Dynamic RHINO2 User manual

RHINO2
DS90, DS120 and DS160
DS90-ACT, DS120-ACT and DS160-ACT
Scooter Controllers
Installation Manual
Rhino2 Installation Manual Issue 2.0, October 2011
GBK51948

About this Manual
About this Manual
This manual can help you understand and install the Dynamic Controls (DYNAMIC) RHINO2scooter
controller. It describes the general principles, but it gives no guidelines for specific applications. If there
is a specific requirement for your application, please contact Dynamic Controls or one of the sales and
service agents to assist you.
This manual must be read together with all other relevant scooter component manuals.
In this manual, a few symbols will help you identify the purpose of the paragraph that follows:
Notes:
Notes provide supporting information in order to install, configure, and use the
product. Not following the instructions given in notes or precautions can lead to
equipment failure.
Warnings:
Warnings provide important information that must be followed in order to install,
configure, and use the product safely and efficiently. Not following the
instructions given in a warning can potentially lead to equipment failure,
damage to surrounding property, injury or death.
The term ‘programming’ used in this manual refers to adjusting parameters and configuring options to
suit an application. ‘Programming’ does not change or alter any software within the controller and is
performed using a controlled programming tool available only to authorised personnel.
The product is not user serviceable. Specialised tools are necessary for the repair of any component.
Do not install, maintain or operate this equipment without reading, understanding and following this
manual –including the Safety and Misuse Warnings –otherwise injury or damage may result. This
manual contains integration, set-up, operating environment, test and maintenance information
needed in order to ensure reliable and safe use of the product.
Due to continuous product improvement, 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 scooter system renders the manufacturer’s warranty void and the
manufacturer free from liability.
DYNAMIC, the DYNAMIC 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 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 2011Dynamic Controls. All rights reserved.

3
Contents
1. Introduction to the RHINO2 ............................................ 7
2. Specifications .................................................................. 9
2.1 Electrical Specifications........................................................................9
2.2 Physical Specifications........................................................................10
3. Installation and Testing................................................. 11
3.1 Mounting...............................................................................................11
3.1.1 General Mounting Conditions................................................11
3.1.2 Mounting Orientation ..............................................................12
3.2Attaching the terminal cover ............................................................13
3.3 Connections and Wiring.....................................................................14
3.3.1 General Wiring Recommendations.......................................14
3.3.2 Wiring Diagram for DS90 and DS120......................................16
3.3.3 Wiring Diagram for DS160........................................................16
3.3.4 Wiring Diagram for DS90-ACT and DS120-ACT ....................17
3.3.5 Wiring Diagram for DS160-ACT ...............................................17
3.4 Battery Connections ...........................................................................18
3.5 Motor Connections .............................................................................20
3.5.1 Motor Protection.......................................................................21
3.5.2 Motor Testing .............................................................................22
3.6 Park Brake Connections .....................................................................22
3.6.1 Park Brake Testing.....................................................................24
3.7 Battery Charging and Programming Connections........................24
3.7.1 Battery charger connections .................................................25
3.7.2 Programmer Connections.......................................................27
3.8 Actuator / Seat Lift Wiring (DS90-ACT, DS120-ACT, DS160-ACT)...28
3.8.1 Overview....................................................................................28
3.8.2 Wiring..........................................................................................28
3.9 Tiller Connector ....................................................................................31
3.10 Throttle Configuration .........................................................................32
3.10.1 ISO7176-14 2008 requirements................................................32
3.10.2 Single throttle wiper..................................................................33
3.10.2.1 Additional hardware to comply with ISO7176-14 2008........... 33
3.10.3 Neutral Detect ..........................................................................34
3.10.3.1 Installation of a Neutral Detect switch....................................... 35
3.10.4 Two throttle wipers - mirrored .................................................36
3.10.5 Throttle Calibration...................................................................36
3.10.6 Speed Limit Pot Connections .................................................37
3.10.6.1 In series with the throttle wiper .................................................... 37
3.10.6.2 In parallel with the throttle............................................................ 37
3.10.7 Alternative Speed Reduction Options ..................................39
3.10.8 Tiller Battery Supply...................................................................40
3.10.9 Key Switch Input .......................................................................41
3.10.10 Status Indicator Output ......................................................41
3.10.11 Beeper Output .....................................................................42

