Dynamic DX User Manual

Modular

powerchair control system

DX SYSTEM MANUAL

About this Manual

This manual can help you understand and install the Dynamic Controls DX System. It describes the general principle, 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 DX Module or DX component manuals, as well as all applicable Dynamic TSBs, application notes and service instructions.

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

Notes & Precautions:

Notes provide supporting information for the previous paragraph or section that should be followed in order to install, configure, and use the product 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 the product safely and efficiently.

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 term ‘accessory’ used in this manual refers to equipment that is ancillary to the main functioning of the DX system. It does not refer to an accessory of the powerchair. The DX System is a component of the powerchair.

DX 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 DX System.

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 renders the manufacturer’s warranty void and the manufacturer free from liability.

Dynamic, the Dynamic logo and the DX logo are trademarks of Dynamic Controls. All other brand and product names, fonts, and company names and logos are trademarks or registered trademarks of their respective companies.

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

All materials contained within this manual, in hard-copy or electronic format, are protected by copyright laws and other intellectual property laws. © Copyright 2007 Dynamic Controls. All rights reserved

Contents

1 Introduction to the DX System .................................9

The heart of the DX System..................................................................... 9

DX System extensions............................................................................... 9

DX System connections ........................................................................... 9

One system fits all ..................................................................................... 9

2 A typical DX powerchair setup..............................10

2.1 Installation procedure................................................................... 11

2.1.1 General wiring recommendations.............................12

2.2 The batteries...................................................................................13

2.2.1 Battery type ................................................................... 13

2.2.2 Battery capacity ........................................................... 13

2.2.3 Battery charging ........................................................... 15

2.2.4 Battery protection......................................................... 16

2.2.4.1 Thermal circuit breakers................................................. 16

2.2.4.2 Battery Saver.................................................................... 16

2.2.4.3 High Voltage Rollback.................................................... 16

2.3 The motors....................................................................................... 17

2.3.1 Motor types....................................................................17

2.3.2 Motor connections ....................................................... 18

2.3.3 Motor resistance............................................................ 18

2.4 The parkbrakes............................................................................... 19

2.4.1 Parkbrake types............................................................. 19

2.4.2 Parkbrake configurations............................................. 19

2.4.2.1 Two 24V parkbrakes – Dual, M1 and M2..................... 19

2.4.2.2 One 24V parkbrake – Single, M1 only.......................... 20

2.4.2.3 Two 12V parkbrakes........................................................ 21

2.4.3 Manual parkbrake release switch.............................. 22

2.4.4 Mechanical parkbrake release..................................22

2.4.5 Parkbrake operation and programming...................22

2.4.5.1 Electrical delay................................................................ 23

2.4.5.2 Mechanical delay........................................................... 23

3 The DX BUS ...............................................................25

3.1 The DX BUS cable........................................................................... 26

3.2 DX BUS Module connection layout............................................. 28

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4 The DX Power Module.............................................29

4.1 General Power Module features................................................. 29

4.2 Available Power Modules............................................................. 30

4.3 Power Module programmable parameters.............................. 31

4.3.1 List of parameters.......................................................... 31

4.3.2 Motors............................................................................. 33

4.3.2.1 Current Limit.....................................................................33

4.3.2.2 Hardware Current Limit Scaler......................................33

4.3.2.3 Load Compensation....................................................... 34

Determining the motor resistance................................35

4.3.2.4 Temp Dependent Load Comp..................................... 40

4.3.2.5 Veer Compensation.......................................................40

Adjusting Veer compensation with the HHP............... 41

4.3.2.6 Emergency Deceleration............................................... 41

4.3.2.7 Left/Right Motor Swap.................................................... 42

4.3.2.8 Motor Invert......................................................................42

4.3.2.9 Motor Stall......................................................................... 43

4.3.2.11 Motor Continuity Test...................................................... 43

4.3.2.12 Maximum Motor Volts..................................................... 44

4.3.2.13 Input Demand Scaler ..................................................... 44

4.3.3 Park Brakes..................................................................... 45

4.3.3.1 Park Brake......................................................................... 45

4.3.3.2 Brake / Bridge Off Delay ................................................ 45

4.3.3.3 Test Park Brake Driving.................................................... 45

4.3.4 Battery............................................................................. 46

4.3.4.1 Battery Guess...................................................................46

4.3.4.2 Voltmeter Battery Gauge .............................................. 46

4.3.4.3 Slow Batt Time Scale Driving.......................................... 46

4.3.4.4 Batt Gauge Ramp Rate.................................................47

4.3.4.5 Batt Gauge Threshold..................................................... 47

4.3.4.6 High Voltage parameters..............................................47

4.3.4.7 Temperature Rollback.................................................... 48

4.3.4.8 Halve Turning Gain.......................................................... 48

5 The DX Master Remote ...........................................49

5.1 Introduction.................................................................................... 49

5.1.1 The User Control Module (UCM).................................50

5.1.2 The physical user interface.......................................... 50

5.2 Available Master Remotes........................................................... 51

5.2.1 Master Remotes with joystick ...................................... 51

5.2.2 Master Remotes without joystick ................................52

5.3 Programmable parameters......................................................... 53

5.3.1 Speed and acceleration principles........................... 53

5.3.1.1 Speed Demand............................................................... 53

5.3.1.2 Speed limiting options.................................................... 54

5.3.1.3 Acceleration and deceleration.................................... 56

Damping Point................................................................. 57

