Dynamic Rhino User manual

Rhino to RHINO2
Conversion Guide
Rhino to RHINO2 Conversion Guide Issue 1, December 2011

Rhino to RHINO2 Conversion Guide Page 2
About
This manual can help you convert an existing Rhino-based scooter system to a RHINO2 scooter system.
This manual must be read together with all other relevant scooter component manuals.
In this manual, a few symbols will help you identify the purpose of the paragraph that follows:
Warnings:
Warnings provide important information that must be followed in order to install, configure, and use
the product safely and efficiently. Not following the instructions given in a warning can potentially
lead to equipment failure, damage to surrounding property, injury or death.
The term ‘programming’ used in this manual refers to adjusting parameters and configuring options to suit an application.
‘Programming’ does not change or alter any software within the controller and is performed using a controlled
programming tool available only to authorised personnel.
The product is not user serviceable. Specialised tools are necessary for the repair of any component.
Do not install, maintain or operate this equipment without reading, understanding and following this manual –including
the Safety and Misuse Warnings –otherwise injury or damage may result. This manual contains integration, set-up,
operating environment, test and maintenance information needed in order to ensure reliable and safe use of the product.
Due to continuous product improvement, DYNAMIC CONTROLS reserves the right to update this manual.
This manual supersedes all previous issues, which must no longer be used.
DYNAMIC CONTROLS reserves the right to change the product without notification.
Any attempt to gain access to or in any way abuse the electronic components and associated assemblies that make up the
scooter system renders the manufacturer’s warranty void and the manufacturer free from liability.
DYNAMIC CONTROLS, the DYNAMIC CONTROLS logo, the RHINO logo, the RHINO2 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 CONTROLS owns and will retain all trademark rights and DYNAMIC CONTROLS 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 2011 Dynamic Controls. All rights reserved.
Notes:
Notes provide supporting information in order to install, configure, and use the product. Not following the
instructions given in notes or precautions can lead to equipment failure.

Rhino to RHINO2 Conversion Guide Page 3
Contents
ABOUT .............................................................................................................................................................2
INTRODUCTION ...............................................................................................................................................4
INTRODUCING THE RHINO2 .............................................................................................................................5
PROCEDURE.....................................................................................................................................................6
STEP 1–CAPTURE THE EXISTING RHINO’S PROFILE ........................................................................................................ 7
STEP 2–REPLACE THE RHINO CONTROLLER WITH THE RHINO2 CONTROLLER..................................................................... 7
STEP 3–ADAPT THE CABLES ..................................................................................................................................... 7
Install the motor, park brake and battery cable adaptors............................................................................. 7
Install the logic cable adaptor...................................................................................................................... 13
STEP 4–SET UP THE SCOOTER PROFILE...................................................................................................................... 14
Set up throttle parameters........................................................................................................................... 14
Set up drive performance parameters ......................................................................................................... 14
Set up motor management parameters ...................................................................................................... 14
Set up park brake management parameters ............................................................................................... 15
Set up battery management parameters..................................................................................................... 15
Set up actuator parameters (where fitted) .................................................................................................. 15
Fine tune Load Compensation...................................................................................................................... 15
To finish........................................................................................................................................................ 15
STEP 5–TEST DRIVE.............................................................................................................................................. 16
FURTHER INFORMATION ...............................................................................................................................17
PROGRAMMING.................................................................................................................................................... 17
EXTERNAL BATTERY CHARGER SOCKET........................................................................................................................ 17
LOGIC CONNECTOR ................................................................................................................................................ 18
Beeper Output.............................................................................................................................................. 18
Speed Reduction Wiper................................................................................................................................ 18
Forward-reverse input.................................................................................................................................. 18
Status LED .................................................................................................................................................... 19
SPEED SETTINGS.................................................................................................................................................... 19
SPEED REDUCTION ................................................................................................................................................ 19
ACCELERATION AND DECELERATION SETTINGS ............................................................................................................ 19
THROTTLE NEUTRAL OFFSET.................................................................................................................................... 20