4
3.10.12 Battery Gauge Output........................................................42
3.10.13 Brake and Reversing Lights ................................................43
3.11 Multi-function Pins................................................................................44
3.11.1 Multi-function Inputs.................................................................44
3.11.1.1 Active States ................................................................................... 46
3.11.1.2 Slows to............................................................................................. 47
3.11.1.3 Latches ............................................................................................. 47
3.11.1.4 Flashes .............................................................................................. 47
3.11.2 Multi-function Outputs .............................................................48
3.12 Testing....................................................................................................49
4. Programming the RHINO2.............................................. 50
4.1 The Hand Held Programmer (HHP) ...................................................51
4.1.1 Programming menu .................................................................52
4.1.1.1 Profile 1/2 ......................................................................................... 52
4.1.1.2 Non-profiled .................................................................................... 53
4.1.1.3 Throttle calibration ......................................................................... 54
4.1.2 Diagnostics menu.....................................................................56
4.1.3 Technician menu......................................................................57
4.2 Dynamic Wizard...................................................................................58
4.2.1 Software revisions .....................................................................58
4.3 Parameter List.......................................................................................59
4.4 Parameter Descriptions ......................................................................63
4.4.1 User Personalisation..................................................................63
4.4.1.1 Sleep Timer....................................................................................... 63
4.4.1.2 Wakeup Style .................................................................................. 63
4.4.1.3 Swap Throttle Direction ................................................................. 64
4.4.1.4 Enable Beeper ................................................................................ 64
4.4.1.5 Flash Code Beeper ........................................................................ 64
4.4.1.6 Sleep Beeper................................................................................... 65
4.4.1.7 Motion Beeper ................................................................................ 65
4.4.1.8 Reversing Beeper ........................................................................... 65
4.4.1.9 Beeper Timing ................................................................................. 65
4.4.1.10 Deep Discharge Beeper ............................................................... 66
4.4.1.11 Sleep on Fault or Inhibit................................................................. 66
4.4.1.12 Power Off after Sleep .................................................................... 66
4.4.2 Throttle Configuration ..............................................................67
4.4.2.1 Throttle Type .................................................................................... 67
4.4.2.2 Throttle Input.................................................................................... 67
4.4.2.3 Throttle Neutral Offset.................................................................... 68
4.4.2.4 Throttle Full Scale Deflection ........................................................ 68
4.4.2.5 Throttle Response ........................................................................... 69
4.4.2.6 Throttle Dead-band ....................................................................... 69
4.4.2.7 Throttle Testing ................................................................................ 70
4.4.2.8 Maximum Throttle Voltage ........................................................... 70
4.4.2.9 Throttle OONAPU Testing............................................................... 71
4.4.2.10 Throttle Fault Non Latching .......................................................... 71
4.4.2.11 Speed Limit Pot ............................................................................... 72
4.4.2.12 Slam Brake ....................................................................................... 73
4.4.2.13 Enable SRW Open Circuit Testing................................................ 73
4.4.3 Drive Performance ...................................................................74
4.4.3.1 Maximum Forward Speed ............................................................ 74
4.4.3.2 Forward Acceleration ................................................................... 75