Soft-Start Acceleration ................................................... 57

5.3.2 Drive Profiles...................................................................58

5.3.2.1 The principle..................................................................... 58

5.3.2.2 Drive Profile 0.................................................................... 59

5.3.2.3 Speed setting recommendations................................. 59

Programming Drive Profiles as a digital Speed Pot.... 59

Programming Drive Profiles for different environments

............................................................................................ 60

5.3.2.4 Single Drive Profile mode...............................................60

5.3.3 Two or more joysticks: choosing the joystick source 61

5.3.4 Reducing the movement to operate the joystick...61

5.3.5 Chair stability ................................................................. 61

5.3.6 List of parameters.......................................................... 62

5.3.7 Drive Profiles parameters............................................. 65

5.3.7.1 Forward Speed @ Maximum ......................................... 66

5.3.7.2 Forward Speed @ Minimum........................................... 66

5.3.7.3 Forward Acceleration..................................................... 66

5.3.7.4 Forward Deceleration..................................................... 66

5.3.7.5 Reverse Speed @ Maximum.......................................... 67

5.3.7.6 Reverse Speed @ Minimum...........................................67

5.3.7.7 Reverse Acceleration..................................................... 67

5.3.7.8 Reverse Deceleration..................................................... 67

5.3.7.9 Turning Speed @ Maximum...........................................68

5.3.7.10 Turning Speed @ Minimum............................................. 68

5.3.7.11 Turning Acceleration ...................................................... 68

5.3.7.12 Turning Deceleration ...................................................... 68

5.3.7.13 Non-Linear Turn................................................................ 69

5.3.7.14 Short Throw Travel / Short Throw Shape....................... 70

5.3.7.15 Grip.................................................................................... 72

5.3.7.16 Damping Point / Turn Damping / Speed Damping... 73

5.3.7.17 Min To Max Decel Ratio ................................................. 73

5.3.7.18 Chair Stability Parameters.............................................. 74

5.3.7.19 Steering stability parameters......................................... 78

5.3.8 Drive Profile Options parameters................................ 80

5.3.8.1 Maximum Profile Number............................................... 80

5.3.8.2 Wrap Profiles..................................................................... 81

5.3.8.3 Change Profile While Driving......................................... 81

5.3.8.4 Allow Non-Driving Profile ................................................ 82

5.3.8.5 Sleep Timeout .................................................................. 82

5.3.8.6 Soft-Start Time .................................................................. 82

5.3.8.7 Joystick Source................................................................83

5.3.8.8 Joystick Swap Forward / Reverse ................................. 84

5.3.9 General User Options parameters.............................. 85

5.3.9.1 Chair Speed.....................................................................85

5.3.9.2 Soft-Start Acceleration ................................................... 85

5.3.9.3 Neutral Maximum............................................................ 85

5.3.9.4 Disable OONAPU Faults.................................................. 86

5.3.9.5 Speed Pot Scaler............................................................. 86

5.3.9.6 Drive Delay After Power-up........................................... 87

5.3.9.7 Lock Enable...................................................................... 87

5.3.9.8 Sleep Mode Enable ........................................................ 87

5.3.9.9 Power-up Profile Number............................................... 88

5.3.9.10 Enable Joystick Wakeup................................................ 88

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5.3.10 System Settings parameters........................................ 89

