessed using the DX HHP Care must be taken while driving the scooter with DX HHP plugged in Bring the scooter to a complete stop before changing between Profiles 1 and 2 Changing profiles while the scooter is in motion may result in an unexpected speed increase or decrease and result in danger to the user 3 1 2 Dynamic Wizard The PC based Dynamic Wizard provides a
57. the throttle backwards and forwards and ensure that the wheels resoond smoothly and in the correct direction Release the throttle to neutral and listen for the click of the park brakes re engaging Turn off the R series and remove the blocks from under the scooter Turn the R series back on and turn the speed dial if installed to the lowest soeed setting Sit in the scooter and drive in all directions slowly checking for precise and smooth control Repeat at higher speeds Drive the scooter on a 1 6 ramp and check for normal power smoothness and parking Test all other hardware fitted Repeat testing until the vehicle performs as expected Chapter 2 Installation and Testing 28 dynamic R series 3 Programming the R series Performance adjustments should only be made by professionals in the health care field or by persons fully conversant with the adjustment process and the operator s capabilities Incorrect settings or programming in an unsafe location could cause injury to the operator or bystanders or damage to the vehicle or surrounding property After the vehicle has been configured check to make sure 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 intended operation cannot be achieved contact your service agent 3 1 Introduction Bo
58. uality parts from a reputable manufacturer The wire gauge recommendations above are the MINIMUM gauge and are generally suitable for runs up to 800 mm Longer runs will require heavier wire typically an extra 1 0 mm for each additional 400 mm run length The heavier the wire the better driving performance will be These notes are in addition to the General Wiring Notes and Recommendations as described in Section 2 2 1 If the two batteries are permanently wired together eg in a single battery box the best position for the circuit breaker is between the two batteries If the batteries are separated individual battery boxes each battery requires a circuit breaker A slow acting thermal type circuit breaker is suggested The final connection to the Battery Positive terminal should not be made until The scooter is completely wired and ready for testing as described in the Testing section The R series has been designed to perform optimally with multiple battery types see below By default Lead Acid and Gel Cell 24 V deep cycle batteries rated between 20 120 Amp hours are to be used A thermal circuit breaker or fuse must be installed between the battery supply and the controller to protect both the batteries and the system wiring This shall be mounted as close as possible to the batteries The thermal circuit breaker should have a trip rating no higher than the current limit of the controller Check thoroughly to e
59. uite 2 Fax 1 440 979 1028 North Olmsted OH 44070 USA E mail sales dynamic controls com Sales amp Service Dynamic North America Sales amp Service Dynamic Control Service Electronic Mobile Service Australia Service Agent Electronic Mobile Service 46 Berripa Close Ph 61 2 9887 2824 North Ryde Fax 61 2 9887 2114 Sydney NSW Australia 2113 E mail fredems ozemail com au Asia Sales Dynamic Controls Ltd Asia Floor 4 2 No 59 Ph 886 955 335 243 Tien Hsiang Rd Fax 886 2 2598 1562 Chung Shan District Taipei 104 Taiwan R O C E mail sgoh dynamic controls co nz Chapter 6 Appendices 59
60. ults and allows for a faster more efficient service process It will also allow for feedback to be given to the user if their use of the scooter is causing any SSUES There are two sources of the advanced diagnostics logs the Usage Counters provide detailed information on the use of the scooter the Run time Readings provide real time analysis of the system in operation Usage Counters available in both Wizard and HHP Counter Description Powered Up Time The total amount of time hours the controller has been turned on Powered Up Count The number of times the controller has been turned on The total amount of time hours the controller has been driving Drive Time oark brakes disengaged The number of times the controller has been driving number of Drive Count i l times the park brakes have disengaged Run time Readings available in HHP Technician mode only Reading Description Battery V The voltage of the batteries Motor V The voltage being applied to the motor Motor A The current being applied to the motor Temperature C The internal temperature of the controller Throttle V The voltage of the throttle 4 5 Service Scheduler The Service Scheduler has been designed as a preventative maintenance feature allowing the OEM to put in place scheduled servicing plans for their scooter customers If enabled a Service Period can be programmed into the controller Once the Drive Time exce
