Rhino2-Installation-Manual-Issue-3_0.pdf

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R
HINO
2
DS90, DS120, DS160 and DS180
DS90-ACT, DS120-ACT and DS160-ACT
R
HINO
2 Classic
DS70C, DS110C and DS160C
Scooter Controllers
Installation Manual
Rhino2 Installation Manual Issue 3.0, May 2013
GBK51948
About this Manual
This manual can help you understand and install the Dynamic Controls (D
YNAMIC
) R
HINO
2 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:
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, D
YNAMIC
reserves the right to update this manual.
This manual supersedes all previous issues, which must no longer be used.
D
YNAMIC
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.
D
YNAMIC
, the D
YNAMIC
logo, the R
HINO
logo, the R
HINO
2 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.
D
YNAMIC
owns and will retain all trademark rights and D
YNAMIC
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 2011Dynamic Controls. All rights reserved.
About this Manual
Contents
1.
2.
3.
Introduction to the
RHINO2
............................................ 7
1.1
1.2
2.1
2.2
3.1
3.2
3.3
R
HINO
2 ...................................................................................................... 7
R
HINO
2 C
LASSIC
......................................................................................... 8
Electrical Specifications ........................................................................ 9
Physical Specifications ........................................................................ 11
Mounting ............................................................................................... 12
3.1.1 General Mounting Conditions ................................................ 12
3.1.2 Mounting Orientation .............................................................. 13
Attaching the terminal cover ............................................................ 14
Connections and Wiring ..................................................................... 15
3.3.1 General Wiring Recommendations ....................................... 15
3.3.2 Wiring Diagram for DS70C, DS110C, DS90 and DS120 ........ 17
3.3.3 Wiring Diagram for DS160, DS160C and DS180 .................... 17
3.3.4 Wiring Diagram for DS90-ACT and DS120-ACT .................... 18
3.3.5 Wiring Diagram for DS160-ACT ............................................... 18
Battery Connections ........................................................................... 19
Motor Connections ............................................................................. 22
3.5.1 Motor Protection ....................................................................... 23
3.5.2 Motor Testing ............................................................................. 24
Park Brake Connections ..................................................................... 24
3.6.1 Park Brake Testing ..................................................................... 26
Battery Charging and Programming Connections ........................ 26
3.7.1 Battery charger connections ................................................. 27
3.7.2 Programmer Connections....................................................... 29
Actuator / Seat Lift Wiring (DS90-ACT, DS120-ACT, DS160-ACT) ... 30
3.8.1 Overview .................................................................................... 30
3.8.2 Wiring .......................................................................................... 31
Tiller Connector .................................................................................... 33
Throttle Configuration ......................................................................... 34
3.10.1 Protection against open-circuit, short-circuit and leakage
current 34
3.10.2 Single throttle wiper .................................................................. 36
3.10.2.1 Additional hardware to comply with ISO7176-14 2008 ........... 36
Specifications .................................................................. 9
Installation and Testing ................................................. 12
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3.10.3 Neutral Detect .......................................................................... 37
3.10.3.1 Installation of a Neutral Detect switch ....................................... 38
3.10.4 Two throttle wipers - mirrored ................................................. 39
3.10.5 Throttle Calibration ................................................................... 39
3.10.6 Speed Limit Pot Connections ................................................. 40
3.10.6.1 In series with the throttle wiper .................................................... 40
3.10.6.2 In parallel with the throttle ............................................................ 41
3.10.7 Alternative Speed Reduction Options .................................. 42
3.10.8 Tiller Battery Supply ................................................................... 43
3
3.11
3.12
3.10.9 Key Switch Input ....................................................................... 44
3.10.10 Status Indicator Output ...................................................... 44
3.10.11 Beeper Output ..................................................................... 45
3.10.12 Battery Gauge Output........................................................ 45
3.10.13 Brake and Reversing Lights ................................................ 46
Multifunction Pins ................................................................................. 47
3.11.1 Multifunction Inputs .................................................................. 47
3.11.2 Multifunction Outputs .............................................................. 49
Testing .................................................................................................... 50
The Hand Held Programmer (HHP) ................................................... 52
4.1.1 Programming menu ................................................................. 53
4.1.1.1
4.1.1.2
4.1.1.3
Profile 1/2 ......................................................................................... 53
Non-profiled .................................................................................... 54
Throttle calibration ......................................................................... 55
4.
Programming the
R
HINO
2..............................................