Rhino to RHINO2 Conversion Guide Page 4
Introduction
This document shows you how to retrofit a RHINO2 scooter control system. It is important that you
read and follow these instructions carefully. Please adhere to all warnings and steps.
To complete the installation, you will need the following:
A copy of the RHINO2Installation Manual
A RHINO2 controller to replace the Rhino
Cable adaptors for battery, motor, park brake and tiller head.
The Wizard for setting parameters and optionally, a DX-HHP (hand-held programmer) for
calibrating the Throttle.
Programmer adaptors: DWIZ-ADAPT and DR-PRGLM02 (see Programming in the Further
information section at the back of this guide)
Warning:
Follow these instructions carefully. The RHINO2’s current capability is higher
than Rhino. Failure to follow these settings can result in damage to the scooter
or serious injury to the user.
Warning:
This manual should be read in conjunction with the RHINO2 Installation
Manual and the procedure should only be carried out by suitably trained
personnel.
Before you start!
Make sure that you have a copy of the RHINO2Installation Manual at hand. This is important for
details of mounting the new controller, setting the controller’s profile, and detailed further
information.
Note:
If you have any difficulty with the instructions in this guide, then please consult your scooter
manufacturer.

Rhino to RHINO2 Conversion Guide Page 5
Introducing the RHINO2
The RHINO2family of scooter controllers provides a reliable, refined, cost-effective control solution
for most mobility scooters and includes:
DS90 - RHINO290A Controller
DS120 - RHINO2120A Controller
DS160 - RHINO2160A Controller
DS90-ACT - RHINO290A Controller with actuator
DS120-ACT - RHINO2120A Controller with actuator
DS160-ACT - RHINO2160A Controller with actuator
RHINO2–DS90 and DS120 RHINO2–DS160
90, 120 and 160A models provide the power you want when you need it
Programmable acceleration curves, improved rollback on slopes, and improved motor matching
algorithms ensuring better curb-climbing and hill-starting capabilities
Speed reduction wiper (SRW) technology provides a seamless speed reduction in curves for extra
stability
Intelligent motor and battery management providing automatic power flow optimisation, auto
battery configuration, 5V and 12V battery capacity outputs (TruCharge™) and in-depth battery
logging and analysis tools
Support for a range of battery types, multi-function pins and flexible drive inhibits
Advanced diagnostics and servicing tools, including event and drive time logging, and
programmable servicing scheduler
2 Drive profiles, brake and reverse lights, reversing beeper and electronic park brake release
IP54 ingress protection
A separately available aluminium terminal cover provides increased protection to IP55 when
fitted
Compliant with EU Directive 2002/95/EC of 27 Jan. 2003 –restrictions on use of Hazardous
Substances (RoHS)
Optional single actuator output (with Wig-wag or dedicated switch activation).

Rhino to RHINO2 Conversion Guide Page 6
Procedure
The procedure for swapping a Rhino system to a RHINO2system involves both adapting the cabling,
and programming some specific parameters. A summary is outlined below:
In step 3, choose and install the correct cable adaptors for your scooter system.
For step 4, the Wizard programming tool is required to program specific parameters (see
Programming, in the Further information section). For each parameter, a reference is provided next
to the parameter’s name (for example, Speed Limit Pot (4.4.2.11)). This refers to the section in the
RHINO2 Installation Manual where you will be able to find out more information on that particular
parameter.
Step 1 –Capture the Rhino’s existing profile
Step 2 –Replace the Rhino controller with the RHINO2 controller
Step 3 –Adapt the cables
Install the motor, park brake and battery cable adaptors
Install the logic cable adaptor
Step 4 –Set up the scooter profile
Set up throttle parameters
Set up motor management parameters
Set up battery management parameters
Set up drive performance parameters
Set up park brake management parameters
Set up actuator parameters
Step 5 –Test drive
Before you start!
Make sure that you have a copy of the RHINO2Installation Manual at hand. This is important for
details of mounting the new controller, setting the controller’s profile, and detailed further
information.

