power module THE ULTIMATE POWERCHAIR CONTROL SOLUTION INSTALLATION MANUAL

Transcription

1 power module THE ULTIMATE POWERCHAIR CONTROL SOLUTION DX2-PMA INSTALLATION MANUAL

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3 About this Manual This manual can help you understand and install the DYNAMIC DX2 PMA Power Module. 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. The product is part of the DX System. This manual must be read together with the DX System Manual and all other relevant DX and DX2 component manuals. In this manual, a few symbols will help you identify the purpose of the paragraph that follows: Notes & Precautions: Notes provide supporting information in order to install, configure, and use the product. Not following the instructions given in notes or precautions can lead to equipment failure. Warnings: Warnings provide important information that must be followed in order to install, configure, and use the product safely and efficiently. Not following the instructions given in a warning can potentially lead to equipment failure, damage to surrounding property, injury or death. The term programming used in this manual refers to adjusting parameters and configuring options to suit an application. Programming does not change or alter any software within the controller and is performed using a controlled programming tool available only to authorised personnel. The 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. The DX System is not user serviceable. Specialised tools are necessary for the repair of any component. Do not install, maintain or operate this equipment without reading, understanding and following this manual including the Safety and Misuse Warnings otherwise injury or damage may result. This manual contains integration, set-up, operating environment, test and maintenance information needed in order to ensure reliable and safe use of the product. Due to continuous product improvement, DYNAMIC reserves the right to update this manual. This manual supersedes all previous issues, which must no longer be used. DYNAMIC reserves the right to change the product without notification. Any attempt to gain access to or in any way abuse the electronic components and associated assemblies that make up the powerchair system renders the manufacturer s warranty void and the manufacturer free from liability. DYNAMIC, the DYNAMIC logo, the DX logo and the DX2 logo are trademarks of Dynamic Controls. All other brand and product names, fonts, and company names and logos are trademarks or registered trademarks of their respective companies. DYNAMIC owns and will retain all trademark rights and DYNAMIC or its licensors own and will retain all copyright, trade secret and other proprietary rights, in and to the documentation. All materials contained within this manual, in hardcopy or electronic format, are protected by copyright laws and other intellectual property laws. Copyright 2009 Dynamic Controls. All rights reserved.

4 Contents 1 Introduction to the DX2-PMA Power Module General features Safety and Protection Features Specifications Electrical Specifications Mechanical Specifications Installation Mounting Wiring Available connectors Connect to the batteries Connect the motors and the parkbrakes Connect to the DX System Connect the lights (70L and 90L only) Connect the Drive Control Input (DCI) DCI Speed Pot Mode DCI High R OBC Mode DCI - Multi Speed/OBC Mode DCI- Multi Function Mode Seat position Mode Seat Position + Invert Demand Mode Programming The System Backup Mirror (DX2 only) Parameter List Parameter descriptions Power Module Options Speed Demand Scaler Turn Demand Scaler Maximum Motor Volts Emergency Deceleration Temperature Rollback Motor Options Current Limit Maximum Stall Time Peak Current Load Compensation Measure Load Compensation automatically Load Compensation Response Left/Right Motor Swap Motor Invert Motor Continuity Test Veer Compensation Parkbrake options Parkbrake Test Parkbrake Driving

5 4.3.4 Battery Options Battery Type DCI Parameters Lighting Outputs Diagnostics / Troubleshooting Diagnostic tools The Module Status LED Hand Held Programmer (HHP) The PC-based Wizard program The DX2-PM Service Data Manager Service Scheduler Service Schedule Type Last service date Time since last service Service schedule due at Time to next service Chair Data Drive Time Drive Cycles Power On Time Power Cycles Power On Cycles Power Off Cycles Battery Data Battery Capacity History Overcharge Cycles Overcharge Time Charge Time High-load Discharge Time Incompatibility with DX (non-dx2) modules DX2-PMA Module + DX Master Remote System Backup Mirror not operational Service Scheduler gives no Service due indication Only use Remotes with Rev C or higher DX2-PMA replacing a DX-PM or a DX-PMB Program conversion from DX-PMB to DX2-PMA Auto download not operational Appendices Intended Use and Regulatory Statement Maintenance Warranty Safety and Misuse Warnings Electromagnetic Compatibility (EMC) Environmental statement

6 1 Introduction to the DX2-PMA Power Module The DX2-PMA is the frontrunner of a new generation of DX Power Modules that sets a new standard for DYNAMIC and the powerchair industry. The DX2-PMA is a fully DX-compatible Power Module that offers many new features and enhancements, including: Varieties of 70 A and 90 A, both with or without lights provide a cost effective scalability to the application requirements Current boost up to 120 A on the 90 A variant provides enough power for very challenging terrain Zero rollback on slopes Battery connector compatible with the DYNAMIC SHARK product range Accessory connector locks on to the Battery connector System Backup Mirror makes it possible to replace a DX2 Master Remote without re-programming. Drive Control Input (DCI) programmable as an input for o External analogue speed pot or speed limit o Drive inhibit for On-board Battery Charger (OBC) o Multispeed input mode (2 switches, 3 speeds, Shark compatible) o Parkbrake release by external switch (so an attendant can release the parkbrakes for pushing the chair) o Seat position switches that can force a specific Drive Profile or swap the drive direction when the seat is swivelled. Service Scheduler shows a message to the end user that the chair should be serviced after a programmable driving time has passed Note: The DX2-PMA is part of the DX System. Read the DX System manual before reading this manual. When this manual refers to sections in the DX System manual, it does so in the format 'see DSM section ' 6

7 1.1 General features Digital DX BUS communication interface, with remote wake up and off/sleep inputs via the DX BUS Two DX BUS sockets with protected 12A RMS maximum battery power supply Digital PWM motor control compatible with 24V DC permanent magnet brush/commutator motors Completely programmable for parameters such as load compensation, motor veer compensation, current limit level and dual or single Parkbrakes Automated measurement of Load Compensation value with Wizard plug-in Protected against external events such as: o reverse battery o battery under and over voltage o overloaded motor or Parkbrakes o external short circuits o stalled motor Extensive range of powerchair system safety and protection features such as: o open circuit motor detection o open and short circuit Parkbrake detection o controlled speed reduction to a stop if a fault is detected; Electromagnetically compatible: o Low RF emissions, compatible with applicable standards o low susceptibility to RF transmissions, compatible with applicable standards o High ESD immunity, compatible with applicable standards Environmentally compatible (sealed to IPx4) Built-in diagnostics with status LED and fault logging Compact, rugged enclosure with robust mounting points Approved by the German Safety Standards Authority TÜV 7

8 1.2 Safety and Protection Features Detection of open or short circuit motors Detection of open or short circuit Parkbrakes Battery under voltage protection with Battery Saver to prevent motor chugging and to protect battery Thermal overload protection with progressive motor current rollback and automatic recovery Over voltage shut down (protect outputs against damage when the battery is disconnected or when the motors are generating while the powerchair is driving downhill) Enhanced downhill control provides a smooth, controlled rollback of speed if the battery voltage rises too high All outputs protected against over voltage transients and short circuits Isolate relay protects against reverse battery connections and prevents runaway in event of H Bridge or Parkbrake driver failure Detection of welded isolate relay contacts Detection of high resistance isolate relay contacts Dynamic braking in neutral Motor drive output monitoring Microcomputer watchdog protection Optional stalled motor time out Self test of current sensor and H Bridge at power up Watchdog, CPU, ROM and RAM testing at power up 8

9 2 Specifications 2.1 Electrical Specifications Parameter Min Nom Max Units Battery Voltage V Battery Saver High threshold Low threshold Quiescent Power (relay de-energised) 2 5 W Standby Power mw Thermal limit 70 C DX BUS CANH and CANL tolerated Voltage 0 38 V DX BUS supply 40 C A Motor Outputs Motor Type 24V DC Maximum output voltage 23.5 V Continuous motor current (@ 20 C ambient temperature) DX2-PMA70/DX2-PMA70L DX2-PMA90/DX2-PMA90L Peak motor current DX2-PMA70/DX2-PMA70L DX2-PMA90/DX2-PMA90L *15 20 C initial case temperature **30 20 C initial case temperature *** sec (programmable boost time) 30* 35* ** 90** 75*** 120*** PWM frequency khz Stall timer (programmable) s Parkbrake outputs Output voltage Vbat - Vbat V 1.1 Output current A Configuration: single/dual Lighting outputs (70L and 90L variants only) Supply Voltage V Output power (per output) 50 W Output current (per output) 2 A On Board Charger supply Voltage 24 V Current 15 A Inhibit via DCI input (see ) A A A A Warning: Make sure that the total power consumption of all modules in the DX System does not exceed the rated DX BUS current at any time. 9