5
4.4.3.3 Forward Deceleration ................................................................... 76
4.4.3.4 Maximum Reverse Speed............................................................. 77
4.4.3.5 Reverse Acceleration .................................................................... 77
4.4.3.6 Reverse Deceleration.................................................................... 78
4.4.3.7 Minimum Forward Speed.............................................................. 78
4.4.3.8 Minimum Reverse Speed .............................................................. 79
4.4.3.9 Soft Start Period .............................................................................. 79
4.4.3.10 Soft Finish.......................................................................................... 80
4.4.3.11 Emergency Deceleration ............................................................. 80
4.4.3.12 Slam Braking .................................................................................... 81
4.4.3.13 Push Speed...................................................................................... 81
4.4.3.14 Roll-away Speed ............................................................................ 82
4.4.3.15 Speed Reduction Wiper (SRW) parameters.............................. 82
4.4.3.16 SRW Scaling Resistor (Ohm).......................................................... 83
4.4.4 OEM Drive Limits........................................................................84
4.4.4.1 Maximum Forward Speed Limit ................................................... 84
4.4.4.2 Maximum Reverse Speed Limit.................................................... 84
4.4.4.3 Minimum Forward Speed Limit .................................................... 84
4.4.4.4 Minimum Reverse Speed Limit ..................................................... 84
4.4.4.5 Acceleration Limit .......................................................................... 84
4.4.4.6 Deceleration Limit .......................................................................... 84
4.4.5 Motor Management ................................................................85
4.4.5.1 Motor Protection ............................................................................ 85
4.4.5.2 Motor Protection Parameters....................................................... 85
4.4.5.3 ThermalRollbackStart / End .......................................................... 86
4.4.5.4 Motor Reverse ................................................................................. 86
4.4.5.5 Load Compensation ..................................................................... 86
4.4.5.6 Maximum Load Compensation .................................................. 88
4.4.5.7 Load Compensation Damping ................................................... 88
4.4.5.8 Remembered Load Compensation........................................... 89
4.4.5.9 Current Limit .................................................................................... 89
4.4.5.10 Boost Current/ Boost Time............................................................. 90
4.4.5.11 Stall Timeout..................................................................................... 90
4.4.5.12 Motor Testing ................................................................................... 92
4.4.5.13 Maximum Motor Voltage ............................................................. 92
4.4.6 Park Brake Management........................................................93
4.4.6.1 Park Brake Testing........................................................................... 93
4.4.6.2 Park Brake Neutral Delay .............................................................. 93
4.4.6.3 Park Brake Release Delay............................................................. 94
4.4.7 Battery Management ..............................................................95
4.4.7.1 Overvoltage Rollback ................................................................... 95
4.4.7.2 Undervoltage Rollback ................................................................. 95
4.4.7.3 Battery Gauge Minimum/Maximum........................................... 96
4.4.7.4 Battery Gauge Warning................................................................ 97
4.4.7.5 Battery Cut-Off Voltage................................................................ 97
4.4.7.6 Battery Gauge Dead-band ......................................................... 97
4.4.7.7 Battery Gauge Sensitivity.............................................................. 98
4.4.8 System Options .........................................................................99
4.4.8.1 Service Scheduler........................................................................... 99
4.4.8.2 Actuator Time-Out ......................................................................... 99
4.4.9 Multi-function Inputs Configuration .....................................100
4.4.9.1 Pin [X] Function .............................................................................100
4.4.9.2 Active States ................................................................................. 103
4.4.10 Multi-function Outputs Configuration..................................104
4.4.10.1 Flash Code Type ...........................................................................104

6
4.4.10.2 Pin 3/11 Function .......................................................................... 105
4.4.10.3 Pin 10 Function ..............................................................................107
4.4.10.4 Key Switch Status LED ..................................................................107
5. Diagnostics .................................................................. 108
5.1 Introduction ........................................................................................108
5.2 Flash Code Display ............................................................................108
5.2.1 Scooter / R-Series Flash Codes*............................................109
5.2.2 SHARK Flash Codes.................................................................110
5.2.3 Type 3 Flash Codes.................................................................111
5.2.4 Type 4 Flash Codes.................................................................111
5.3 Diagnostics Tools................................................................................112
5.4 HHP Fault Codes with sub codes ....................................................113
5.5 Advanced Diagnostics Logs............................................................115
5.6 Service Scheduler..............................................................................116
6. Appendices................................................................. 117
6.1 Neutral Detect Active States ...........................................................117
6.2 Accessories + Parts List......................................................................118
6.3 Intended Use and Regulatory Statement......................................120
6.4 Service life...........................................................................................120
6.5 Maintenance .....................................................................................121
6.6 Warranty..............................................................................................121
6.7 Safety and Misuse Warnings ............................................................122
6.8 Electromagnetic Compatibility (EMC)...........................................124
6.9 Environmental statement .................................................................124
7. Index ............................................................................ 125