Rhino to RHINO2 Conversion Guide Page 7
Step 1 –Capture the existing Rhino’s profile
Connect the existing Rhino system to a PC or laptop, and with the Wizard application, read the
existing Rhino’s configuration profile. You will use some of the existing configured parameters to set
up the RHINO2 controller in later steps. For more information on programming, see Programming, in
the Further information section. Save and print out the profile for reference later on.
Step 2 –Replace the Rhino controller with the RHINO2 controller
Replace the existing Rhino controller with the new RHINO2controller. Note that the mounting holes
of the RHINO2are different from the Rhino. For more information on this and the recommended
mounting orientation, please see the RHINO2 Installation Manual (section 3.1.1 & 3.1.2).
Step 3 –Adapt the cables
Install the motor, park brake and battery cable adaptors
RHINO2uses different cable connectors compared with the Rhino. For this reason, you will need to
adapt the existing looms. Dynamic Controls have produced a number of adaptors to help you. The
table below summarises the cable adaptors to use with the RHINO2variants.
Rhino to RHINO2
Adaptor Loom
Part No.
Use for DS52K to DS90
Use for DS72K to DS90
Use for DS72KA to DS90-ACT
Use for DS112K to DS120
Use for DS162K to DS160
Notes
DS90 MTR/PB ADAPT LOOM
GLM51981



Suitable for motor looms
using Tyco 170258-2 housing.
DS120 MTR/PB ADAPT LOOM
GLM51983

Suitable for motor looms
using Dynamic Controls
GCN51315 housing.
RHINO2 BATT/ACT ADAPT
LOOM
GLM51984

RHINO2 MTR-4/RING ADAPT
LOOM
GLM51985

RHINO2 BATT-6/RING ADAPT
LOOM
GLM51986

Warning:
Check the motor connector on the existing motor to ensure that the
receptacles are not loose or damaged. Loose or damaged receptacles can lead
to over-heating, and the connector housing melting.

Rhino to RHINO2 Conversion Guide Page 8
Warning:
The motor and battery adaptor looms are only suitable for use with scooter
wiring that uses genuine AMP/Tyco housings and terminals and/or genuine
Dynamic housings as specified in the Rhino installation manual.
Type
Part No.
6-way 250 series Plug Housing
171898-1
4-way 250 series Plug Housing
172134-1
250 series Receptacle w/o latch 14-12 AWG
170258-2
AMPINNERGY Connector Contact dual-beam 10-12 AWG
556880-2
Dynamic 4-way Connector Housing
GCN51315
Terminal kits
Alternatively, you can use the following terminal kits to re-terminate your existing looms. These kits
are available from your Dynamic Controls supplier.
Terminal kit
Part No.
Details
RHINO2 - Loom Kit Logic
GSM51982
2, 4 and 14 pin connectors and terminals
RHINO2 –Loom Kit 4W MTR 6W BAT
GSM51988
4-way and 6-way housings and spade
receptacles to suit DS90 and DS120
RHINO2 - Loom Kit Ring Term
GSM51989
8 ring terminals rated for 10-12 AWG wire,
to suit DS160 only
Warning:
Only use genuine AMP or MOLEX crimp tools. Failure to properly crimp the
terminals may result in high resistance terminations.
Note:
A DS90-ACT can be used to replace a DS52K or DS72K using the same looms as required by the
DS90 and simply leaving the actuator pins unused. Plug the scooter's battery lead directly into
the DS90-ACT. Do not use a GLM551984 "RHINO2 BATT/ACT ADAPT LOOM".
Similarly a DS120-ACT can replace a DS112K with the same looms as required by the DS120, and
a DS160-ACT can replace a DS162K with the same looms as required by the DS160.

Rhino to RHINO2 Conversion Guide Page 9
Adapting DS52K or DS72K to DS90 / 90-ACT
To adapt a DS52K loom to a DS90 / 90-ACT
loom, use the DS90 MTR/PB ADAPT LOOM
(part no., GLM51981) to connect the motor and
park brakes. This is suitable for motor looms
using Tyco 172134-1 housing.
GLM51981: Fit to RHINO2 motor connector
socket
GLM51981: Fit to existing motor loom
connector
GLM51981: Fit to RHINO2 park brake connector
socket
For more information, see the
RHINO2Installation Manual,
section 3.5 & 3.6
Note:
The DS52K, DS72K and DS112K do not require a battery adaptor loom. Simply connect the
existing scooter battery connector directly into the RHINO2controller’s battery connector.