10 2.2 Mechanical Specifications M5 All dimensions ± 0.5 mm. Parameter Min Nom Max Units Installed depth including connectors mm inch Mounting torque (M5 bolts) Nm Weight 1040 g Operating Temperature Range -25 (-13) 50 (122) C ( F) Storage Temperature Range -40 (-40) 65 (149) C ( F) Operating Humidity Range 0 90 %RH Battery Connector Cycles 10 cycles Motor Connector Cycles 100 cycles Material pressure die cast aluminium alloy Protection rating IPx4 Warning: To achieve the specified IPx4 rating, do not mount the DX2 Power Module with the connectors facing upward. If necessary, add a water shielding cover to protect the Power Module from water entry as appropriate to the environment that the chair will be used in. 10

11 3 Installation Warning: The DX2-PMA is part of the DX System. Before reading this chapter, first read the DX System Manual, in particular the following sections: DX System installation and wiring recommendations DSM section 2.1 Batteries, chargers and battery protection DSM section 2.2 Motor connections and wiring DSM section 2.3 Parkbrake configurations and wiring DSM section 2.4 DX BUS Module connection layout DSM Section Mounting M5 Mounting torque of the M5 bolts: Nm. Dimensions ± 0.5 mm. Warning: To achieve the specified IPx4 rating, do not mount the DX2 Power Module with the connectors facing upward. If necessary, add a water shielding cover to protect the Power Module from water entry as appropriate to the environment that the chair will be used in. Mount the Power Module in a location where the user cannot touch the unit, especially when the Temperature Rollback parameters (see ) are increased. 11

12 3.2 Wiring Available connectors Part Part Number Description GME65146 Battery connector housing GCN60321 (DX2 only) or GCN60326 (DX2 + SHARK) GCN60322 (DX2 only) or GCN60327 (DX2 + SHARK) GCN60320 (DX2 only) or GCN60325 (DX2 + SHARK) Motor connector housing Left (M1) keyed Motor connector housing Right (M2) keyed Motor connector housing Universal (unkeyed) GCN60323 Connector key to make GCN60320/GCN60325 left or right keyed GME65147 Lights/Accessory connector housing (attaches to battery connector housing) GCN65129 Boot for Battery and Motor connectors GCN65128 Boot for Battery connector + attached Lights/Accessory connector GCN8002 GCN0781 GCN0793 GCN0794 Crimp contact for 6-10 mm 2 / 7-10 AWG (battery) Crimp contact for 3-6mm 2 / AWG (motors) Crimp contact for mm 2 / AWG (lights / accessories) Crimp contact for mm2 / 20 AWG (parkbrakes / accessories / DCI) Connector kits DX2LOOM-PM1: DX2 Battery & Motor Connector kit (housings + boots + contacts) 1x GCN65146, 2x GCN60320, 2x GCN60323, 3x GCN65129, 2x GCN8002, 4x GCN0781, 4x GCN0794. DX2LOOM-PM2: DX2 Battery & Motor & Lights/Accessory Connector kit DX2LOOM-PM1 + 1x GCN65147, 1x GCN65128 (instead of one GCN65129), 7x GCN

13 3.2.2 Connect to the batteries The DX2-PMA has a two Pole battery connector (compatible with DYNAMIC SHARK). + - Battery Warning: Do not connect the '+' terminal of the battery to the DX System until the powerchair is completely wired and ready for testing. Read DSM section 2.2 (batteries, chargers and battery protection) before installing the batteries Connect the motors and the parkbrakes The DX2-PMA has two Motor connector sockets, which are compatible with the existing DX and SHARK Power Modules. M2 M1 The M1 and M2 connector sockets are keyed, so the M1 motor connector does not fit in the M2 motor connector socket Connect to the DX System The DX2-PMA module has two DX BUS sockets. DX BUS Precautions: Connect high current modules such as an Actuator Module as close as possible to the Power Module (see DSM section 3.2). If the second DX BUS connector is not used, cover it with a GME64909 DX BUS Connector Cover. This also complies with ISO requirements. 13

14 3.2.5 Connect the lights (70L and 90L only) The DX2-PMA supports 24V light bulbs with a maximum power of 50 W (2 A). Connect the lights via the accessory connector. Accessory Connector The light outputs are low active. For this reason, connect the lights to B+ (either pin 1 or pin 2) and the corresponding light outputs (pin 3, 4 or 5). The light outputs must be enabled with the Accessory Pin 3, Accessory Pin 4 and Accessory Pin 5 parameters (see 4.3.6) Connect the Drive Control Input (DCI) Accessory Connector B+ B+ Left Ind. Right Ind. DCI* B The DX2-PMA provides a DCI on pin 6 of the accessory connector. RDCI Use the DCI for: An external switch that releases the parkbrake for easy pushing of the chair An external switch that can force the system to go to a specific Drive Profile (for example, when the seat is swivelled). An extra external speed pot or speed limit pot Seat position switches that can slow down or stop the chair when the seat is in a position that makes the chair not stable enough to drive. Warning: 1. Do not use any parkbrake release (mechanical or electronic) on a slope. If the parkbrakes are released on a slope, the chair could tip over when the chair stops and the parkbrakes are applied again. 2. Make sure that the DX System cannot drive when the parkbrakes are released manually. This can be achieved by installing a switch that causes a parkbrake fault or a drive inhibit when the manual parkbrake release is operated. Note: To make sure that the DCI operates correctly in all operating conditions, use resistors with 1% tolerance and a temperature coefficient of 100 ppm/c or better. 14

15 The DCI can be set to 6 different modes. Mode Operation Speed Pot Multi Speed/OBC Normally Open or Normally Closed Speed Pot or Speed Limit High R OBC Normally Open or Normally Closed Multi Function Seat position (swivel 90 or 180 ) Seat position + Invert demand (swivel 180 ) Analog input that scales down the speed of the powerchair, depending on the resistance between the DCI pin and B-. Either a 500 Ω linear potentiometer or discrete resistors can be used. 3 Different input resistor bands are recognised. Each band can limit the chair speed to a different value. Short Circuit and Open Circuit either allow the chair to drive normally or inhibit drive, dependent on the NO/NC setting. It is possible to use the drive inhibit band to connect an On Board Charger (OBC), if the internal resistance of the OBC is suitable for the chosen configuration. All resistor values can be obtained using 150 Ω resistors only, or alternatively 120 Ω and 330 Ω resistors (SHARK compatible). This mode is especially designed for On Board Chargers that have a high series resistance on the inhibit pin (typically 1 kω). These Chargers can not be used in the Multi Speed/OBC mode because their high resistance would be detected as an open circuit in that mode. 4 Different input resistor bands are recognised, while short circuit and open circuit generate a fault. This allows the use of two input switches in a fail safe way. Each input switch can Release the parkbrake for manual pushing, or Force the system into a specific Drive Profile, or Apply a speed limit. All resistor values can be obtained using 150 Ω resistors only. Recognises two position switches that can force a specific Drive Profile (for example, when the seat is swivelled 90 or 180 ). Can also be used for any application that uses two switches that are wired as exclusive or (only one switch can be active simultaneously, both active or none active are not valid states), for example an attendant RJM switch or a handlebar switch. Recognises two seat position switches that can force a specific Drive Profile and invert the powerchair drive direction (forward becomes reverse and reverse becomes forward). Use this for swivelling chairs when the fitted Master Remote does not support joystick rotation. All modes are described in detail on the following pages. 15