Chapter 1: Introduction to the RHINO2
7
1. Introduction to the RHINO2
The RHINO2family of scooter controllers provides a reliable, refined, cost-effective control
solution for most mobility scooters and includes:
DS90 - RHINO2 90A Controller
DS90-ACT - RHINO2 90A Controller with actuator
DS120 - RHINO2120A Controller
DS120-ACT - RHINO2120A Controller with actuator
DS160 - RHINO2160A Controller
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
Throttle Dual Decode (requires ISO compliant speed pot) provides extra safety in case of
a throttle failure, and allows OEMs to comply with the new requirements of ISO7176-14
(2008).
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).

Chapter 1: Introduction to the RHINO2
8
Note:
Unless otherwise specified, all references in this manual apply to all variants of
the RHINO2controller.

Chapter 2: Specifications
9
2. Specifications
2.1 Electrical Specifications
Parameter
Description
Compatible Battery
Supply
24V supply, 2 x 12V in series, circuit breaker protected
Compatible Motor
24V DC permanent magnet type, typically rated 200-1000 watts.
Min
Nominal
Max
Units
Operating Voltage ( Vbatt )
18
24
32
V
Reverse Supply Voltage
-32
V
Quiescent Current (idle)
80
mA
Quiescent Current (sleep)
1
mA
Quiescent Current (Key-Off)
1
mA
Charging Current
4
8
A (RMS)
Throttle Resistance (Pin 2 - Pin 8)
4
5
6
kΩ
Speed Limit Pot –Pin 9 (linear)
90
100
110
kΩ
Speed Reduction Wiper –Pin 4, 6 or 12 (log)
9
10
11
kΩ
Current Rating –DS90
Continuous (@ 20°C ambient)
36
A
Peak (180 seconds @ 20°C initial) See warning below
90
A
Boost Current
10
A
Boosted Current
100
A
Boost Time
10
s
Current Rating –DS120
Continuous (@ 20°C ambient)
48
A
Peak (180 seconds @ 20°C initial) See warning below
120
A
Boost Current
20
A
Boosted Current
140
A
Boost Time
10
s
Current Rating –DS160
Continuous (@ 20°C ambient)
64
A
Peak (180 seconds @ 20°C initial) See warning below
160
A
Boost Current
20
A
Boosted Current
180
A
Boost Time
10
s
Park Brake Output
Voltage
24
V
Current
1.25
A
Actuator Output (DS90-ACT, DS120-ACT and DS160-ACT only)
Voltage
17
24
32
V
Current
10
12.5
A

Chapter 2: Specifications
10
Warning:
The Peak Currents indicated above are for a MINIMUM of 180 seconds @ 20°C
ambient when Stall Timeout is set to zero. The installer must ensure that the
scooter’s wiring, connectors, and motor will not be damaged if the duration of
these high currents is exceeded.
2.2 Physical Specifications
Parameter
Aluminium Top, Base and Terminal
cover
Aluminium alloy ADC12
Protection Rating (with cover)
Electronics rated to IP55
Protection Rating (without cover)
Electronics rated to IP54
Shipping Weight:
Controller Unit
Terminal cover
DS90, 120, 160
DS90-ACT, 120-ACT, 160-ACT
952 grams
55 grams
988 grams
55 grams
Min
Nominal
Max
Units
Operating Temperature Range
-25
-13
50
122
°C
°F
Storage Temperature Range
-40
-40
65
150
°C
°F
Operating Humidity Range
0
90
%RH
For Mounting Hole dimensions, refer to Section 3.1
DS90 and DS120 variants
DS160 variants