Rhino to RHINO2 Conversion Guide Page 10
Adapting DS72KA to DS90-ACT
To adapt a DS72KA loom to a DS90-ACT loom,
use the DS90 MTR/PB ADAPT LOOM (part no.,
GLM51981), and the RHINO2BATT/ACT ADAPT
LOOM (part no., GLM51984).
GLM51981: Fit to RHINO2motor connector socket
GLM51981: Fit to existing motor loom
connector
GLM51981: Fit to RHINO2park brake connector
socket
GLM51984: Fit to existing battery / actuator
loom connector
GLM51984: Fit to RHINO2battery connector
socket
GLM51984: Fit to RHINO2actuator connector
socket
Warning:
Do not plug the scooter’s battery / actuator connector directly into the DS90-ACT
as this will cause the actuator to be driven.
For more information, see the
RHINO2Installation Manual,
section 3.4

Rhino to RHINO2 Conversion Guide Page 11
Adapting DS112K to DS120
To adapt a DS112K loom to a DS120 loom,
use the DS120 MTR/PB ADAPT LOOM (part
no., GLM51983). This is suitable for motor
looms using Dynamic Controls GCN51315
housing.
GLM51983: Fit to RHINO2motor connector socket
GLM51983: Fit to existing motor loom
connector
GLM51983: Fit to RHINO2park brake connector socket
For more information, see the
RHINO2Installation Manual,
section 3.5 & 3.6
Note:
The DS52K, DS72K and DS112K do not require a battery adaptor loom. Simply connect the
existing scooter battery connector directly into the RHINO2controller’s battery connector.

Rhino to RHINO2 Conversion Guide Page 12
Adapting DS162K to DS160
To adapt a DS162K loom to a DS160
loom, use the RHINO2 MTR-4/RING
ADAPT LOOM (part no., GLM51985),
and the RHINO2BATT-6/RING ADAPT
LOOM (part no., GLM51986).
GLM51985: Fit connector to existing motor loom
connector, and the ring terminals to RHINO2’s motor
connectors.
GLM51985: Fit connector to existing
battery loom connector, and the ring
terminals to RHINO2’s battery
connectors.
Note:
The torque settings for the DS160 and DS160-ACT motor and battery terminals should be
between 4.5Nm and 5.5Nm

Rhino to RHINO2 Conversion Guide Page 13
Install the logic cable adaptor
For all RHINO2variants, connect the RHINO2
LOGIC ADAPT LOOM (part no., GLM51987)
between the RHINO2controller (14-way
connector) and the existing tiller head
connector (8-way). The table below shows the
corresponding mapping between the two
connectors.
GLM51987: Fit to RHINO2tiller connector
GLM51987: Fit to existing Rhino 8-way tiller
connector
Rhino
8-way
Logic Connector
RHINO2
14-way
Logic Connector
Function
Active
Slow To
Latch
Flash
Pin 1
Pin 5
Key switch, Status LED
-
-
-
-
Pin 2
Pin 8
Throttle -
-
-
-
-
Pin 3
Pin 1
Throttle Wiper
-
-
-
-
Pin 4
Pin 2
Throttle +
-
-
-
-
Pin 5
Pin 3
Beeper
-
-
-
-
Pin 6
Pin 4
Slow/Stop, SRW
Low
50%
No
No
Pin 7
Pin 12
Reverse Drive,
Actuator Select
Low
-
-
-
Pin 8
Pin 14
Charging Inhibit
Low
-
No
No
For more information, see the RHINO2
Installation Manual, section 3.9 and the
Logic connector section in this guide.