16 DCI Speed Pot Mode The DCI acts as an Analog input that scales down or limits the speed of the powerchair, depending on the resistance between the DCI terminals. Either a 500 Ω linear potentiometer or discrete resistors can be used. The Speed Pot value works in parallel with all other Speed Pots that are present in the DX System: the one with the lowest momentary value will determine the speed. Band Range (Ω) Speed Pot (%) short circuit linear range full speed open circuit > 575 Fault (see note) Any number of resistors totalling 500 Ω DCI 500 Ω linear DCI Potentiometer input Resistor chain input Note: Open circuit displays Flash Code 2 (Accessory Fault) and sets the global Speed Limit to the value of the DCI Speed 3 parameter. To apply Drive Inhibit in an open circuit condition, set the value of this parameter to zero DCI High R OBC Mode This mode is especially designed for On Board Chargers that have a high series resistance on the inhibit pin (typically 1 kω). Chargers with a series resistance that is lower than 550 Ω can be used in the Multi Speed/OBC and Multi Function modes as well. The DX2-PMA supports the use of an OBC that has a maximum continuous current of 15A. Connect the OBC via the accessory connector. B+ B+ Left Ind. Right Ind. OBC Inhibit* B Accessory Connector Inh OBC 16

17 DCI - Multi Speed/OBC Mode Multi Speed/OBC Mode offers 3 input resistor bands that can limit the chair speed. Multi Speed Mode can be set to Normally Open (NO) or Normally Closed (NC) operation. This mode is compatible with the DYNAMIC SHARK system. Band Range (Ω) Function (NO) Function (NC) Short circuit Drive Inhibit Normal Drive 120/150/220 Ω Speed 1 Speed 1 300/330 Ω Speed 2 Speed 2 450/470 Ω Speed 3 Speed 3 Open circuit > 575 Normal Drive Drive Inhibit OBC* DI Sp1 Sp2 Sp3 DI Sp1 Sp3 Sp2 120 Ω 330 Ω 75 Ω 120 Ω 330 Ω 470 Ω DI Sp3 Sp2 Sp1 150 Ω 150 Ω 150 Ω Normally open one by one Normally Closed Some schematics many more options are possible. All resistor band values can be obtained with 150 Ω resistors only. The 3 Speeds can be given as a Speed Pot or a Speed Limit value. If a Speed Pot has the value zero, the maximum speed of the powerchair is not zero, it is equal to the Forward Minimum parameter for the currently active Drive Profile. If a Speed Limit has the value zero, the maximum speed of the powerchair is also zero. The Speed Pot/Speed Limit value works in parallel with all other Speed Pots/Speed Limits that are present in the DX System: the one with the lowest momentary value will determine the speed. For more information about the Speed Pot and Speed Limit functions, see the Speed limiting options section in the DX System Manual (chapter 5). Precaution: The effect of the Speed Pot function is different for each Drive Profile, because it scales the maximum speed to the value of the Forward Maximum parameter. Choose the Speed Pot value so that the chair will still be safe in the fastest Drive Profile. Note: *It is possible to use the inhibit band of the Multi Speed/OBC mode for an On Board Charger (OBC), if the internal resistance of the OBC is suitable for the chosen configuration. For example, in Normally Open mode the resistance of the OBC must be 75 Ω or lower. 17

18 DCI- Multi Function Mode Four valid input resistor bands are recognised. Open circuit and short circuit are not valid bands, which makes it possible to create a fail safe switch circuit. Band Typ. R Range (Ω) Function Parameter B0 525 Ω Normal Drive - B1 375 Ω DC Function 1 (DCF1) DCI Speed 1 B2 225 Ω DC Function 2 (DCF2) DCI Speed 2 B3 75 Ω DC Function 1+2 DCI Speed 3 (if applicable) Fault - All other DCI Accessory Fault See fault table S2 S1 S1 S2 DCI 300 Ω 150 Ω DCI 150 Ω DCI 300 Ω B- 75 Ω B- 375 Ω B- 225 Ω Two switch fail safe input One switch fail safe input One switch fail safe input Possible schematics - all resistor values can be obtained using 150 Ω resistors only. For a fail safe circuit: route the DCI wire physically close to the B- wire, preferably as a pair use single resistors and mount the resistors as close to the switches as possible mount the termination resistor close to the switch at the end of the loop (B- side). The DC Function 1 and DC Function 2 parameters can have the following values: DC Function None Speed Pot Speed Limit Parkbrake Release Force Profile Operation when corresponding switch is active Normal drive Applies a Speed Pot* value. Applies a Speed Limit** value. If the chair is not driving when the switch is closed, the parkbrakes are released for manual pushing of the chair. If the chair is driving when the switch is closed, the chair stops and applies the parkbrakes. Close the switch again to release the parkbrakes for manual pushing. Activates the Drive Profile specified by DCI Profile, and applies a Speed Limit while the Power Module is switching Drive Profiles. If a function is assigned to DC Function 1, its settable value (Speed Pot value or Speed Limit value) is typically set by the DCI Speed 1 parameter. If a function is assigned to DC Function 2, its settable value is typically set by the DCI Speed 2 parameter. If the same function is assigned to DC Function 1 and DC Function 2, its settable value when band B3 is active (both switches are closed) is typically set with the DCI Speed 3 parameter. Note: if in this case band B1 or B2 is active (just one switch is closed), the settable values are still set by DCI Speed 1 or DCI Speed 2 respectively. See the tables on the following pages for more details. 18 *If a Speed Pot has the value zero, the maximum speed of the powerchair is not zero, it is equal to the Forward Minimum parameter for the currently active Drive Profile. **The Speed Limit ranges from zero speed (drive inhibit) to the maximum speed of the chair. The effect of a Speed Limit is the same for each Drive Profile.

19 DC Function matrix State B0 B1 B2 B3 F Meaning No switches closed Normal drive (not shown below). Switch S1 is closed. This activates DC Function 1 (DCF1). Switch S2 is closed. This activates DC Function 2 (DCF2). Switch S1 and S2 are both closed simultaneously. Typically combines the functionality of B1 and B2*. DC Accessory Fault (the measured resistance is invalid). Shows flash code 2 on the Power Module and the Master Remote. Typically sets the Speed Limit to the value of DCI Speed 3*. To apply a drive inhibit in this case, set DCI Speed 3 to zero. *The behaviour of B3 or the Fault band can be different when the same function is assigned to DCF1 and DCF2, as shown in the light blue cells. DCF1 None Speed Pot Speed Limit DCF2. Parkbrake release Force profile State None Speed Pot Speed Limit Parkbrake release Force profile B1 Normal drive Normal drive Normal drive Normal drive Normal drive B2 Normal drive SP = DCI Spd 2 SL = DCI Spd 2 PB released DP = DCI Profile SL = DCI Spd 2 B3 Normal drive SP = DCI Spd 2 SL = DCI Spd 2 PB released DP = DCI Profile SL = DCI Spd 2 F SL = DCI Spd 3 SL = DCI Spd 3 SL = DCI Spd 3 SL = DCI Spd 3 SL = DCI Spd 3 B1 SP = DCI Spd 1 SP = DCI Spd 1 SP = DCI Spd 1 SP = DCI Spd 1 SP = DCI Spd 1 B2 Normal drive SP = DCI Spd 2 SL = DCI Spd 2 PB released DP = DCI Profile B3 SP = DCI Spd 1 SP = DCI Spd 3 SP = DCI Spd 1 SL = DCI Spd 2 F SL = DCI Spd 3 SP = Min of Spd1, Spd2, Spd 3 SP = DCI Spd 1 PB released SL = DCI Spd 2 SP = DCI Spd 1 DP = DCI Profile SL = DCI Spd 2 SL = DCI Spd 3 SL = DCI Spd 3 SL = DCI Spd 3 B1 SL = DCI Spd 1 SL = DCI Spd 1 SL = DCI Spd 1 SL = DCI Spd 1 SL = DCI Spd 1 B2 Normal drive SP = DCI Spd 2 SL = DCI Spd 2 PB released DP = DCI Profile B3 SL = DCI Spd 1 SL = DCI Spd 1 SP = DCI Spd 2 SL = DCI Spd 3 SL = DCI Spd 1 PB released F SL = DCI Spd 3 SL = DCI Spd 3 SL = Min of Spd1, Spd2, Spd 3 SL = DCI Spd 2 DP = DCI Profile SL = Min of Spd 1 and Spd 2 SL = DCI Spd 3 SL = DCI Spd 3 B1 PB released PB released PB released PB released PB released B2 Normal drive SP = DCI Spd 2 SL = DCI Spd 2 PB released DP = DCI Profile SL = DCI Spd 2 B3 PB released PB released SP = DCI Spd 2 PB released SL = DCI Spd 2 PB released PB released DP = DCI Profile SL = DCI Spd 2 F SL = DCI Spd 3 SL = DCI Spd 3 SL = DCI Spd 3 SL = DCI Spd 3 SL = DCI Spd 3 B1 DP = DCI Profile DP = DCI Profile (SL = DCI Spd 1) (SL = DCI Spd 1) DP = DCI Profile (SL = DCI Spd 1) DP = DCI Profile (SL = DCI Spd 1) DP = DCI Profile (SL = DCI Spd 1) B2 Normal drive SP = DCI Spd 2 SL = DCI Spd 2 PB released DP = DCI Profile (SL = DCI Spd 2) B3 DP = DCI Profile DP = DCI Profile (SL = DCI Spd 1) (SL = DCI Spd 1) SP = DCI Spd 2 DP = DCI Profile SL = Min of Spd 1 and Spd 2 DP = DCI Profile SL = DCI Spd 1 PB released DP = DCI Profile (SL = DCI Spd 3) F SL = DCI Spd 3 SL = DCI Spd 3 SL = DCI Spd 3 SL = DCI Spd 3 SL = DCI Spd 3 Warning: To prevent rollaway of the chair due to either a defective Parkbrake Release Switch or accidental operation of that switch, use two switches in series that both have to be pushed together to activate the parkbrake release. 19