Chapter 3: Installation and Testing
11
3. Installation and Testing
3.1 Mounting
3.1.1 General Mounting Conditions
RHINO2Mounting Configuration
The position and orientation should give maximum mechanical protection to the
controller.
Mount out of the path of water splashes from wheels or cowling and protect the
connector panel from direct splashing.
The controller should be mounted under the scooter cover.
Failure to adhere to the mounting conditions specified may lead to water ingress, which
could result in system malfunctions and long-term damage to the unit.
For peak performance, locate the controller so that air can flow over and around the
case, particularly if mounting in the tiller.
A position close to the batteries and motor is recommended to reduce the length of high-
current wires.
Use both screw positions to attach the controller. M5 cap screws are recommended.
Other M5 fasteners can also be used. Do not over tighten the mounting screws (max
8Nm).
Use a magnetic tip screwdriver for removing and fitting fasteners.
Refer to section 3.1.2 for recommended mounting orientations.
Regardless of mounting orientation, protect scooter wiring, connectors and
components (including those of the tiller head) from the risk of damage, water
splashes and/or water ingress, and route the cabling so that water will not run
down into the connector system.
Do not mount the RHINO2 in a position where the user can come into contact with
the unit. The case temperature can exceed 41°C.
If cover accessory is used and product is mounted in an orientation that will allow
water to pool, a drain or drain holes (of 2.5 mm diameter) should be drilled in the
cover.

Chapter 3: Installation and Testing
12
3.1.2 Mounting Orientation
Recommended Mounting Orientation:
The recommended mounting orientations for RHINO2units are vertical (with connector
side on the bottom) and horizontal (with connector facing upwards or downwards). The
horizontal (with connector facing downwards) mounting orientation is permitted to be
tilted a further 30° for mounting.
Vertical (Connector side on the bottom) Mounting Orientation
Horizontal (Connector facing upwards) Mounting Orientation
Horizontal (Connector facing downwards) Mounting Orientation
30° max

Chapter 3: Installation and Testing
13
Not Recommended Mounting Orientation:
The horizontally tilted mounting orientations and vertical (with connector side on the top)
orientation, which have chances of water and dirt accumulation, are not recommended.
Horizontally Tilted Mounting Orientations
Vertical (Connector side on the top) Mounting Orientation
3.2 Attaching the terminal cover
An optional terminal cover is available for the RHINO2controller. This can be ordered
separately –see Accessories + Parts List (6.2) for more details.
The terminal cover kit comprises a terminal cover and three M3x8mm screws.
To attach the terminal cover, offer it towards the top case ensuring that the locating-lugs
(see image below) are positioned in the recesses in the top case, and then screw the
terminal cover to the top case with the M3 screws provided.
Notes:
1. Tighten the screws with a hand torque wrench to 80cNm. Over-
tightening may cause thread damage on the top case.
2. When attaching the terminal cover, ensure that no cables are trapped.

Chapter 3: Installation and Testing
14
3.3 Connections and Wiring
3.3.1 General Wiring Recommendations
To maximise performance, minimise EMC emissions, maximise EMC and ESD immunity, and to
keep the cabling of the scooter safe and tidy, please observe the following guidelines.
Keep all cables as short as possible.
Avoid wire loops, especially loops of single wires instead of wire pairs.
Try to run wires in pairs or bunches. For example, run the battery positive and negative
wires together, and the motor positive and negative wires together. Bind wires together
and fix them to the chassis.
Do not route the cables (including the motor cable) near the motor case, where possible.
Do not leave electrical connections unnecessarily exposed. Insulate exposed
connections (for example with sleeving) to reduce the risk of short circuits, exposure to
water and connection stress.
Make sure that all vehicle sub-frames, particularly the transaxle, controller case and tiller
head assemblies, are electrically connected.
Make sure that the controller and speed setting potentiometers are electrically
connected to the vehicle frame.
Do not use the vehicle frame as the earth return. Any electrical low-resistance connection
to the frame is a safety risk and is not allowed by international safety standards.
To minimise electromagnetic emissions by the motor brushes, it may be necessary to fit
capacitors between the brush holders and the motor case. Make sure that the leads are
kept as short as possible. A suitable capacitor is 4n7, 2kV Ceramic.