Rhino to RHINO2 Conversion Guide Page 14
Step 4 –Set up the scooter profile
The following section involves programming various parameters to set up the scooter profile. For
more information on programming, including cable requirements, see the Programming section on
page 17.
Set up throttle parameters
Set RHINO2Swap Throttle Direction (4.4.1.3) to match the Rhino’s Pot Reverse setting.
Set RHINO2Throttle Input (4.4.2.2) to “Single”.
Set Throttle Neutral Offset based on Rhino’s Speed Pot Neutral setting. Please see Throttle
Neutral Offset (page 20) for more information.
Set RHINO2Throttle Full Scale Deflection (4.4.2.4) to ensure that the scooter’s full speed can
be attained with the throttle’s movement. For more information, please see the RHINO2
Installation Manual, section 4.4.2.4.
Set RHINO2Throttle Response (4.4.2.5) to match the Rhino’s Demand Curve setting, typically
80%.
Set RHINO2Speed Limit Pot (4.4.2.11) to “No”.
Set up drive performance parameters
Set RHINO2parameters in the Drive Performance (4.4.3) section of the RHINO2profile, for
acceleration and deceleration, to meet the scooter’s requirements. See Acceleration and
Deceleration Settings (page 19) in this guide for more information.
Set RHINO2Soft Start Period (4.4.3.9) to a similar level of Rhino.
Set RHINO2Soft Finish (4.4.3.10) between 25 to 28% in order to match Rhino deceleration
characteristics.
Set up motor management parameters
Set RHINO2Motor Reverse (4.4.5.4) to match the Rhino’s Motor Reverse setting.
Set RHINO2Load Compensation (4.4.5.5) to match the Rhino’s Motor Resistance setting; this
parameter will be fine-tuned later.
Set RHINO2Load Compensation Damping
1
(4.4.5.7) to, initially, 25% to give a similar
behaviour to that of the Rhino.
Set RHINO2Remembered Load Compensation
2
(4.4.5.8) to near zero (but not actually zero)
to give a similar performance to that of Rhino.
Set RHINO2Stall Timeout (4.4.5.11) to match the Rhino’s Current Limit Time (Stall Time)
setting (typically 10 –15 seconds).
Set RHINO2Motor Testing (4.4.5.12) to “All” (unless motor faults cause problems during
testing).
Set RHINO2Current Limit (4.4.5.9) as shown in the next table (page 15).
Set RHINO2Boost Current (4.4.5.10) as shown in the next table (page 15).
Set RHINO2Boost Time (4.4.5.10) as shown in the next table (page 15).
1
This parameter is new to RHINO2–please see RHINO2Installation Manual, section 4.4.5.7 for more details.
2
This parameter is new to RHINO2–please see RHINO2 Installation Manual, section 4.4.5.8 for more details.
Note:
Use the HHP to calibrate the unit instead of setting a value manually, see 'Throttle calibration'
in section 4.1.1.3 of the RHINO2 Installation Manual for details.

Rhino to RHINO2 Conversion Guide Page 15
For example, when swapping a DS72K to a RHINO2DS90, set the Current Limit to 70A, Boost Current
to 10A, and the Boost Time to 3 seconds.
Rhino
RHINO2
RHINO2 Current Limit
RHINO2Boost Current
RHINO2Boost Time
DS72K
DS90
70A
10A
3 seconds
DS112K
DS120
110A
10A
3 seconds
DS162K
DS160
160A
20A
3 seconds
Set up park brake management parameters
Set RHINO2Park Brake Testing (4.4.6.1) to “Driving” if the Rhino’s PB Open Circuit Drive Test
is set to “Yes”, otherwise, set it to “Pre-drive”. DO NOT set it to “None” as this will
contravene an ISO7176 requirement.
Set RHINO2Park Brake Neutral Delay (4.4.6.2) to a similar value to Rhino’s Park Brake Delay.
Note that the RHINO2’s value is displayed in milliseconds, rather than seconds.
Set RHINO2Park Brake Release Delay (4.4.6.3) to “0”.
Set up battery management parameters
Set RHINO2Undervoltage Rollback Start (4.4.7.1) to 19.6V.
Set RHINO2Undervoltage Rollback End (4.4.7.1) to 17.6V.
Set RHINO2Battery Gauge Low Warning (4.4.7.3) to 23.4V.
Set up actuator parameters (where fitted)
Set RHINO2Actuator Time-Out (4.4.8.2) to “60” to match the Rhino. This value can be
decreased for greater protection if the travel of the actuator takes less than 60 seconds to
complete under full load.
Fine tune Load Compensation
Fine tune Load Compensation (4.4.5.5). Do not over compensate. For more details, see the
RHINO2 Installation Manual (4.4.5.5 Load Compensation).
To finish
Save a copy of the profile to your computer, and write the profile to the controller.
Calibrate the throttle with the DX-HHP or the Wizard's HHP emulator
3
3
If you do not have access to the DX-HHP, then use the Wizard’s HHP emulator. This can be found by selecting
"Tools", "Plug-ins", "HHP Emulation" and clicking on the 4 soft keys, or pressing the "1", "2", "3" or "4" numeric
keys on the keyboard.
Warning:
Follow these instructions carefully. The RHINO2’s current capability is higher
than Rhino. Ensure that these motor management parameters are set to that
of the existing motor and no greater than that of the table below. Failure to
follow these settings can result in damage to the scooter or serious injury to
the user.