20 Seat position Mode This mode can be useful for chairs that have a seat that can swivel between forward facing and backward facing. Two position switches can indicate to the system if the seat is swivelled or not. If the seat is swivelled, this mode can automatically select a Drive Profile that accommodates for the swivelled situation. Note: This mode only selects a specific Drive Profile when the seat is swivelled, it does not adjust that Drive Profile to the swivelled situation. Program the selected Drive Profile for the swivelled situation, for example by rotating the joystick input 90 or 180 in that Drive Profile. Four valid input resistor bands are recognised. Open circuit and short circuit are not valid bands, which makes it possible to create a fail safe switch circuit. Band Typ. R Range (Ω) Function Speed Limit Ω Out of position DCI Speed Ω Normal position Ω Swivelled position DCI Speed Ω Out of position DCI Speed 2 Fault - All other DCI Accessory Fault, Flash code 2 on PM DCI Speed 3 Swiv Norm DCI 300 Ω 75 Ω 150 Ω Two switch fail safe input Possible schematics - all resistor values can be obtained using 150 Ω resistors only. For Fail Safe operation, mount the resistors as close to the switches as possible. DC Function Normal position Swivelled position Meaning/Operation Activated when the Norm switch is closed and the Swiv switch is open. Normal position indicates that the seat is facing forward. Normal position returns the DX System to the Drive Profile that was active before the seat was swivelled. Activated when the Swiv switch is closed and the Norm switch is open. Swivelled position indicates that the seat is facing reverse (or sideways). Swivelled Position sets the DX System to the Drive Profile that is specified by the DCI Profile parameter. Out of position Activated when the Swiv switch and the Norm switch are both open or both closed. Out of position indicates that the seat is currently swivelling. Out of position does not change the Drive Profile, shows flash code 2 on the Master Remote and applies a Speed Limit of DCI Speed 2. Alternatively this mode can also be used for any application that uses two switches that are wired as exclusive or (only one switch can be active simultaneously), for example an attendant switch or a handlebar switch that selects an RJM Drive Profile. 20

21 Seat Position + Invert Demand Mode This mode can be useful for chairs that have a seat that can swivel between forward facing and backward facing. Two position switches can indicate to the system if the seat is swivelled or not. If the seat is swivelled, this mode automatically swaps the driving directions and selects a Drive Profile that accommodates for the swivelled situation. Note: This mode only selects a specific Drive Profile when the seat is swivelled, it does not adjust that Drive Profile to the swivelled situation. Program the selected Drive Profile for the swivelled situation. For example, it may not be necessary to rotate the joystick in the swivelled Drive Profile because the driving directions are already swapped, but it may be necessary to have lower speed limits if the chair is not stable in the swivelled position. Four valid input resistor bands are recognised. Open circuit and short circuit are not valid bands, which makes it possible to create a fail safe switch circuit. Band Typ. R Range (Ω) Function Speed Limit Ω Out of position DCI Speed Ω Normal position Ω Swivelled position DCI Speed Ω Out of position DCI Speed 2 Fault - All other DCI Accessory Fault, Flash code 2 on PM DCI Speed 3 Swiv Norm DCI 300 Ω 75 Ω 150 Ω Two switch fail safe input Possible schematics - all resistor values can be obtained using 150 Ω resistors only. For Fail Safe operation, mount the resistors as close to the switches as possible. DC Function Normal position Swivelled position Out of position Meaning/Operation Activated when the Norm switch is closed and the Swiv switch is open. Normal position indicates that the seat is facing forward. Normal position returns the DX System to the Drive Profile that was active before the seat was swivelled. Activated when the Swiv switch is closed and the Norm switch is open. Swivelled position indicates that the seat is facing reverse (or sideways). Swivelled Position swaps the driving directions and sets the DX System to the Drive Profile that is specified by the DCI Profile parameter. Activated when the Swiv switch and the Norm switch are both open or both closed. Out of position indicates that the seat is currently swivelling. Out of position does not change the Drive Profile, shows flash code 2 on the Master Remote and applies a Speed Limit of DCI Speed 2. 21

22 4 Programming Warning: The DX2 Power Module is part of the DX System. Read the DX System Manual programming chapter (DSM chapter 7) including all its warnings and notes before reading this chapter. The programming chapter of this DX2 Power Module manual only describes Power Module specific programming. 4.1 The System Backup Mirror (DX2 only) The DX2 Power Module and the DX2 Master Remote both have a backup copy of all the system parameters. If either the DX2 Master Remote or the DX2 Power Module is replaced, the DX2 Master Remote asks the user to choose which module has the correct backup copy. Choose the module that has not been replaced. After the user has selected the module with the correct backup copy, that module automatically copies the backup settings into the new module. This makes it possible to replace any module including the Master Remote without re-programming the system. Notes: 1. Look in the manual of the Master Remote to see how this remote asks for the selection of the module with the correct backup copy. 2. The System Backup Mirror only works when both the Power Module and the Master Remote belong to the DX2 family. If either the Power Module or the Master Remote is a DX Module (and not a DX2 Module), the System performs an Auto Download instead of a System Restore. See the DX System Manual for more information about Auto Download. 22

23 4.2 Parameter List Key: Editable at this level (see section of the DX System manual) Viewable at this level Parameter Possible Values Default HHP Lite Std Adv Power Module Options (4.3.1) Power Module Type DX2-PMA70 DX2-PMA70L DX2-PMA90 DX2-PMA90L DX2-PMA in DX Mode - - Speed Demand Scaler % 95 % - Turn Demand Scaler % 50 % - Maximum Motor Volts V 26 V - Emergency Deceleration % 75 % - Temperature Rollback Min C 50 C - Temperature Rollback Max C 70 C - Motor Options (4.3.2) 10-70A (PMA70) Current Limit 70 A A (PMA90) Maximum Stall Time 5 50 s 15 s - Peak Current Limit A (PMA70) A (PMA90) 75 A - Peak Current Time s 1 s - Load Compensation m Ω 139 m Ω - LC Response Default % 80 % - LC Response Profiled No/Yes No - Left/Right Motor Swap No/Yes No - M1 Motor Invert No/Yes No - M2 Motor invert No/Yes No - Motor Continuity Test No/Yes Yes - Veer Compensation % 0 % - Parkbrake options (4.3.3) Parkbrake Single/Dual Dual - Test Parkbrake Driving No/Yes No - Battery Type Battery Options (4.3.4) Standard Small Large Standard - Custom 23

24 Parameter Possible Values Default HHP Lite Std Adv DCI Parameters (4.3.5) DCI Mode DCI Off Multi Speed/OBC High R OBC Speed Pot Seat position Seat position + Invert demand Multi Function DCI Off - DC Function 1 DC Function 2 None Speed Pot Speed Limit Parkbrake Release Force Profile None - DCI Speed % 0 % - DCI Speed % 0 % - DCI Speed % 0 % - DCI Profile Accessory Pin 3 Accessory Pin 4 Accessory Pin 5 Lighting Outputs (4.3.6) Off Left Indicator Off - Off Head Lights Off - Off Right Indicator Off - 24