61. us LED in line Status LED E 3 Key Switch Key Switch 1 10mMA Pin 5 Pin 5 M Status LED 2 10MA Key Switch a Status LEDs Pin 5 The ability to install an LED in line with the Key Switch may be disabled by setting Key Switch Status LED to no This will decrease the current drain of the R series by 1OmMA whenever the key is turned on 2 8 6 Status Indicator Output Pins 3 10 and 11 on the tiller connector can be configured as dedicated status outputs Pin 10 also has the ability to be active either high or low Pin 10 is rated for 50mMA sink and 10mA source whereas Pins 3 and 11 are capable of an output up to 500mA Select a resistor to limit LED current if Pin 10 Status Output Options Pin 3 and 11 Status Output Options Status High Status Low Status High Status B B B Pin 10 gt 10MA _ SOMA 24V Status 24V Status Status a LED LED LED The status indicator can be configured to display 1 of 5 different diagnostics flash code Chapter 2 Installation and Testing 25 dynamic R series 2 8 7 Beeper Output Pins 3 and 11 on the tiller connector can be configured as a beeper output They are both capable of an output up to 500mA Beeper Pin 3 or 11 The following beeper functions can be enabled or disabled beeping when entering sleep mode beeping the fault codes beeping when driving in reverse 2 8 8 Battery Gauge Output The R series has incorporated a battery capac
62. witch is active or the park brake is faulty e Check the park brake and associated connections and wiring e Ensure any associated switches are in their correct positions Throttle Fault The Throttle is out of neutral when turning the controller on The throttle or soeed limit pot or their associated wiring may be faulty Ensure the throttle is in neutral when turning the controller on The Throttle may require re calibration Check the throttle and soeed pot and associated connections and wiring System Fault The controller may have an internal fault e Check all connections amp wiring Chapter 4 Diagnostics 45 dynamic 4 2 3 Type 3 Flash Codes Flash Description Low Battery Bad Motor Connection Motor Short Circuit unused Unused 6 Drive inhibi Throttle Fault Controller Fault 8 9 Park Brake Fault 10 High Battery Voltage 4 2 4 Type 4 Flash Codes R series A Type 4 flash code involves the use of twin flashes to identify the type of fault Flash Description 1 1 Thermal Cut back Thermal Cutback Brake Off Fault High Pedal Disable Fault Current Sense Fault 4 3 Motor Voltage Fault EEPROM Fault Power Section Fault Chapter 4 Diagnostics 46 dynamic R series 4 3 Diagnostics Tools While the R series may indicate the abnormal condition a hand held programmer or the PC based Wizard 5 will provide more detailed information on the fault
63. y copyright laws and other intellectual property laws Copyright 2006 Dynamic Controls Christchurch New Zealand All rights reserved About this Manual dynamic R series Contents 1 Introducing the R series csscssccsscesccesccsccescescees I 2 Installation and Testing ccscccsccesccsscssccescesceecees 2 2al A eee E A A 2 2 2 Connections and Wiring sasssctecavcodedsniocstnagracadteassasimetstojandiectneodatoesaseneetiiaedsbinieasiacgduesd 3 2 2 1 General Wiring Notes and Recommendations essesescssrrrreeeeessrcrree 3 2 2 2 Typical R Series Wiring Installation eeseesssseeeseesssrrrersesssrrrrrresesrrerereess 4 2 3 BUMS Olde ON arccosscencions cescnteacsacc EE act avesenctocessaceccausatenncuusasctes 5 2 4 IVOTCINC INS CIO 10S carina ents idotiate nds conasadiecatacaiaadateniedenscaedieastecuiupastesieattegusdenteatectunawieods 7 24V Motoi Frolechon Lovells esserne rr a EET 8 DEF MOTO VSS eE OEEO 8 2 9 FaK Brake COnN COM cctaccetssctatacostconeisadevanvocansditatectaeobestaaeeunecscncetastdowiac macdaouncectan 9 251 PaKBOKS VES IG so sedsansessncconsiccats nerne nE E 1 2 6 Battery Charging and Programming CONNECTIONS sessssessrreseessrrrrrresessrreeeen 1 2 6 1 Battery Charger CONMECTIONS lt cccacansvindidenienadsspeescxsasciaunbassedsentsaiesbaeeiasas 12 2 6 2 Programmer Connections cecincsecnatercesiaevnssocsnssciebesdsnadoasetowimdtucsiateeraevsides 13 2 7 MONACOON PO e A A R A 14

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