Rhino to RHINO2 Conversion Guide Page 16
Step 5 –Test drive
To ensure that each scooter meets a minimum level of safety, the following procedure should be
undertaken. This procedure should be carried out in a spacious environment and with due regard to
any possible unexpected scooter movement in the event of faulty installation.
1. Raise the wheels off the ground using blocks under the scooter frame so that the wheels
can turn freely.
2. Recheck all wiring, paying particular attention to polarities of batteries, motor and park
brake.
3. Make the final connection to the Battery Positive (+) terminal, open the key switch and
close the circuit breakers.
4. Turn the key-switch to turn the RHINO2on. Ensure it turns on correctly.
5. Turn the key-switch again to turn the RHINO2off. Ensure it turns off correctly. Turn the key-
switch again to turn the RHINO2back on.
6. Ensure all installed hardware is functioning correctly by activating appropriate
buttons/switches etc.
7. Move the throttle slightly out of neutral and listen for the “click” as the park brakes
disengage.
8. Move the throttle backwards and forwards and ensure that the wheels respond smoothly
and in the correct direction.
9. If a Speed Dial is fitted, turn it to various positions to check that it can limit the speed of the
wheels correctly.
10. Release the throttle to neutral and listen for the click of the park brakes re-engaging.
11. Turn off the RHINO2and remove the blocks from under the scooter.
12. Turn the RHINO2back on and turn the Speed Dial (if installed) to the lowest speed setting.
13. Sit in the scooter and drive forward and reverse slowly, checking for precise and smooth
control.
14. Repeat at higher speeds.
15. Drive the scooter on a 1:6
4
ramp and check for normal power, smoothness and parking.
16. Test all other hardware fitted.
17. Repeat testing until the scooter performs as expected.
4
This is for guidance only. Low-current controllers may not be able to handle a 1:6 ramp at full load.
Warning:
Scooters can be very heavy. It is recommended that you use a jack or similar
tool to help you lift the scooter.
Note:
Wait approximately 5 seconds after closing the circuit breakers before proceeding to step 4,
as the controller takes a few seconds to charge its internal circuitry after the first connection of
battery power before it will be ready to drive.

Rhino to RHINO2 Conversion Guide Page 17
Further information
Programming
The Rhino can be programmed by simply plugging in the DS-HHP or Wizard cable directly into the
round 5-pin programming connector socket on the Rhino DS52Kx, DS72K, DS72KA, DS112Kx or
DS162Kx (the DS72KSPx is an exception). For programming the RHINO2, an adaptor, DWIZ-ADAPT, is
required. A DR Programming Loom (DR-PRGLM02) may also be required unless the scooter is wired
to take an external battery charger - see note below.
The DWIZ-ADAPT and DR-PRGLM02 allows the Wizard cable to be plugged into the 4-pin battery
charger connector of the RHINO2controller. In addition, the RHINO2supports the DX Hand-Held
Programmer (DX-HHP) using the DWIZ-ADAPT and DR-PRGLM02.
External battery charger socket
The RHINO2can be wired to an external battery charge socket in two ways. The socket can be wired
to either the 14 pin tiller head connector, or it can be wired to the 4 pin Battery Charger connector
(see image above). If the battery charger socket is mounted on the tiller head of the scooter, then
the wiring will be simplified if it is wired to the 14-pin tiller head connector. If the battery charger
socket is mounted close to the RHINO2controller and no on-board charger is used, then the wiring
will be simpler if it is wired to the 4-pin Battery Charger connector. If an industry-standard 3-pin XLR
connector is used for the external battery charger socket then it can also be used for programming
and diagnostics, providing the inhibit pin is connected to either pin 14 of the tiller head connector or
pin 4 of the Battery Charger connector. The RHINO2should be programmed so the function of the
chosen inhibit pin is set to Battery Charger Inhibit (see RHINO2 Installation Manual 4.4.9.1).
Note:
The RHINO2 DOES NOT support the DS Hand-Held Programmer (DS2K-PD, DS2K-PM, etc.). If
you do not have access to the DX-HHP, then use the Wizard’s HHP emulator. This can be
found by selecting "Tools", "Plug-ins", "HHP Emulation" and clicking on the 4 soft keys, or
pressing the "1", "2", "3" or "4" numeric keys on the keyboard.