25 4.3 Parameter descriptions Power Module Options Speed Demand Scaler Parameter Possible Values Default HHP Lite Std Adv Speed Demand Scaler % 95 % - The Speed Demand Scaler scales down the Speed Demand that the Power Module receives from the UCM (see also Speed and acceleration principles in the DX System Manual). This makes sure that the powerchair does not slow down when it changes direction. To adjust the direction of the powerchair when the chair travels forward, the Power Module speeds up one wheel while it keeps the speed of the other wheel constant. The Power Module can only speed up one wheel if that wheel is not turning at maximum speed already. If both wheels are turning at maximum speed, the Power Module must slow down one wheel to change direction. This slows down the whole powerchair during the turn, which can be annoying. A Speed Demand Scaler value of 95% limits the maximum speed of the chair to 95% of the maximum achievable speed during normal driving. This leaves 5% of the maximum wheel speed reserved for turning. The Speed Demand Scaler is also useful to further slow down a chair when the minimum speed settings of the Drive Profiles are still too fast. Note: The Speed Demand Scaler parameter only scales the forward and reverse speed demand. To scale the turning speed demand, use the Turn Demand Scaler parameter ( ) Turn Demand Scaler Parameter Possible Values Default HHP Lite Std Adv Turn Demand Scaler % 50 % - The Turn Demand Scaler scales down the values of the Turning Maximum and the Turning Acceleration parameters for every Drive Profile (for more information on Drive Profiles see the DX2 System Manual). This allows lower turning speeds and acceleration without a loss of resolution. Setting Turn Demand Scaler to a lower value is particularly useful for high speed chairs and Front Wheel Drive chairs where low turning speeds are required. See also the Non-Linear Turn parameter in the DX System manual. 25

26 Maximum Motor Volts Parameter Possible Values Default HHP Lite Std Adv Maximum Motor Volts V 26 V - Maximum Motor Volts sets the maximum voltage that the Power Module will apply to the motor. Note: If local regulations require that the powerchair speed is limited to a specific value, use this parameter to set a speed limit for a particular chair type (for specific motors and a specific wheel diameter). If the momentary battery voltage is less than the programmed Maximum Motor Volts value (for example when the battery is almost empty), then the battery voltage itself is the maximum applied voltage at 100% speed demand Emergency Deceleration Parameter Possible Values Default HHP Lite Std Adv Emergency Deceleration % 75 % - Emergency Deceleration sets the rate at which the powerchair comes to a halt when a fault that requires an emergency stop occurs the user switches off the system while driving. If Emergency Deceleration is set to a higher value, the powerchair will stop in a shorter time period. The optimum value depends on the powerchair type, the preference of the manufacturer and the regulations that apply to the country of use. Test this parameter by switching off the system while driving. Warning: The powerchair can tip over or throw the user out of the chair if this parameter is set too high. 26

27 Temperature Rollback Parameter Possible Values Default HHP Lite Std Adv Temperature Rollback Min C 50 C - Temperature Rollback Max C 70 C - To protect the Power Module from overheating, a thermal rollback algorithm reduces the output current when the Power Module becomes too hot. Temperature Rollback Min is the temperature at which the thermal rollback starts. Temperature Rollback Max is the temperature at which the thermal rollback limits the output current to zero. Current Limit ( ) Maximum Current Temp Rollback Minimum Temp Rollback Maximum Temp. Note: In an environment with high ambient temperatures the DX2-PMA may be in Thermal Rollback almost continuously, resulting in poor performance. If this is the case, increase the Thermal Rollback parameters. Warning: If the values of the Thermal Rollback parameters are increased, the case of the DX2-PMA may become hot. Make sure that the user cannot touch the hot surface, and warn the user not to touch the hot surface to prevent burns to the skin. 27

28 4.3.2 Motor Options Current Limit Parameter Possible Values Default HHP Lite Std Adv Current Limit 10-70A (PMA70) 10-90A (PMA90) 70A (PMA70) 90A (PMA90) - The Current Limit is the maximum sustained current that the Power Module is programmed to deliver to the motor. To protect the electronics of the Power Module, the maximum current will be reduced further if the Power Module becomes too hot, dependent on the setting of the Temperature Rollback parameters (see ). Warning: Do not set this parameter too high for the type of motor used. Note: The time that the Power Module will deliver the maximum sustained current to the motors is limited by the Maximum Stall Time parameter ( ) Maximum Stall Time Parameter Possible Values Default HHP Lite Std Adv Maximum Stall Time 5 50 s 15 s - If the joystick is deflected but the powerchair can not drive because it is on a slope that is too steep, or it tries to climb up a curb that is too high, or it is trapped, the maximum current (as set by the Current Limit parameter, see section ) will flow through the motors continuously, because the motors are still trying to drive. This situation is called motor stalling. Motor stalling can cause motor damage when the motor becomes too hot. To prevent motor damage, the Power Module disables drive after Maximum Stall Time seconds of maximum continuous current. If a stall timeout has occurred: The powerchair will not drive and Flash Code 11 (see the DX System manual) will be shown on the System Status LED of the DX Master Remote. After a cool down period of Maximum Stall Time seconds, the flash code goes away and the system drives normally. If the joystick is out of the centre position when the cool down period ends, the system will not drive until the joystick is released back to the centre. Note: Some safety standards require a particular Maximum Stall Time to be set. 28

29 Peak Current Parameter Possible Values Default HHP Lite Std Adv Peak Current Limit A (PMA70) A (PMA90) 75 A - Peak Current Time s 1 s - The Power Module can deliver a current of Peak Current Limit Ampere for Peak Current Time seconds. If the Peak Current Time is reached, the current is limited to Current Limit. Before the current can reach the Peak Current Limit again, the motor current must stay below 80% of the Current Limit for at least twice as long as that it has been above Current Limit. 29

30 Load Compensation Parameter Possible Values Default HHP Lite Std Adv Load Compensation m Ω 139 m Ω - Load Compensation automatically compensates for changes in motor speed when the chair drives over loads such as sidewalks, curbs or slopes. Correct Load Compensation is important for all chairs to reach acceptable performance, especially when a chair has switched controls, for example a scanner or Sip and Puff. Load compensation Too low Correct Too high Chair behaviour Drives like it is going through thick mud Slows down when it goes up a sidewalk edge or up a ramp Slows down with heavier users Changes direction when it drives over a bump Changes direction when the weight of the user shifts. Drives smoothly Keeps the speed reasonably constant. Only slightly slows down on a slope. Keeps the direction constant. Only slightly changes direction when it drives over a bump. Drives very rough Hard to steer or control, vibrates Swerves when it drives over a bump. Motor becomes hotter than normal very easily, decreased motor life Aaagh! Hnnng! Set Load Compensation to the correct motor resistance value of the motor used. Note: It is not possible to change the value of Load Compensation with the HHP, because Load Compensation must be set by an OEM for a particular chair type and motor, and should not be modified for specific users. To provide smoother control for specific users or situations using the HHP, set the LC Response Profiled parameter ( ) to Yes. This enables the use of the Load Compensation Response parameter. The Load Compensation Response parameter (available on DX2 Master Remotes only) softens the behaviour of the Load Compensation and can be changed with the HHP for each individual Drive Profile separately. For more information see Load Compensation Response ( ). 30

31 Measure Load Compensation automatically The Wizard has a plug-in that can determine the Load Compensation automatically on a powerchair that has a DX2 Power Module. To measure the motor resistance accurately, use the following procedure. Install and connect the complete DX System (Master Remote, Power module, motors, batteries) first Turn the system on and set the Load Compensation to 0 Turn the system off and on to activate the new value Select a slow Drive Profile Lock or stall the wheels of the powerchair so that the wheels are not able to turn. For a reliable measurement, it is important that the motors are not able to move. Connect a computer to the DX System with a programming cable. Start the Wizard and wait until controller connected is shown in the status window Start the plug-in: Tools Plug-ins DX2 Power Module Load Compensation Real-time voltage and current measurement for each motor Slowly deflect the joystick in all directions until the motor current is at least 10 A for both motors. If the current is high enough, the bar of the current becomes green. Return the joystick to the centre. The calculated motor resistance is shown in the resistance fields. Lock the wheels in a different position and repeat the measurement. Perform the test when the motors are cold and when the motors are hot. Use the measurement with the lowest value. Decrease this value by 20% and set that as Load Compensation resistance with the Wizard. Test if the chair drives as expected. If the chair drives too soft or rolls back on a slope, increase Load Compensation, but NEVER increase it above the lowest measured value. 31