5.3.10.1 CLAM Slowdown............................................................. 89

5.3.10.2 Neutral to PB Delay......................................................... 90

5.3.10.3 Chair Speed Enable........................................................ 90

5.3.10.4 Single Profile Mode ......................................................... 91

5.3.10.5 CANH Power Switch........................................................ 91

5.3.10.6 CAN Terminator...............................................................91

5.3.10.7 UCM Joystick Swap Left/Right....................................... 92

5.3.10.8 Rotate UCM Joystick....................................................... 92

5.3.10.9 ACU Enable...................................................................... 92

5.3.10.10 ACU Joystick Swap Left/Right ....................................... 93

5.3.10.11 ACU has Momentary Switch.......................................... 93

5.3.10.12 ACU Momentary Switch Timeout.................................. 93

5.3.10.13 RJM Enable....................................................................... 94

5.3.10.14 RJM Joystick Swap Left/Right........................................94

5.3.10.15 RJM has Analog Joystick................................................ 94

5.3.10.16 Joystick Switch Threshold ............................................... 96

6 DX Modules .............................................................97

6.1 Introduction.................................................................................... 97

6.1.1 The GPSB/SLIO ............................................................... 97

6.2 Secondary Remotes...................................................................... 98

6.2.1 Available Secondary Remotes................................... 98

6.3 DX Steering/Actuator/Lighting Modules.................................... 99

6.4 DX Environmental Control Modules..........................................100

6.5 DX Auxiliary Modules...................................................................100

6.6 Programmable parameters.......................................................101

6.6.1 Actuator Settings (CLAM/TAM)................................. 103

6.6.1.1 CLAM Enable.................................................................103

6.6.1.2 CLAM is Critical.............................................................. 103

6.6.1.3 Actuator While Driving.................................................. 103

6.6.1.4 Actuator 1 - 5 Enable.................................................... 104

6.6.1.5 Actuator 1 - 5 Current Limit.......................................... 104

6.6.1.6 Actuator Timeout .......................................................... 105

6.6.1.7 Actuator Open Circuit Test.......................................... 105

6.6.1.8 Joystick Actuators ......................................................... 105

6.6.1.9 Actuator buttons are bi-directional ........................... 106

6.6.2 Lighting Settings (CLAM/LM/LMZ).............................106

6.6.2.1 CLAM Lighting Enable..................................................107

6.6.2.2 Lighting Module Enable ............................................... 107

6.6.2.3 Lighting Module is Critical............................................107

6.6.2.4 Side Lights Enable.......................................................... 108

6.6.2.5 Indicators Enable........................................................... 108

6.6.2.6 Hazard Lights Enable .................................................... 108

6.6.2.7 Remember Hazard State ............................................. 108

6.6.3 Remote Control Settings (ARC/RSM)....................... 109

6.6.3.1 ARC Enable....................................................................109

6.6.3.2 ARC Always Drives Actuators 1&2.............................. 109

6.6.3.3 ARC Drives Actuators 1&2 in Profile 0......................... 109

6.6.3.4 ARC Drives Actuator 3, 4, 5.......................................... 110

6.6.4 Environment Control Settings (ECU1/ECU2)............ 111

6.6.4.1 ECU Enable..................................................................... 111

6.6.4.2 ECU Channel ENABLE ................................................... 111

7 DX programming...................................................113

7.1 Programming tools ...................................................................... 114

7.1.1 The Hand Held Programmer (HHP)........................... 114

7.1.1.1 HHP Technician Mode.................................................. 114

7.1.2 The PC-based Wizard program ................................115

7.1.2.1 Dongle versions.............................................................. 115

7.1.3 Programming accessories ordering information.... 116

7.2 Localised parameter storage....................................................117

7.3 Auto Download............................................................................ 118

7.4 Programming and testing a DX chair for stability................... 119

7.5 Retain the settings with a Master Remote replacement ...... 125

7.5.1 Replacement with the same type Master Remote125

7.5.2 Replacement with another type Master Remote .128

8 Testing ....................................................................130

8.1 Before testing................................................................................ 130

8.2 The testing procedure................................................................. 130

9 Diagnostics ............................................................133

9.1 Limp Mode.................................................................................... 133

9.2 Stuck Power Button...................................................................... 133

9.3 Out Of Neutral At Power Up (OONAPU).................................. 134

9.4 Diagnostic tools............................................................................ 134

9.5 Battery warning conditions ........................................................135

9.6 Flash codes...................................................................................136

10 Appendices ...........................................................139

10.1 Intended Use and Regulatory Statement................................ 139

10.2 Maintenance................................................................................ 140

10.3 Warranty........................................................................................ 140

10.4 Safety and Misuse warnings....................................................... 141

10.5 Electromagnetic Compatibility (EMC).....................................143

10.6 Minimising emissions .................................................................... 143

10.7 Environmental statement........................................................... 143

Contact Details ...........................................................144

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1 Introduction to the DX System

The DX-system is a modular powerchair control system. This modularity makes it possible to design a powerchair that can meet the requirements of any user requirements that can range from simple drive-only control to full environmental control. Just add additional modules when requirements grow.

The heart of the DX System

The most basic DX control system consists of two parts:

A DX Power Module, connects to the battery and to the motors

A DX Master Remote

The Master Remote is the brain of the DX System. Every DX System must have one, and only one. There are several different Master Remotes available to choose from: with joystick, without joystick, ch in remote, attendant remote, etc.

DX System extensions

In addition to the Power Module and the Master Remote, many other remotes and modules are available to extend the DX System, like:

• Secondary Remotes, for example: attendant remotes, sip ‘n puff, finger steering

• Switch input modules

• Lighting and Seating control modules

• Environmental control modules

The DX System can be extended to a maximum of 16 modules.

DX System connections

All modules are connected to each other by a DX BUS cable. Most DX Modules have two DX BUS connector sockets. That way you can connect another DX part easily.

DX BUS is an interface (the way the modules "talk" to each other) based on the CAN interface, which is widely used in the automotive industry. CAN is well known for its reliability and its fault detection. DX BUS inherits this reliability, and even improves on it.

One system fits all

Start out with a simp le system and add the modules you need at the time they become available, or when the application requirements grow. See the Dynamic Controls pr oduct catalogue for the latest a dditions to the product range.

2 A typical DX powerchair setup

A standard powerchair installation with the DX System consists of the following electrical parts:

The Batteries (section 2.2)

The Motors (section 2.3)

The Parkbrakes (section

2.4)

A DX Power Module (chapter

A DX Master Remote (chapter

The DX BUS cables (section

3.1)

Optional: Actuator or Lighting Modules (chapter

PB1

PB2

To HHP or Wizard

24V Batter

DX Master Remote

To Battery Charger

DX Power Module

DX BUS

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2.1 Installation procedure

To install the DX System safely:

• First read and understand the DX System manual and the manuals of all the used DX components.