Rhino to RHINO2 Conversion Guide Page 18
The wiring of the industry-standard XLR battery charger
connector is:
oPin 1 = Battery Positive
oPin 2 = Battery Negative
oPin 3 = Inhibit
The battery charger plug should be wired so that pin 3 (Inhibit) is linked to pin 2 (Battery Negative).
When properly wired and configured, plugging in the external battery charger will automatically
inhibit driving, as required by ISO7176.
Logic connector
Beeper Output
Some Rhino controllers can be programmed so that the "beeper" output (pin 5 of the 8-pin
Logic connector) performs a Brake Light function or a Reverse Light function. If this option is
used and the Rhino needs to be replaced by a RHINO2, we recommend using pin 11 rather
than pin 3 for this function. However if an adaptor loom is used, then pin 3 will need to be
used, and programmed for the Brake or Reverse Light option. If the Rhino has been
programmed so that the "beeper" output functions as both a Brake Light output and a
Reverse Light output, then equivalent functionality can be achieved by using both pin 3 and
pin 11 of the RHINO2and programming one to be a Brake Light output and the other to be a
Reverse Light output. If necessary, pins 3 and 11 can be wired together so that the same
lights operate as both Brake Lights and Reverse Lights.
Speed Reduction Wiper
Some Rhino controllers (DS52K, DS72KB, DS112KB, DS162K, and DS162KD) support an
analogue speed-limit potentiometer wired between pin 6 of the 8-pin Logic connector and
Battery Negative. For the RHINO2, this functionality is called Speed Reduction Wiper (see
RHINO2 Installation Manual 4.4.3.15) and is available only on pin 4 of the 14-way tiller head
connector; the analogue speed-limit potentiometer should be wired between this pin and
Battery Negative.
The Rhino DS72KSP supports a 100kΩspeed potentiometer wired across the main throttle
(Wig-Wag) potentiometer. The RHINO2controllers support this as well, and if this feature is
required, then the wiper of the speed potentiometer should be wired to pin 9 of the
RHINO2's 14-way tiller head connector. The parameter Speed Limit Pot (see RHINO2
Installation Manual 4.4.2.11) should be set to "Yes" if this feature is required.
Forward-reverse input
Pin 7 of the Rhino's Logic connector is normally the Forward-Reverse input (except for the
DS72KA where it is the Actuator Select input). We recommend using pin 12 of the RHINO2's
tiller head connector for the equivalent function and programming it to be either a Reverse
Note: The RHINO2can be programmed to perform a battery charger inhibit function on the
other 3 secondary input pins of the 14-pin tiller head connector, but we do not recommend
this option as these pins do not support the programming communications.
Note that pin 3 is
the centre pin.