32 Load Compensation Response Load Compensation Response lowers the Load Compensation value when the powerchair drives at higher speeds. At lower speeds, the Load Compensation setting is not affected. This makes it possible to set a Load Compensation value that is high enough to provide zero rollback and fast response at a low speed, while a soft response setting retains smooth control at higher speeds. If the DX2 system has a DX2 remote and LC Response Profiled is set to 'Yes', the value of Load Compensation Response is set with the Load Compensation Response parameter for each individual Drive Profile separately (the Load Compensation Response parameter is located in the Drive Profile section of DX2 Master Remotes). Parameter Possible Values Default HHP Lite Std Adv LC Response Default % 80 % - If the DX2 System has an older DX remote, the Load Compensation Response parameter is not available. In this case, all Drive Profiles use the value of the LC Response Default parameter that has been set by the OEM to provide a suitable default for the chair design. Note: LC Response Default is only used when the DX2 Load Compensation Response parameter (located in the Drive Profiles section) is not available or LC Response Profiled is set to 'No'. Parameter Possible Values Default HHP Lite Std Adv LC Response Profiled Yes/No No - No All Drive Profiles use the value of the LC Response Default parameter for the calculation of Load Compensation Response. Yes Each Drive Profile uses its own Load Compensation Response setting for the calculation of Load Compensation Response (the Load Compensation Response parameter is located in the Drive Profile section of DX2 Remotes). This provides the flexibility to create responsive Drive Profiles as well as smooth Drive Profiles in one wheelchair program, for example, a responsive sports profile and a smooth cruising profile. Note: This parameter only has effect on DX2 Master Remotes. DX Master Remotes do not have the Load Compensation Response parameter and always use the LC Response Default parameter for each Drive Profile. 32

33 Load Compensation Response (if available) Location: DX2 Master Remote (profiles) Set for each Drive Profile separately LC Response Default (if is not available or disabled) Location: DX2-PMA Power Module One value for all Drive Profiles together Value Result Value Result 0 % Profiled response disabled, - - use LC Response Default value for this profile 1 50 % Too low; not recommended % Soft response % Soft response % Normal response % Normal response % Hard response % Hard response 100 % Profiled response disabled, use LC Response Default value for this profile 100 % Very hard response, Load Compensation value not lowered at any speed 33

34 Left/Right Motor Swap Parameter Possible Values Default HHP Lite Std Adv Left/Right Motor Swap No/Yes No - If this parameter is set to Swap, the Power Module swaps the Left and Right motor outputs. Swapping the motor outputs allows the cabling between the Power Module and the motors to be optimised for particular mounting orientations of the Power Module. Parameter value Normal Swap Left motor M1 Left motor M2 Motor connection Right motor M2 Right motor M1 Note: Most Fault messages and Diagnostic messages ignore the value of this parameter. Left Motor/Parkbrake fault is always the motor/parkbrake connected to M1, Right Motor/Parkbrake fault is always the motor/parkbrake connected to M Motor Invert Parameter Possible Values Default HHP Lite Std Adv M1 Motor Invert No/Yes No - M2 Motor invert No/Yes No - If these parameters are set to Yes, they swap the polarity of the motor connector: '+' will become ' ' and ' ' will become '+'. Note: 1. If you invert only one of the two motors, the performance of the DX2 System will be reduced. This situation is not recommended for long term use. 2. These parameters are not affected by the value of the Left/Right Motor Swap parameter. M1 is always the M1 socket on the Power Module and M2 is always the M2 socket on the Power Module. 34

35 Motor Continuity Test Parameter Possible Values Default HHP Lite Std Adv Motor Continuity Test No/Yes Yes - Every time before the powerchair starts to drive, Motor Continuity Test checks that the connections of the motors are not loose and the motor is not broken. Always set this parameter to 'Yes', except if motor faults occur because the motor brushes frequently lose contact after the motor has stopped, or the motor resistance is higher than approximately 1 Ω, which causes the Power Module to think that the motor has an open circuit Veer Compensation Parameter Possible Values Default HHP Lite Std Adv Veer Compensation % 0 % - If the two motors of the powerchair do not perform exactly the same, the chair will not drive in a straight line. The chair will slightly change its direction (veer) when it drives forward. Veer Compensation calculates how much the chair must correct its direction to go in a straight line. Intended direction Veer Compensation Actual direction Actual direction Veer Veer The chair does not drive straight when the performance of the two motors is not equal The chair now drives straight because Veer Compensation corrects the direction Notes: 1. Do not use Veer Compensation to compensate for out-of-centre joystick deflection by the user, use the Joystick Angle Compensation parameter instead (available on DX2 remotes only). 2. Other factors than motor performance can cause chair veer, for example bent frames, flat tyres or faulty castor wheels. Correct these problems at the source, do not use Veer Compensation. 3. Adjust this parameter every time a motor is replaced. 35

36 4.3.3 Parkbrake options Parkbrake Parameter Possible Values Default HHP Lite Std Adv Parkbrake Single/Dual Dual - Single Only parkbrake output M1 is active. Do not use parkbrake output M2. Dual Parkbrake output M1 and M2 are both active. See the Parkbrake Configurations section in the DX2 System Manual for more information on how to connect the parkbrakes Test Parkbrake Driving Parameter Possible Values Default HHP Lite Std Adv Test Parkbrake Driving No/Yes No - Yes No The parkbrakes are periodically checked for open-circuit while the chair is driving. Some parkbrakes produce a noise during this test, which can annoy the user. The parkbrakes are not checked for open-circuit while the chair is driving, only before the chair starts to drive. The parkbrake short-circuit test is not affected by the value of this parameter. The short-circuit test will still be performed while driving. 36

37 4.3.4 Battery Options Battery Type Parameter Possible Values Default Battery Type Standard Small Large Custom Standard HHP Lite Std Adv - The rated capacity in Ampere-hours (Ah) of a battery is usually specified for a 20-hour discharge rate (an average current of 5% of the rated capacity, or 0.05 CA). A higher continuous discharge current dramatically reduces the available battery capacity. When the average discharge current equals the rated capacity (1 CA) the battery does not last one complete hour as expected, but only 30 minutes, giving an actual available capacity of only 50%. Rated capacity 20 Ah 20 Ah 20 Ah 20 Ah 20 Ah Average discharge current 40 A (2 CA) 20 A (1 CA) 12 A (0.6 CA) 8 A (0.4 CA) 1 A (0.05 CA) Actual capacity 5 Ah (25 %) 10 Ah (50 %) 12 Ah (60 %) 15 Ah (75 %) 20 Ah (100 %) The Battery Type parameter matches the powerchair application to the size of the battery and influences the speed by which the battery gauge decreases when the battery voltage decreases. Standard For applications where the average driving current is between 0.2 CA and 0.3 CA, and where the average high-load current (on hills and thick carpets) is between 0.3 CA and 0.5 CA. The battery gauge acts normally. Small For applications where the average driving current or the average high-load current is higher than the standard range (for example lightweight indoor chairs that are used mainly on thick carpet, or heavy-duty chairs with a relatively small battery). The battery gauge decreases faster, because the actual capacity of the battery will be smaller than expected. Large For applications where the average driving current and the average high-load current is lower than the standard range (for example efficient chairs with a large battery). The battery gauge decreases slower, because the actual capacity of the battery will be larger than expected. Note: 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%. 37

38 4.3.5 DCI Parameters Parameter Possible Values Default HHP Lite Std Adv DCI Mode DC Function 1 DC Function 2 DCI Off Multi Speed/OBC High R OBC Speed Pot Seat position Seat position + Invert demand Multi Function None Speed Pot Speed Limit Parkbrake Release Force Profile DCI Off - None - DCI Speed % 0 % - DCI Speed % 0 % - DCI Speed % 0 % - DCI Profile For a description of the Drive Control Input (DCI) see section Lighting Outputs Parameter Possible Values Default HHP Lite Std Adv Accessory Pin 3 Accessory Pin 4 Accessory Pin 5 Off Left Indicator Off Head Lights Off Right Indicator Off - Off - Off - These parameters assign the output pins of the accessory connector. Off Left Indicator Head Lights The output pin is not active (high resistance). The output pin is assigned to the Left Indicator lights. The output pin is assigned to the Side/Position lights. Right Indicator The output pin is assigned to the Right Indicator lights. The light outputs are active low. For this reason connect the lights to B+ (either pin 1 or pin 2) and the corresponding light output (pin 3, 4 or 5). Each output can sink a current of up to 2 A. 38