• Mount all the electrical parts o f the powerchair setup (motors, parkbrakes, batteries, DX Modules and remotes) on the powerchair. See the manuals of the used DX Modules for the physical dimensions and mounting recommendations.

• Do not connect any cables before all the parts of the DX System are mounted.

• Connect the DX Power Module to the rest of the DX System with the DX BUS cables (see section

2.1.1 for general wiring recommendations).

• Cover any unused DX BUS sockets with a GME64909 DX BUS Connector Cover.

• Conn ec t the DX Power Mo dul e to the mo tors ( see secti on

2.3.2) and the park

brakes (see section

2.4.2).

• Connect the DX Power Module to the batter ies (see section

2.2.4.1).

Do not turn on the DX System yet.

• Lift the powerchair off the ground and check the installation thoroughly (see section

8.1)

• Program the system to the requirements of a particular powerchair or user (see chapter

7).

• Test the system for functionality and safe ty (see chapter

8).

Warning:

Do not connect the '+' terminal of the battery to the DX System until the powerchair is completely wired and ready for testing as described in the

Testing section (chapter 8).

2.1.1 General wiring recommendations

• Keep all cables as short as possible.

• Try to run wires in pairs or bunches.

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

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

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

• Do not leave electrical connections unnecessarily exposed.

• Make sure that all vehicle sub-frames are electrically connected.

• To minimise electromagnetic emissions by the motor brushes, it may be necessary

to fit capacitors between the brush hold ers and the motor case. Make sure that the leads are kept as short as possible. A suitable capacitor is 4n7, 250V Polypropylene.

• For low-current signals, do not use wire sizes smaller than 0.5 mm

/AWG20, because

smaller wires are physically not strong enough for this application.

• For best electrical performance, the wire size must be as large as possible.

Maximum Wire

Current

Recommended Minimum Wire Size

Power Module

60A 3 mm2 / AWG 12 80A 4 mm2 / AWG 11

100A 6 mm2 / AWG 9

The Power Module wire sizes above are appropriate for cable lengths up to 400 mm / 15". For longer cables, increase the wire si ze by 0.5 mm

for every additional 200 mm / 7.5" in length. G enerally, the larger the wire size, the better the powerchair performance will be.

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

• Protect all cables against possible contact with flammable material.

• Where possible, the installation must prevent and/or discourage the user to

disconnect the DX BUS cable.

Warning:

1. Route the cables and fasten all DX components in a position so

that the cables, the connectors and the connector sockets do not allow water entry or suffer from physical strain, abuse or damage, like cutting or crushing. Take particular care on powerchairs with movable structures like seat raise/tilt or swing-away arms. Make sure that the cables do not extend from the powerchair so that they can not be caught or damaged by external objects.

2. The DX BUS cable distributes 24V power to the DX modules, even

when the system is switched off. Avoid short circuit between the DX BUS cable pins whenever a DX BUS connector is removed from its socket. Make sure that the DX BUS connector can not reach potential shorting points. If any protruding, bare metal screws or pins are within reach of a DX BUS cable end, cover or plastic-coat them to make sure that they do not cause short circuits between DX BUS cable pins. Disconnect all the cables of the powerchair at the powered end whenever units are replaced or moved.

3. The user maintenance schedule and the service instructions of the

powerchair must include the appropriate inspection and maintenance requirements for the connectors and the cables.

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2.2 The batteries

The batteries provide the energy for the powerchair to drive. The batteries are connected to the DX Power Module. The DX Power Module sends the energy of the batteries to the motors and to the other modules.

The batteries must be operated and maintained according to the instructions of the battery manufacturer.

2.2.1 Battery type

• 24V (commonly 2 x 12V)

• Lead -Acid / Deep Cycle Gel Cell

• Rated capacity: 20 – 120 Ah (dependent on application and Power Module)

2.2.2 Battery capacity

Choose a battery capacity that is compatible with the intended use. This ensures that the required chair range and/or operating time is achieved.

The rated capacity in Ampere-hours (Ah) of a battery is usually specified for a 20 hour discharge rate (or 0.05 CA, a current of 5% of the rated capacity). A higher continuous discharge current dramatically reduces the available battery capacity. As the graph shows, when the discharge current equals the rated capacity (1 CA),

DX Saver active (2.2.4.2)

1 2 4 6 8 10 20 40 60 2 4 6 8 10 20

Typical discharge times for lead acid batteries

Hours Minutes

Discharge time

Normal operation

Battery fault

Battery voltage (V)

the battery does not last the expected one complete hour, but only 30 minutes, giving an actual available capacity of only 50%.

Rated

capacity

Average

discharge current

Actual

capacity

20 Ah 40 A (2 CA) 5 Ah (25%) 20 Ah 20 A (1 CA) 10 Ah (50%) 20 Ah 12 A (0.6 CA) 12 Ah (60%) 20 Ah 8 A (0.4 CA) 15 Ah (75%) 20 Ah 1 A (0.05 CA) 20 Ah (100%)

Notes:

1. Dynamic Controls recommends to use batteries with a

capacity that is

at least twice as high as the average

discharge current.