Chapter 3: Installation and Testing
15
For best electrical performance, the wire size must be as large as possible.
Recommended minimum wire sizes are shown in the wiring sections.
For low-current signals, do not use wire sizes smaller than 0.5mm2/AWG20, because
smaller wires are physically not strong enough for this application.
Make sure that only supplied terminal screws are used.
The type of cable used must be appropriate for the mechanical and environmental
abuse it is likely to encounter.
Do not use damaged or abused cables. A damaged cable can potentially produce
localised heat, sparks or arcing and as such it can cause a fire.
Protect all cables against possible contact with flammable material.
The installation must prevent and/or discourage the user from accessing any cable.
Route the actuator wires to the side of the terminal cover. While assembling the terminal
cover, make sure that the wires are not trapped under the cover.
While installing power and battery connectors of DS90 and DS120 variants, make sure to
insert until you feel them click into position.
Refer sections 3.3.2 to 3.3.5 for wiring diagrams for all RHINO2variants.
Warning:
1. Route the cables and fasten all scooter components in a position so that the
cables, the connectors and the connector sockets of the RHINO2 do not allow
water entry or suffer from physical strain, abuse or damage, such as cutting or
crushing. Take particular care on scooters with movable structures such as seat
raise. Make sure that the cables do not extend beyond the scooter so that they
cannot be caught or damaged by external objects.
2. Disconnect all the cables of the scooter at the powered end whenever units are
replaced or moved.
3. The user maintenance schedule and the service instructions of the scooter must
include the appropriate inspection and maintenance requirements for the
connectors and the cables.
4. It is the responsibility of the installer to make sure that the finished wiring package
is safe and fit for purpose.
5. Before making any connections to the controller, disable the scooter by one of
the following means to prevent accidental movement.
Place the battery circuit breaker in the open position.
Disconnect the motor or batteries and/or elevate the drive wheels.
6. To meet ISO requirements, the Battery and Motor connectors must be fixed in
such a way they cannot be swapped or transposed. Alternatively, these may be
protected by a cover that cannot be removed without the use of tools.
7. If the DS160, or DS160-ACT is not mounted under the scooter cover, then the
cover accessory must be used.
8. The terminal cover should not be fitted more than five times. If fitted more than
five times, there is a risk of stripping the threads of the screw holes.
Note:
To meet the requirements of relevant standards, a status indicator must be fitted
to the scooter.

Chapter 3: Installation and Testing
16
3.3.2 Wiring Diagram for DS90 and DS120
3.3.3 Wiring Diagram for DS160
Warning: The fuses shown in these diagrams should be located as close to the
controller as is practical to minimise the length of unprotected cables.

Chapter 3: Installation and Testing
17
3.3.4 Wiring Diagram for DS90-ACT and DS120-ACT
3.3.5 Wiring Diagram for DS160-ACT
Warning: The fuses shown in these diagrams should be located as close to the
controller as is practical to minimise the length of unprotected cables.