39 5 Diagnostics / Troubleshooting 5.1 Diagnostic tools The Module Status LED The DX2-PMA has a green LED to indicate the status of the Power Module. Module Status LED If the system is on and there are no faults present, the LED is continuously on. If a DCI (3.2.6) switch condition or other condition is present that changes the drive characteristics of the chair (normally this is a slow or stop condition), the Module Status LED and the System Status LED (on the Master Remote) show Flash Code 2. If the Power Module detects a fault, the LED shows a Flash Code that indicates the cause of the fault. The flash codes are identical to the DX System flash codes. See the diagnostics section of the DX System Manual for a description of the DX System flash codes and the possible solutions to the faults Hand Held Programmer (HHP) If you plug an HHP into the DX System when a fault condition exists, the HHP will display the detected fault on its screen The PC-based Wizard program The Wizard provides a full fault history and shows a description of any current faults. To create a diagnostic report, click on the icon with the wrench or click Tools Diagnose Controller. Create Diagnostic Report It is possible to print or save a diagnostic report for further analysis by a service centre. 39

40 5.2 The DX2-PM Service Data Manager The Service Data Manager is a Wizard plug-in that controls the Service Scheduler shows detailed information on the usage of the powerchair and the state of the battery. To start the Service Data Manager, connect the DX System to the computer, start the Wizard and click Tools Plug-ins DX2 Power Module Service Data Manager. Wait until the status bar shows Data Successfully Received. The plug-in now shows up-to-date information Service Scheduler With the service scheduler, the person who performs maintenance on the chair can program a suitable time at which the chair must be brought in for maintenance. After the set time has passed, the Master Remote indicates to the operator that the chair should be serviced, each time that the DX System is turned on. Note: Only DX2 Master Remotes show a maintenance indication to the user. A DX Master Remote does not communicate with the Service Scheduler and therefore takes no action. It is however still possible to look at the Service Scheduler data with the Service data Manager when a DX Master Remote is installed. After a chair has received maintenance, the service technician can edit the parameters to set the correct servicing date and to set the Service Schedule Due At parameter to the correct value. To save the new settings in the Power Module, click Write Service Schedule Type Off The Service Scheduler does not indicate to the user that the chair must be brought in for maintenance. All the chair usage data is still visible with the Service Data Manager, only the indication on the Master Remote is not shown. Drive Time The Service Scheduler indicates that the chair must be brought in for maintenance when the Drive Time (the total time that the joystick is deflected) in the Chair Data section exceeds Service Schedule Due At (in hours). Use this setting for standard chairs that are used outdoors as well as at home. 40

41 Drive Cycles The Service Scheduler indicates that the chair must be brought in for maintenance when the number of Drive Cycles (the number of times that the joystick is deflected and returned back to the centre) in the Chair Data section exceeds Service Schedule Due At (in cycles). Use this setting for chairs that are mainly used at home, because the drive time remains relatively small while the parkbrakes, motors and joystick are used heavily for many small chair movements. On Time The Service Scheduler indicates that the chair must be brought in for maintenance when the Power On Time (the total time that the DX System has been turned on) in the Chair Data section exceeds Service Schedule Due At (in hours). Use this setting for chairs where the drive time or drive cycles do not give an accurate measure for the wear of the chair, for example, chairs that have fragile movable structures that are used frequently when the chair is not driving Last service date After a chair has received maintenance, the service technician can set the Last service date to the current date. This way, another technician or a therapist can check when the last maintenance of the chair has occurred. To save the new setting in the Power Module, click Write Time since last service Dependent on the value of Service Schedule Type, this parameter shows the drive time, the drive cycles or the on time that has elapsed since the last maintenance of the chair. The service technician should reset this value to zero after chair maintenance. This parameter is only an indication for the therapist/technician and is not used in the Service Scheduler calculation Service schedule due at The total drive time, on time, or number of drive cycles (dependent on the Service Schedule Type) after which the chair must receive maintenance. The service technician should set this parameter to the appropriate value for the chair, the driving style of the user and the terrain that the chair is used in. If the value of Drive Time, Drive Cycles or Power On Time exceeds Service schedule due at, the Master Remote indicates to the operator that the chair should be serviced, each time that the DX System is turned on. To clear the indication, the service technician can either reset the Chair Data parameters to zero or increase the value of Service Schedule Due At, dependent on the way the chair data is used (see for details). If Service Schedule Type is set to Off, this parameter is ignored Time to next service As an indication for the therapist/technician, this parameter shows the value of Service Schedule Due At minus Drive Time/DriveCycles/Power On Time. This shows how much time/cycles are left before the Master Remote indicates that the chair should be serviced. 41

42 5.2.2 Chair Data The chair data can be used in two different ways: A measurement of chair usage over the total life of the chair. In this case, the chair data should never be reset to zero. If the Power Module is ever replaced, write down the chair data values from the old Power Module, and use the Service Data Manager to write these values to the new power module (edit the values and click Write). A measurement of chair usage between maintenance dates. In this case the service technician should reset all these values to zero after chair maintenance (click Clear All and click Write) Drive Time The total time that the joystick has been deflected out of the centre position Drive Cycles The total number of times that the joystick has been deflected and returned back to the centre Power On Time The total time that the DX System has been turned on Power Cycles The number of times that the Power Module has been turned on by the correct wake-up voltage on the DX BUS. This value should be almost the same as the value of Power On Cycles and Power Off Cycles. If Power Cycles is much higher than the other two, it may indicate A problem with the DX BUS, for example an intermittent short circuit between the CANH line and Battery positive. Check the DX BUS cables and connections for damage, and replace the DX BUS cables if necessary. The Power Module frequently being disconnected from the DX BUS while the battery is still connected. This may cause a small voltage spike on the DX BUS that wakes up the Power Module while the Master Remote is still off Power On Cycles The number of times that the Power Module has completed the power-up sequence successfully Power Off Cycles The number of times that the Power Module has completed the power-down sequence successfully after the DX System was turned off with the on/off button. If this number is much lower than the Power On Cycles value, it may indicate an intermittent problem with the battery connection or users disconnecting the battery. If the battery power is lost, the Power Module cannot perform a power-down sequence, while it will perform a power-up sequence the next time that the system is turned back on. 42

43 5.2.3 Battery Data The battery history can help the person who performs maintenance on the chair to analyse the usage of the chair and the state of the battery. Reset these values to zero when the battery is replaced Battery Capacity History Bat Time % Capacity Bat Time 50-75% Capacity Bat Time % Capacity Bat Time 0-25 % Capacity These four parameters show the total elapsed time that the battery capacity has been at a certain level while the DX System has been turned on. These parameters together give an indication of how the battery and the chair have been used. For example, if the battery has been at less than 50 % capacity for most of the time, it may indicate a battery with a bad cell, or a charger that is too light for the type of battery (it takes too long to charge the battery), or a user who never leaves the charger in long enough to charge the battery completely. In either case, it may be necessary to replace the battery. Note: If the battery has just been charged and the DX System is turned on, the battery capacity history is only updated after a drive cycle is completed. No drive cycle is required if the battery has not been charged Overcharge Cycles The number of times that the battery voltage has been higher than the High Voltage Warning* value for a long continuous period. The higher the battery voltage, the shorter the time before a cycle is counted. Only overcharge cycles that occur while the DX System is turned on are counted. Many overcharge cycles may indicate a bad battery connection, or a battery with a bad cell, or a defective charger. *Normally High Voltage Warning has the value of 29 V. Create a diagnostic report (see section 5.1.3) to check the actual value. 43

44 Overcharge Time The total time that the battery voltage has been higher than the High Voltage Warning value. Only overcharge time that occurs while the DX System is turned on is counted. Note: If there are many overcharge cycles while there is not much overcharge time, the overcharging could be drive related: the user may go uphill and downhill often. If there is much overcharge time but not many overcharge cycles, the overcharging could be charger related: the charger used may actually overcharge the battery Charge Time The time during which the battery has been charged with several Amperes while the DX System was turned on. Normally this value should be very low, because charging of the battery usually takes place while the system is turned off. If this value is high, it may indicate that The user charges the battery while the system is turned on. This may cause problems if the user operates the actuators during charging, and the charger that is used is not able to cope with a load while charging. Some chargers interpret the decreased battery voltage during the operation of the actuators as the battery being not full yet, and as a result overcharge the battery, which decreases the life span of the battery. The chair frequently drives downhill with a fully charged battery. This may also cause overcharging of the battery High-load Discharge Time The total amount of time during which the chair was used in high-load situations, such as driving up a ramp, driving up a hill, or driving on thick carpet. If this value is greater than 30% of the total drive time, the battery may be too small for the application. 44