2. New batteries often start with only 80% of their rated capacity.

After a few charging cycles the capacity will increase to 100%.

3. Deep discharging or overcharging dramatically decreases the

capacity of the battery. This damage is permanent, the battery will never return to its original capacity. See also section

9.5: Battery warning conditions.

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2.2.3 Battery charging

The battery charging socket of the DX System is a 3-pin XLR type normally located on the DX Master Remote.

Battery

charger

Pin Signal

1 Battery Positive (B+) 2 Battery Negative (B-) 3 Drive Inhibit

B+

B-

The Drive Inhibit signal makes sure that the powerchair does not drive when the batteries are being charged. This signal must be provided within the battery charger plug as a connection between pin 2 and pin 3. Ensure that the battery charger is compatible with this configuration before connecting it to the charging socket.

When turned on during charge, DX Master Remotes that have a 7-segmen t display will show a dash to indicate that the powerchair is inhibited to drive. It is still possible to use accessory functions like actuators.

Once the Battery Charger displays a ‘full’ battery charge, the battery charger plug may be removed.

Notes:

1. For the exact location of the battery charging socket, see the

manual of the Master Remote that is used.

2. It is recommended to leave the system off while charging when

possible. A load during charging – especially a large load like the use of actuators - can cause some battery chargers to think that the battery is more empty than that it actually is. Dependent on the specifications of the battery charger, this can result in overcharging and possible battery damage. Read the manual of the used battery charger for more information.

3. Overcharging dramatically decreases the lifespan of a battery.

Warnings:

1. Do not disconnect the batteries or open the circuit breaker

during charging. See the manual of the battery charger for more information.

2. If during charging the battery gauge starts to flash to indicate

an overvoltage condition, immediately turn off either the battery charger or the DX System.

3. To remove the charger plug, pull in the direction of the cable.

Do not try to turn the plug.

4. The battery charger used must be correctly selected and

adjusted according to the instructions of the battery manufacturer. Failure to do so can damage or destroy the batteries, give poor range, or be potentially dangerous.

2.2.4 Battery protection

2.2.4.1 Thermal circuit breakers

To protect the batteries and the system cables f rom external short circuits, a therma l circuit breaker or fuse must be installed between the batteries and the rest of the system - as close as possible to the batteries. If the two batteries are permanently wired together in a single battery box, the best position for the circuit breaker is between the two batteries. If the batteries are separated in individual battery boxes, each battery requires its own circuit breaker.

The circuit breaker or fuse must be of the slow acting type. The rating of the circuit breaker must be appropriate for the power requirement, inclu ding the total weight of the chair, the battery capacity and the wiring.

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2.2.4.2 Battery Saver

If the battery Voltage falls below 21V, the DX System reduces the performance of the powerchair. This

• pro tects th e battery

• gives the powerchair a longer range before the battery is completely empty

• gives the user a physical warning that the battery is almost empty before

the battery is damaged.

2.2.4.3 High Voltage Rollback

High Voltage Rollback is a battery protection feature that is especially useful for users who have to drive downhill often.

When a powerchair drives downhill, the Power Module sends the generated motor current to the battery. However, if the battery is fully charged already, it can not accept the generated current anymore. This causes the battery voltage to become too high, which can cause damage to the battery or the controller.

High Voltage Rollback gradually decreases the speed of the powerchair until the battery can accept more current. The deceleration of the powerchair gives a timely physical wa rning to the us er to take corrective acti o n , like turni ng on the lights or slowing down.

High Voltage Rollback can be enabled wi th the Wizard (see

4.3.4.6).

Single Battery Box

Thermal Circuit

Breake

Separate Battery Boxes

Thermal Circuit

Breake

2.3 The motors

The wheel motors control the powerchair speed and direction. The motors are connected to the DX Power Module.

Note:

If one of the motors is not connected to the DX Power Module, the DX System detects a Motor Fault (see

9.6) and prevents driving.

2.3.1 Motor types

Drive motor type

Motor resistance

Current Power

Module

Min. wire size

2 x 60A DX-PMB 3 mm

2 x 75A DX2-PMA75L 4 mm

2 x 80A DX-PMB2 4 mm

24V DC* 0 – 0.5 Ω

1 x 120A (2x 60A parallel)

DX-PMB-S 3 mm

(two wires in parallel,

each carrying 60A) 24V AC Gearless Brushless

N/A 2 x 100A DX-GB 6 mm

*12V DC motors can be used if the controller is programmed to half speed.

Notes:

1. The motor wire sizes above are appropriate for motor loom

lengths up to 400 mm. For longer looms, increase the wire size by 0.5 mm

for every additional 200 mm length. Generally, the

larger the wire size, the better the powerchair performance.

2. The chosen size and length of the motor wires can affect the

optimum setting of the Load Compensation parameter (see section

4.3.2.3).

3. Gearless Brushless motors and the DX-GB Power Module are

not covered in this manual. Any reference to motors or motor connectors in this manual is referring to DC motors and the applicable Power Modules. Read the DX-GB manual for more information about the Gearless Brushless system.