Rhino to RHINO2 Conversion Guide Page 19
Drive input or an Actuator Wig-Wag input depending on the controller being replaced. Do
not select "Actuator Control" as this is not the equivalent function. See RHINO2 Installation
Manual 4.4.9.
Status LED
If a Status LED is wired in series with the key switch, then program the RHINO2Key Switch
Status LED (see RHINO2 Installation Manual 4.4.10.4) parameter to “Yes”. Note that wiring a
resistor in series with the status LED on the Key Switch input can cause the RHINO2to switch
off under low battery conditions and therefore should not be done. The RHINO2will limit the
current through the Status LED itself making an extra resistor unnecessary.
Speed Settings
The Rhino’s Forward Speed, Reverse Speed and Reduce Speed parameters range from 1 to 10.
These translate directly into percentages from 10% to 100% used by the RHINO2. See next section
regarding speed reduction.
The Rhino’s Maximum Motor Speed parameter is a percentage. This should be multiplied by 24 volts
to give the correct value for the RHINO2's equivalent parameter Maximum Motor Voltage (see
RHINO2 Installation Manual 4.4.5.13).
Speed Reduction
The Rhino has a Reduce Speed input, also known as the Turn input, which is pin 6 of its Logic
connector. When asserted, this causes the speed demand to be limited to the value of Reduce
Speed unless the Forward Speed or Reverse Speed parameter (depending on the direction of travel)
already has a lower value. Some Rhino variants also support an analogue speed-limit potentiometer
on this pin - see above.
The RHINO2has several ways of achieving a similar function. One way is to program one of the multi-
function inputs to be a Slow (see RHINO2 Installation Manual 4.4.9) input, and to program the value
of the corresponding "Slows to" parameter to the Rhino's Reduce Speed setting (after multiplying by
10 to convert it into a percentage). Another way is to program one of the multi-function inputs to
be a "Profile 2" input and to program the Profile 2 Forward Speed (see RHINO2 Installation Manual
4.4.9) parameter to match the Rhino's Reduce Speed setting. If this method is used, then the Profile
2 Forward Acceleration and Reverse Acceleration settings may need to be reduced to give a similar
feel, but this method does give more flexibility. In either case, we recommend using pin 4 of the
RHINO2's tiller head connector for this function.
Acceleration and Deceleration Settings
The Rhino Acceleration and Deceleration settings range from 1 to 10, displayed as 10% to 100% on
the Wizard. The RHINO2Acceleration and Deceleration settings (see RHINO24.4.4), including Slam
Brake Deceleration and Emergency Deceleration, have finer resolution and are displayed as 0% to
100%. However it is implemented as a non-linear (exponential) function, so 0% does not mean zero
deceleration, but gives a 10 second nominal stopping time. In addition, the RHINO2Acceleration and
Deceleration range has been widened to suit a range of applications, and so a 100% rate gives a
nominal stopping time of just 0.4 seconds. For high speed scooters (14km/h or more), stopping
times around 2.0 to 2.5 seconds are required, requiring deceleration rates around 50% - 45%. For
low speed scooters (6km/h or less), stopping times around 1.0-1.2 seconds are required, requiring

Rhino to RHINO2 Conversion Guide Page 20
deceleration rates of 70% - 65%. 10km/h scooters require stopping times around 1.5 seconds,
requiring deceleration rates around 60%.
Acceleration rates should be programmed to be no higher than Deceleration rates for safety, and
the Forward Acceleration rates may also have to be lowered below the Deceleration rates to prevent
the front wheels lifting when accelerating up a slope.
The Reverse Deceleration rates should be less than the Forward Deceleration rates if the
corresponding Reverse Speed is lower than the corresponding Forward Speed to reduce the risk of
the front wheels lifting when decelerating while reversing down a slope. Note that in the Rhino
controllers, there is only one Acceleration rate and one Deceleration rate, but these rates are
affected by the maximum speed in the Forward or Reverse direction so the effective Reverse
Deceleration is automatically reduced with the Reverse Speed.
High Acceleration or Deceleration rates require high motor torques, which in turn require high
motor currents, particularly on slopes. The required currents are much higher for high-speed
scooters as the required torque requires a proportionally higher motor current. However if the
acceleration or deceleration rate is not adjusted for the speed of the scooter, the physical
acceleration rate (in metres per second per second) increases proportionally with the top speed of
the scooter, requiring a proportionally higher torque. These effects are multiplicative, so it is very
important to reduce the programmed acceleration and deceleration rates for the higher speed
vehicles.
In order to achieve the required stopping distances without requiring too high deceleration rates,
the Soft Start and Soft Stop parameters should only be set as high as necessary to control the
starting and stopping jerks. Setting the Soft Start Time parameter too high will delay maximum
deceleration and lead to a significantly increased stopping distance. Setting the Soft Finish
parameter too high will delay the final reduction to zero speed and delay the application of the park
brakes, and can also increase the distance that the scooter "creeps" down a slope when stopping on
a slope.
Throttle Neutral Offset
The RHINO2’s Throttle Neutral Offset is equivalent to the Rhino’s Speed Pot Neutral setting. This
setting accounts for any mechanical offset between the throttle neutral position and the centre
position of the throttle wiper. The offset is an absolute voltage above or below neutral.
The default neutral value is dependent on the value of the Throttle Type parameter:
Wig-Wag and Uni-polar both have the default neutral value at 2.5 V.
Single-ended has its default neutral value at 0 V + Minimum Throttle Voltage.
In this case all negative values of Throttle Neutral Offset are ignored and all positive values
are multiplied by 2, which means that a Wizard setting of 0.5V will produce an actual neutral
offset of 1.0V.
Note:
Use the HHP to calibrate the unit instead of setting a value manually. See 'Throttle calibration'
in section 4.1.1.3 of the RHINO2 Installation Manual for details.