45 5.3 Incompatibility with DX (non-dx2) modules DX2-PMA Module + DX Master Remote System Backup Mirror not operational The System Backup Mirror only works when both the Power Module and the Master Remote belong to the DX2 family. If either the Power Module or the Master Remote is a DX Module (and not a DX2 Module), the System performs an Auto Download instead of a System Restore. This means that in a DX System containing a DX Master Remote and a DX2 Power Module, the DX2 Power Module can be replaced without reprogramming the DX System, but the DX Master Remote cannot be replaced without reprogramming the DX System. See section 4.1 for more information about the System Backup Mirror. See the DX System Manual for more information about Auto Download Service Scheduler gives no Service due indication If a service is due, the service scheduler normally indicates on the Master Remote that the chair should be brought in for maintenance, each time when the DX System is turned on. A DX Master Remote does not show the message of the Service Scheduler because it does not recognise the message. It is however still possible to look at the service scheduler data with the Wizard plug-in (see 5.2) for easy battery usage and chair usage statistics Only use Remotes with Rev C or higher The DX2-PMA currently only works with DX Master Remotes that have UCM software version Rev C and higher: REM55x, REMG90, REMG91/REMG91S, and REM24-SC/SD. 45

46 5.3.2 DX2-PMA replacing a DX-PM or a DX-PMB Program conversion from DX-PMB to DX2-PMA The DX2-PMA has some enhancements that make a few old DX Power Module parameters obsolete. To convert the obsolete parameters to the new parameters manually, use the following procedure. Old parameter New parameter Conversion value Input Demand Scaler Speed Demand Scaler Speed Demand Scaler ( ) = Input Demand Scaler Halve Turning Gain Left Motor Invert* Right Motor Invert* Left/Right Motor Swap Turn Demand Scaler ( ) M1 Motor Invert** ( ) M2 Motor Invert** ( ) Left/Right Motor Swap ( ) If Halve Turning Gain = No : Turn Demand Scaler = Input Demand Scaler If Halve Turning Gain = Yes : Turn Demand Scaler = Input Demand Scaler / 2 If Left/Right Motor Swap = No : M1 Motor Invert = Left Motor Invert M2 Motor Invert = Right Motor Invert If Left/Right Motor Swap = Yes : M1 Motor Invert = Right Motor Invert M2 Motor Invert = Left Motor Invert Left/Right Motor Swap = Left/Right Motor Swap *Which motor is inverted depends on the value of Left/Right Motor Swap **Which motor is inverted does not depend on the value of Left/Right Motor Swap Auto download not operational If the parameter values stored in the Master Remote are not compatible with the DX2-PMA (as is the case with DX Power Modules, see ), an auto download will fail. This means that a DX2-PMA cannot replace a DX Power Module without reprogramming the DX System with the Wizard. 46

47 6 Appendices 6.1 Intended Use and Regulatory Statement Intended Use The DX2-PMA is a module of the DX System intended to provide dual drive motor control for powered wheelchairs fitted with the DX System. The DX System is a family of modules intended to control powered wheelchairs. The DX System offers flexibility in integrating compatible input and output devices, as configured and connected, and provides extensive adaptability to meet specific user needs through optimal programmability. The DX System is intended to operate powered wheelchairs utilising 24V motors with integrated parkbrakes. The powerchair manufacturers are provided with the integration, set-up, operating environment, test and maintenance information needed to ensure reliable and safe use of the DX System. Device Classification Europe The DX System is a component of a Class I medical device as detailed in the Council Directive 93/42/EEC concerning Medical Devices. USA The DX System is a component of a Class II medical device (Powered Wheelchair) as detailed in 21 CFR Compliance and Conformance with Standards In accordance with the device classification, the DX System and all its modules have been designed to enable the powerchair manufacturer to comply with the relevant requirements of the European Medical Device Directive 93/42/EEC and 21 CFR 820. The DX System and all its modules have been designed such that the combination of the wheelchair and the DX System, along with accessories as applicable, complies with the Essential Requirements of the MDD by adopting relevant clauses of harmonised standards EN12184 and EN12182 and the FDA Consensus standard ISO 7176 for performance. However, final compliance of the complete powerchair system with international and national standards is the responsibility of the powerchair manufacturer or installer. 47

48 6.2 Maintenance 1. Keep all DYNAMIC electronic components free of dust, dirt and liquids. For cleaning the product, use a cloth dampened with warm soapy water. Do not use chemicals, solvents or abrasive cleaners, as this may cause damage to the product. 2. Regularly check all vehicle components for loose, damaged or corroded components such as connectors, terminals, or cabling. Restrain all cables to protect them from damage. Replace damaged components. 3. Regularly test all switchable functions on the DYNAMIC electronics system to ensure they function correctly. 4. There are no user-serviceable parts in any DYNAMIC electronic component. Do not attempt to open any case or undertake any repairs, else warranty will be voided and the safety of the system may be compromised. 5. Where any doubt exists, consult your nearest service centre or agent. Warning: If any component is damaged in any way, or if internal damage may have occurred (for example by being dropped), have it checked by qualified personnel before operating. 6.3 Warranty All equipment supplied by Dynamic Controls is warranted by the company to be free from faulty workmanship or materials. If any defect is found within the warranty period, the company will repair, or at its discretion replace, the equipment without charge for materials or labour. This warranty is subject to the provisions that the equipment: has been correctly installed. has been thoroughly checked upon completion of installation, and all programmable options correctly adjusted for safe operation prior to use. has been used solely in accordance with this manual and the DX System Manual. has been properly connected to a suitable power supply in accordance with this manual and the DX System Manual. has not been subjected to misuse or accident, or been modified or repaired by any unauthorised personnel. has been used solely for the driving of electrically powered wheelchairs in accordance with the intended use and the recommendations of the wheelchair manufacturer. 48

49 6.4 Safety and Misuse Warnings The DX2 Power Module is part of the DX System and therefore all safety and misuse warnings that appear in the DX System Manual apply to the DX2 Power Module as well. See DSM section Additional warnings to be included in the User Manual The following warnings must be passed on to the operator of the vehicle before use of the product. In the case of an emergency while the vehicle is driving, press the On/Off button to perform an emergency stop and turn the system off. If operators of the vehicle are left with limited or no mobility because the vehicle loses electric power or breaks down, it is important that they can still call for assistance from wherever they may be. Do not store or operate the DX2 Power Module at a temperature that is outside the temperature ranges specified in this manual. Service and Configuration Warnings The following warnings are applicable to the installer and therapist only. It is the responsibility of the OEM and installer to make sure that the maximum driving speed of the chair is limited as appropriate when the chair is in a mechanically unstable position, for example when the seat is raised. It is the responsibility of the therapist/ installer to minimize any risk of use error, including those arising from ergonomic features and/or the environment in which the device is intended to be used. The chair set up and configuration process should take into consideration the o technical knowledge, experience and education, and o medical and physical condition, including the level of disability and capability of each individual user. Prior to handing over the vehicle, make sure that users are fully able to operate the product by providing them appropriate training on functionality and safety features, and having them test-drive the vehicle in a safe area in the presence of their agent. After maintenance or service of the chair, check the functional operation of the lights and the DCI circuit, if fitted. 49

50 6.5 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: Sec 21 Europe: EN12184: 1999 Sec National and international directives require confirmation of compliance on particular vehicles. Since EMC is dependent on a particular installation, each variation must be tested. Minimising emissions To minimise emissions and to maximise the immunity to radiated fields and ESD, follow the general wiring recommendations in section of the DX System Manual. 6.6 Environmental statement This product has been supplied from an environmentally aware manufacturer. Please be environmentally responsible and recycle this product at the end of its life through your local recycling facility. This product may contain substances that could be harmful to the environment if disposed of into a landfill. Do not dispose of this product in fire. 50

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