Warning:

The Power Module must be correctly configured for the applicable motor resistance with the Load Compensation parameter, see section

4.3.2.3. Failure to set this parameter correctly can be dangerous for the powerchair user, because the chair can become uncontrollable.

2.3.2 Motor connections

The DC motor cables must be connected to the Motor/Parkbrake connectors of the DX Power Module.

M2 / Right M1 / Left

Notes:

1. Keep the motor cables as short as practical to minimise

voltage drops in the cable.

2. If the

Left/Right Motor Swap parameter (see section 4.3.2.7) is

set to

Swap instead of Normal, the Power Module will assign

M1 to the Right motor and M2 to the Left motor.

3. If the

Motor Invert parameter (see section 4.3.2.8) is set to Yes

instead of

No, the polarity of the + and - terminals will be

swapped.

2.3.3 Motor resistance

The resistance of different motor types varies typically between 20 and 350 mΩ. The DX Power Module must know what the motor resistance is because the motor

resistance determines the internal voltage drop in the motor when the motor is under high load (when the motor needs a lot of current to do a task).

If the voltage inside the motor drops too much, the performance of the powerchair will be decreased:

• It will feel unresponsive

• It will slow down or stop when it tries to go up a slope or up a sidewalk edge.

The DX

Load Compensation feature compensates for the voltage drop in the motor. If the motor has a high resistance, the Power Module applies a higher voltage to the motor terminals in high load conditions. This prevents a loss of performance.

To find o ut how to determine the motor resistance and how to progr am Load Compensation, see section

4.3.2.3.

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2.4 The parkbrakes

The parkbrakes make sure that the powerchair does not move when it is not actively driven or when the power is turned off.

For safety, parkbrakes are always applied unless they are actively released, either by the Power Module or manually with a parkbrake release switch.

Note:

If the parkbrakes are not connected to the DX Power Module, the DX System detects a Parkbrake Fault (see

9.6) and prevents driving.

2.4.1 Parkbrake types

• Fail-saf e ele c tro-magne tic parkbrak es attached to each motor

• 24V or 12V

• 1A – 2A maximum current per parkbrake (dependent on the Power Module used,

see the PM manual for the correct specification)

2.4.2 Parkbrake configurations

The parkbrake connection pins are located in the mo tor connectors of the DX Power Modules.

PB+

PB-

2.4.2.1 Two 24V parkbrakes – Dual, M1 and M2

In the dual configuration each parkbrake is driven from a separate output.

For this configuration the DX Power Module

Park Brake parameter (see section

4.3.3.1) must be set to Dual.

24V

Park

Brake

24V

Park

Brake

2.4.2.2 One 24V parkbrake – Single, M1 only

In the single configuration the parkbrake is driven from the M1 output only.

For this configuration the DX Power Module

Park Brake parameter (see section

4.3.3.1) must be set to Single.

Do not connect

a 2

24V park-

brake like this

24V

Park

Brake

Warning:

Do not connect a second 24V parkbrake in parallel to M1, because an open circuit fault in only one of the two parkbrakes can not be detected. Always use the dual configuration for two 24V parkbrakes.

Note:

1. If in this configuration the parkbrake is connected to M2

instead of M1, a Left Parkbrake Fault (flash code 5) will occur.

2. If the Park Brake parameter is set to Dual in this configuration

(with no parkbrake connected to M2), a Right Parkbrake Fault (flash code 6) will occur.

See also section

9.6: Flash codes

2.4.3 Manual parkbrake release switch

Manually operated parkbrake release switch es must be fitted together with a suitable suppression device across each parkbrake.

The suppression device prevents the genera tion of high voltage transients causing possible damage to the Power Module or to the parkbrake release switch itself.

Some suitable suppression devices are:

Always fit a suppression device

2x zener diode

39V, min 2W

Surge: min 50W, 2ms

Parkbrake

PB+

Battery+

Fuse

Release switch

PB-

Do NOT

connect like this

Motorola Philips

3EZ39D5 BZX70C36 3EZ36D5 BZX70C39 1N5365A BZT03C36 1N5366A BZT03C39

2.4.4 Mechanical parkbrake release

To make it possible to manually push the chair if the battery is empty, some form of mechanical clutch or parkbrake release is required. For safety, if the parkbrake is mechanically released the chair must not be able to drive.

One way to achieve this is to put a switch that disconnects the parkbrake from the Power Module in the mechanical parkbrake release. When the parkbrake is disconnected from the Power Module a Parkbrake Fault will occur and the powerchair will not be able to drive.

2.4.5 Parkbrake operation and programming

For safety, parkbrakes are always mechanically applied in their electrical "off"-state. This makes sure that the parkbrakes do not consume energy when the powerchair is turned off. It also makes sure that the powerchair does not roll away if the battery becomes empty on a slope.

To release the parkbrake, it must be "energised" (switched on), either by the Power Module or manually with a parkbrake release switch.

• Energise a parkbrake to release it

• De-energise a parkbrake to apply the brake.