Chapter 3: Installation and Testing
18
3.4 Battery Connections
Battery Connections
Note: Images shown are for the –ACT units. Position of
battery terminals for non –ACT units are identical.
Pin
Function
Minimum Wire
Gauge
(see notes
below)
B+
Battery Positive
DS90: 2 x 3mm2
(2 x12 AWG)
DS120: 2 x 3mm2
(2 x 12AWG)
DS160: 2 x 5mm2
(2 x 10AWG)
B-
Battery
Negative
DS90: 2 x 3mm2
(2 x12 AWG)
DS120: 2 x 3mm2
(2 x 12AWG)
DS160: 2 x 5mm2
(2 x 10AWG)
Mating Connector Part Numbers DS90, DS90-ACT, DS120, DS120-ACT
Dynamic Part #
Part Description
Supplier Part #
GCN51971
6W Housing 250 Series Plug
V0
N/A
GCN0690
Terminal Female 12-14AWG
170258-2
Mating Connector Part Numbers DS160, DS160-ACT
Dynamic Part #
Part Description
Supplier Part #
GCN1286
Crimp terminal M5 ring yellow
10-12AWG
2-130171-1
The wire gauge recommendations given above are the MINIMUM gauge and are generally
suitable for runs up to 800mm. Longer runs will require heavier wire –typically an extra 1.0mm2
for each additional 400mm run length. The heavier the wire, the better driving performance
will be. These notes are in addition to the General Wiring Recommendations as described in
Section 3.3.1.
The final connection to the Battery Positive (+) terminal should not be made until the
scooter is completely wired and ready for testing as described in the Testing section.
The RHINO2 has been designed to perform optimally with multiple battery types (see
below). By default Lead-Acid Gel Cell or AGM 24 V deep cycle batteries rated
between 30 - 120Ah are to be used.
To comply with ISO requirements, a red wire for the Battery Positive must be used.
This must be the only use of a red wire in the controller installation.
The torque settings for the DS160, and DS160-ACT unit battery terminal’s screws
should be between 4.5Nm and 5.5Nm. For DS90, DS90-ACT, DS120, and DS120-ACT
units, it is essential that at least four (2 pairs) battery terminals are used.

Chapter 3: Installation and Testing
19
Warning:
A thermal circuit breaker or fuse must be installed between the battery supply and
the controller, to protect both the batteries and the system wiring. This shall be
mounted as close as possible to the battery terminals as per ISO7176-14
requirements.
The thermal circuit breaker should have a trip rating no higher than the current limit
of the controller or the protection wire. Check thoroughly to ensure that it provides
the necessary degree of motor protection.
Model
Fuse rating
Circuit Breaker rating
DS90
75A
60A
DS120
85A
70A
DS160
100A
80A
If the two batteries are permanently wired
together (for example in a single battery box),
the best position for the circuit breaker is
between the two batteries. If the batteries are
separated (individual battery boxes), each
battery requires a circuit breaker or fuse. A slow-
acting, thermal type circuit breaker is suggested.
Make sure that the protection system is in
compliance with ISO7176-14 requirements.

Chapter 3: Installation and Testing
20
3.5 Motor Connections
Motor Connections
Note: Images shown are for the –ACT units. Position of motor
terminals for non –ACT units are identical.
Pin
Function
Minimum Wire
Gauge
(see notes
below)
M+
Motor Positive
DS90: 2 x 3mm2
(2x12AWG)
DS120: 2 x 3mm2
(2x12AWG)
DS160: 2 x 5mm2
(2x10AWG)
M-
Motor
Negative
DS90: 2 x 3mm2
(2x12AWG)
DS120: 2 x 3mm2
(2x12AWG)
DS160: 2 x 5mm2
(2x10AWG)
Mating Connector Part Numbers DS90, DS90-ACT, DS120, DS120-ACT
Dynamic Part #
Part Description
Supplier Part #
GCN51970
4W Housing 250 Series Plug
V0
N/A
GCN0690
Terminal Female 12-14AWG
170258-2
Mating Connector Part Numbers DS160, DS160-ACT
Dynamic Part #
Part Description
Supplier Part #
GCN1286
Crimp terminal M5 ring
yellow 10-12AWG
2-130171-1
The wire gauge recommendations above are the MINIMUM gauge and are generally
suitable for runs up to 400mm. Longer runs will require heavier wire –typically an extra
1.0mm2for each additional 200mm run length. The heavier the wire, the better driving
performance will be. In particular the length and gauge of wire affects the wire
resistance and hence the optimum Load Compensation setting.
Make sure that the Load Compensation parameter (4.4.5.5) is tuned to match the
scooter wiring for best driving performance.
These notes are in addition to the General Wiring Recommendations as described in
Section 3.3.1.
The motor polarity can be swapped with the Motor Reverse parameter (4.4.5.4).
Note:
The torque settings for the DS160, and DS160-ACT motor terminals should be between
4.5Nm and 5.5Nm.
For DS90, DS90-ACT, DS120, and DS120-ACT units, it is essential that all four motor
terminals are used.