51
4.1
4.2
4.3
4.4
4.5
4.1.2 Diagnostics menu ..................................................................... 57
4.1.3 Technician menu ...................................................................... 58
Dynamic Wizard ................................................................................... 59
4.2.1 Software version and module version ................................... 59
Parameter List ....................................................................................... 60
Parameter variations ........................................................................... 64
4.4.1 Variations by module ............................................................... 64
4.4.2 Variations by Profile 1 ............................................................... 64
4.4.3 Variations by Profile 2 ............................................................... 64
Parameter Descriptions ...................................................................... 65
4.5.1 User Personalisation .................................................................. 65
4.5.1.1
4.5.1.2
4.5.1.3
4.5.1.4
4.5.1.5
4.5.1.6
4.5.1.7
4.5.1.8
4.5.1.9
4.5.1.10
4.5.1.11
4.5.1.12
4.5.2.1
4.5.2.2
4.5.2.3
4.5.2.4
4.5.2.5
4.5.2.6
4.5.2.7
4.5.2.8
4.5.2.9
4.5.2.10
4.5.2.11
4.5.2.12
Sleep Timer....................................................................................... 65
Wakeup Style .................................................................................. 65
Swap Throttle Direction ................................................................. 66
Enable Beeper ................................................................................ 66
Flash Code Beeper ........................................................................ 66
Sleep Beeper ................................................................................... 67
Motion Beeper ................................................................................ 67
Reversing Beeper ........................................................................... 67
Beeper Timing ................................................................................. 67
Deep Discharge Beeper ............................................................... 68
Sleep on Fault or Inhibit ................................................................. 68
Power Off after Sleep .................................................................... 68
Throttle Type .................................................................................... 69
Throttle Input.................................................................................... 69
Throttle Neutral Offset .................................................................... 70
Throttle Full Scale Deflection ........................................................ 70
Throttle Response ........................................................................... 71
Throttle Dead-band ....................................................................... 71
Throttle Testing ................................................................................ 72
Maximum Throttle Voltage ........................................................... 72
Throttle OONAPU Testing............................................................... 73
Throttle Fault Non Latching .......................................................... 73
Speed Limit Pot ............................................................................... 74
Slam Brake ....................................................................................... 75
4.5.2 Throttle Configuration .............................................................. 69
4
4.5.2.13 Enable SRW Open Circuit Testing ................................................ 75
4.5.3 Drive Performance ................................................................... 75
4.5.3.1
4.5.3.2
4.5.3.3
4.5.3.4
4.5.3.5
4.5.3.6
4.5.3.7
4.5.3.8
4.5.3.9
4.5.3.10
4.5.3.11
4.5.3.12
4.5.3.13
4.5.3.14
4.5.3.15
4.5.3.16
4.5.3.17
4.5.3.18
4.5.4.1
4.5.4.2
4.5.4.3
4.5.4.4
4.5.4.5
4.5.4.6
4.5.5.1
4.5.5.2
4.5.5.3
4.5.5.4
4.5.5.5
4.5.5.6
4.5.5.7
4.5.5.8
4.5.5.9
4.5.5.10
4.5.5.11
4.5.5.12
4.5.5.13
4.5.5.14
4.5.5.15
4.5.5.16
4.5.5.17
4.5.5.18
4.5.6.1
4.5.6.2
4.5.6.3
4.5.7.1
4.5.7.2
4.5.7.3
4.5.7.4
Maximum Forward Speed ............................................................ 75
Forward Acceleration ................................................................... 76
Forward Deceleration ................................................................... 77
Maximum Reverse Speed ............................................................. 78
Reverse Acceleration .................................................................... 78
Reverse Deceleration .................................................................... 79
Lowest (Minimum) Forward Speed ............................................. 79
Lowest (Minimum) Reverse Speed .............................................. 80
Soft Start Period .............................................................................. 80
Soft Finish .......................................................................................... 81
Emergency Deceleration ............................................................. 81
Slam Braking .................................................................................... 82
Push Speed ...................................................................................... 82
Roll-away Speed ............................................................................ 83
Speed Reduction Wiper (SRW) parameters .............................. 83
SRW Scaling Resistor (Ohm) .......................................................... 84
SW Current Limit Decel Scalar ..................................................... 85
HW Current Limit Decel Scalar ..................................................... 85
Maximum Forward Speed Limit ................................................... 86
Maximum Reverse Speed Limit .................................................... 86
Minimum Forward Speed Limit .................................................... 86
Minimum Reverse Speed Limit ..................................................... 87
Acceleration Limit .......................................................................... 87
Deceleration Limit .......................................................................... 87
Motor Protection ............................................................................ 87
Motor Protection Parameters....................................................... 88
Thermal Rollback Start / End ........................................................ 88
Motor Reverse ................................................................................. 89
Load Compensation ..................................................................... 89
Maximum Load Compensation .................................................. 91
Load Compensation Damping ................................................... 91
Remembered Load Compensation ........................................... 92
Current Limit .................................................................................... 92
Boost Current/ Boost Time ............................................................. 93
Stall Timeout..................................................................................... 93
Motor Testing ................................................................................... 94
Maximum Motor Voltage ............................................................. 95
Max Motor V Scalar ....................................................................... 95
Max Motor V Demand Limit ......................................................... 96
Max Motor V Ramp Down Time .................................................. 96
Max Motor V Recovery Time ........................................................ 96
Downhill Speed Limiting ................................................................ 96
Park Brake Testing ........................................................................... 97
Park Brake Neutral Delay .............................................................. 98
Park Brake Release Delay ............................................................. 99
Overvoltage Rollback ................................................................... 99
Undervoltage Rollback ................................................................. 99
Battery Gauge Minimum/Maximum ......................................... 100
Battery Gauge Warning .............................................................. 101
4.5.4 OEM Drive Limits ........................................................................ 86
4.5.5 Motor Management ................................................................ 87
4.5.6 Park Brake Management ........................................................ 97
4.5.7 Battery Management .............................................................. 99
5

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