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2.4.5.1 Electrical delay

When the powerchair stops, the parkbrakes will be applied. However, the parkbrakes must not be applied too early. The parkbrakes must

not engage

• if the powerchair stops to change direction (for example forward to reverse)

• before the powerchair has come to a halt after high deceleration

• before the powerchair has come to a halt when parking on a slope

The

Neutral to PB Delay parameter (see section 5.3.10.2) is the delay between zero

speed demand and the moment that the parkbrakes are de-energised. The correct value of this parameter is dependent o n the mechani c s o f the parkbrake

that is used on the chair. The delay must be longer for fast acting parkbrakes. This parameter is set by the powerchair manufacturer for specific powerchair types. It

cannot be adjusted by dealers.

2.4.5.2 Mechanical delay

There is a significant delay between the moment that the parkbrake is de-energised and the moment that the parkbrake actually engages mechanically. This delay becomes important when the powerchair decelerates and stops. When the powerchair has stopped, it will take some time before the parkbrakes are actually engaged.

The Power Module uses the motors to brake and hold the powerchair during the time that the parkbrakes are not engaged (active motor braking). The motor braking time can be programmed with the

Brake / Bridge Off Delay parameter (section 4.3.3.2).

After the time defined in the Brake / Brid ge Off Delay parameter the Power Module will switch off the motors.

Warning:

Make sure that the Brake / Bridge Off Delay time is greater than the mechanical delay of the parkbrakes used. The parkbrakes must engage before the motors turn off, or the chair will roll away.

Brake / Bridge

Off Delay

Speed

Demand

Active Motor Braking

Parkbrakes engaged Motors switched off

Neutral to

Parkbrake

Delay

Parkbrake

de-energised

Zero

Speed demand decreases according to deceleration parameter

Joystick returned to the center

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3 The DX BUS

DX BUS is the interface (the way the modules "talk" to each other) that connects all the DX components together.

The DX BUS interface is based on CAN-Bus tech nology, which is commonly used in safety critical applications like automotive and industrial control networks. CAN provides extremely robust data reliability wi th excellent error detection and correction capabilities. This makes the DX BUS a safe and fault tolerant data network.

The DX BUS also distributes power to the DX Modules and can safely carry up to 12 Ampere continuously.

DX BUS Connector Pinout

Pin Function

1 Communications – CANL 2 Communications – CANH 3 DXB+ (24 V, fused) 4 DXB- (0 V)

CAN-H and CAN-L are used for communication between the modules. DXB+ and DXB- supply power to the modules and to the loads connected to them. The maximum continuous current over the DX BUS DXB+ and DXB- wires is 12A.

Most DX devices have two DX BUS connectors

Notes:

Dynamic recommends to fit unused DX BUS connectors with a GME64909 DX BUS Connector Cover. This also complies with ISO 7176 requirements.

3.1 The DX BUS cable

Cable specifications - straight cable

The part number of the straight cable is GSM630YY, where YY = the length in 100 mm.

DX BUS cable straight

Length Part/Order number

300 mm 1 ft GSM63003 500 mm 1' 8" GSM63005

1.0 m 3' 3" GSM63010

1.5 m 4' 11" GSM63015

2.0 m 6' 7" GSM63020

2.5 m 8' 2" GSM63025

DX BUS cable with Ferrite bead to improve EMC

2.0 m 6' 7" GSM63020F

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Parameter Value

Contact Resistance (per contact) As per IEC 512-2, Positronic

3 mΩ nom, 7 mΩ max

Wire resistance @ 20°C DXB+ DXB-

15.1 mΩ/m, 4.6 mΩ/ft

8.5 mΩ/m, 2.6 mΩ/ft Operating Current (DXB+/DXB-) 12 A nom, 20 A RMS max Connector Latch Holding Force 40 N min Cable Strain 100 N max (accidental, non-repetitive) Cable Flex Force 10 N max Minimum Cable Bend Radius Flexing values for (T > –10°C/14°F)

10 mm / 0.39 inch - fixed installation 25 mm / 1 inch - occasional flexing

50 mm / 2 inch - frequent flexing Operating Temperature (ambient, fixed installation)

–25°C to +50°C

–13°F to +12 2°F Cable Temperature Rating 80°C / 176°F (internal operating temp)

Warning:

The specified bend/flex radiuses are minimum values and must be considered as a guideline only. Where frequent flexing is part of the intended application, the installer must ensure an appropriate bend/flex radius for the intended and foreseeable environmental conditions. Extreme cold temperatures considerably reduce cable flexibility. Appropriate life testing must be carried out to determine/confirm the expected service life and inspection and maintenance schedule.

YY x 100 ± 10

Ø7.0

13 x 16

Cable specifications – curly cable

DX BUS Curly Cable

Tail Length La Coil Length Tail Length Lb Part/Order number

200 mm / 8 inch 300 mm / 1 ft 200 mm / 8 inch GSM63051 500 mm / 1'8" 300 mm / 1 ft 200 mm / 8 inch GSM63052

La ± 20

Ø26 ± 2

300 ± 30 approx. 40 coils

compressed coil length

Lb ± 20

Ø7.5

13 x 16

Parameter Value

Contact Resistance (per contact) As per IEC 512-2, Positronic

3 mΩ nom, 7 mΩ max

Wire resistance @ 20°C DXB+ DXB-

15.1 mΩ/m, 4.6 mΩ/ft

8.5 mΩ/m, 2.6 mΩ/ft Curly Cable electrical length 2.3 m / 7'6" nom for the coiled section Operating Current (DXB+/DXB-) 12 A nom, 20 A RMS max Connector Latch Holding Force 40 N min Cable Strain 100 N max (accidental, non-repetitive) Spring Force - extension refers to the coiled section

< 20N @ 2x extension (T > 10°C/50°F) < 50N @ 2x extension (T > –10°C/14°F)

< 30N @ 3x extension (T > 10°C/50°F) Minimum Cable Bend Radius Flexing values for (T > –10°C/14°F)

20 mm / 0.8 inch - fixed installation

30 mm / 1.2 inch - occasional flexing

50 mm / 2 inch - frequent flexing Operating Temperature (ambient, fixed installation)

–25°C to +50°C

–13°F to +12 2°F Cable Temperature Rating 80°C / 176°F (internal operating temp)

Warnings:

1. Do not extend the spring coils below 0°C. Do not extend the coils

farther than 2x compressed length below 10°C, or 3x compressed length above 10°C. Avoid extension above 3x compressed length because this can cause a permanent stretching of the coil.

2. Make sure that no spring force is applied to the DX BUS connector;

fasten a strain relief or cable tie on or near to the coiled section of the cable.

3.2 DX BUS Module connection layout

DX Modules normally have one or two DX BUS sockets for system interconnections. Smaller DX Modules can have a permanently mounted cable ending in a DX BUS plug, instead of DX sockets.

The optimu m connectio n lay out is depend ent on the type of module s th at are present in the DX System. Low-current modules can be co nnected in series. This provides a low-cost and simple solution.

ause a voltage drop on the DX BUS when they are connec ted far away from the

Because of the internal resistance of the DX BUS cable, high-current modules can c Power Module. For this reason all high-current DX Modules (for example actuators and lights) must be connected as close to the Po wer Module as possible, preferably in parallel.

DX modules connected in series

DX Master Remote

Power

Module

module

24V

DX BUS

High-current DX modules connected in parallel

24V

power

module

DX BUS

module

HIGH I

module

HIGH I

module

HIGH I

module

LOW I

module

LOW I

DX Remote

DX splitter box

DX-SKT-X4

Note:

l length of all DX BUS cables together must not exceed 15 m.

The tota

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4 The DX Power Module

The DX Power Module converts the speed and direction signals generated by a DX Remote into high current outputs. These outputs drive the motors and activate the parkbrakes.

The Power Module must be connected to:

• The DX BUS (see chapter

• The battery (see section

2.2)

• The mo tors (see section

2.3)

• The parkbrakes (see section

2.4).

The Power Module is fully programmable for a wide range of powerchair types and user needs.

M/PB-2 Battery DX BUS M/PB-1

4.1 General Power Module features

• D i g ital motor con tro l

• Supply Voltage compensation

• Motor resistance and load compensation (see 4.3.2.3)

• Tracking (veer) compensation (see

4.3.2.5)

• Smart curre nt limiting and temperature limiting (see

4.3.2.1 and 4.3.4.7)

• Left/Right Motor swap option to facilitate motor cabling (see

4.3.2.7)

• Motor connector polarity swap for different motor polarity options (see

4.3.2.8)

• Single or dual parkbrakes (see

2.4.2)

• Programmable parkbrake delay (see

4.3.3.2)

• Dynamic braking in neutral

• Protected against external events such as:

o reverse battery polarity o battery undervol tage and overvoltage (see

4.3.4.6)

o motor or parkbrake overload (see

4.3.2.9)

o external short circuits

• Extensive range of powerchair system safety and protection features such as:

o open circuit motor detection o open and short circuit Park Brake detection o controlled speed reduction to a stop if a fault is detected (see

4.3.2.6)

o protected against runaway in the event of an internal hardware failure

• Electromagnetically compatible:

o low RF emissions o high immunity to RF transmissions

• Built-in diagnostics with status LED and fault logging

• Watchdog, CPU, ROM and RAM testing at power up

• Compact, rugged enclosure with robust mounting points

• Environmentally compatible (sealed to IP54)

Warning:

This manual gives a description of a generic DX System and Power Module use. It must be read together with the installation manual of the actual Power Module that is installed on the powerchair.

Correct installation and programming are essential to ensure optimum performance and safety.

4.2 Available Power Modules

Power Module Current Motor type Lighting

DX-PMB 60A dual 24V DC no DX-PMB2 80A dual 24V DC no DX-PMB-S* 120A single (2x 60A parallel) 24V DC no

DX-GB

100A dual 24V AC no

* The PMB-S has its two motor and Park Brake channels driven in parallel, for a single motor output with twice the current of each channel of a standard Power Module. The PMB-S is used in DX Systems with only one drive motor, like many servo steered powerchair systems.

** The DX-GB drives gearless brushless AC motors. The DX-GB is not covered in this manual.

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+ 114 hidden pages

Dynamic DX User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual