Dynamic DX-SLM User manual

DX-SLM
Servo Steering and Lighting Module
DX-SLM INSTALLATION MANUAL
GBK60027: Issue 5 - March 2014
DX-SLM
Servo Steering and Lighting
Module
THE
ULTIMATE
POWERCHAIR
CONTROL
SOLUTION
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GBK60027 DX-SLM Installation Manual Issue 5
Contents
1Introduction.............................................................3
2Related Documentation.........................................4
3General Description ...............................................5
3.1 General Features........................................................................ 6
3.2 Safety and Protection Features............................................... 6
4Specifications..........................................................7
4.1 Electrical Specifications............................................................ 7
4.2 Mechanical Specifications....................................................... 9
4.3 Environmental Specifications................................................... 9
5Installation.............................................................10
5.1 Introduction............................................................................... 10
5.2 Mounting ................................................................................... 10
5.3 SLM Connection with the DX System .................................... 12
5.3.1 DX BUS Connections..................................................... 12
5.3.2 DX Module Interconnection Topology Options ....... 13
5.3.3 DX BUS Length and Voltage Drop Restrictions......... 14
5.4 SLM 21 Way Connector........................................................... 17
5.4.1 21 Way Connector Pin Definitions.............................. 17
5.4.2 21 Way Connector Wires and Terminations.............. 17
5.4.3 Power Supply from the DX BUS.................................... 18
5.4.4 Power Supply from the Battery ................................... 19
5.4.5 SLM Connection to Lights ............................................ 20
5.5 SLM Servo Connector.............................................................. 22
5.5.1 Servo Connector Pin Definitions.................................. 22
5.5.2 Servo Connector Wires and Terminations................. 22
5.5.3 SLM Connection to Servo Devices............................. 22
6Operation..............................................................24
6.1 SLM Activation.......................................................................... 24
7Programming ........................................................25
7.1 Introduction............................................................................... 25
7.1.1 Adding an SLM to the DX System............................... 25
7.2 DX Remote Wizard Parameters.............................................. 26
7.2.1 Lighting Parameters...................................................... 26
7.2.2 Drive Program Parameters .......................................... 27
7.3 SLM Wizard Parameters........................................................... 29
7.3.1 Steering Program Parameters..................................... 29
7.3.2 Steering Motor Parameters.......................................... 32
7.3.3 Steering Position Feedback Pot Parameters ............ 35
7.3.4 Joystick Restrictor Plate Table..................................... 37
7.3.5 Miscellaneous Parameters........................................... 37
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GBK60027 DX-SLM Installation Manual Issue 5
7.4 Calibrating the SLM using the HHP........................................ 40
7.4.1 Initial Operation............................................................. 40
7.4.2 Calibrating Parameters................................................ 41
8Diagnostics............................................................43
8.1 Troubleshooting........................................................................ 43
8.2 Flash Codes............................................................................... 43
8.3 Wizard Diagnostics................................................................... 46
9Maintenance ........................................................47
10 Safety and Misuse Warnings................................48
11 Warranty................................................................49
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GBK60027 DX-SLM Installation Manual Issue 5
1Introduction
The Servo Steering and Lighting Module (SLM) controls the steering and lighting for
servo steered power wheelchairs. It is part of a DX System also comprising a DX Power
Module and a DX Remote as a minimum system.
Example of Minimum DX System with the SLM
The servo wheelchair has one motor for steering, and either one or two motors to
provide the driving power of the wheelchair. The DX Remote controls both functions.
If two drive motors are used then a dual channel DX Power Module (DX2-PMAxx) is
required. If only one drive motor is used then a single channel DX Power Module (DX-
PMB2-S) is required.
The lighting consists of sidelights and turn indicators. The indicators can be flashed
together to provide a hazard warning. The DX Remote also controls the lights.
The SLM has two standard DX BUS connectors so that it may be connected to the DX
System.
This manual, and others listed in Section 2, must be read and understood. For more
information, please contact Dynamic Controls or one of the sales and service agents
listed at the back of this manual.
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GBK60027 DX-SLM Installation Manual Issue 5
2Related Documentation
A DX based wheelchair control system may comprise between two and sixteen DX
compatible modules depending on the application. Each DX compatible module
has its own Installation Manual, which describes the installation requirements of that
particular module.
This manual describes the installation of the SLM only and must be read in conjunction
with the:
•DX System Manual
•Relevant DX Remote Installation Manual
•DX Power Module (PM) Installation Manual
•DX Hand Held Programmer (HHP) Manual
•Wizard User Manual
•Installation Manuals for all other DX modules to be used in your system.
Important Notes:
1. Read this Manual carefully before installing or operating your DX control
system.
2. 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.
3. 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.
4. The latest version of this manual can be downloaded from the Dynamic
Controls website: www.dynamiccontrols.com
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GBK60027 DX-SLM Installation Manual Issue 5
3General Description
The SLM is designed to enable the DX System to run on a servo steered power
wheelchair, with lights. The wheelchair will have: a servo motor, a position sense
potentiometer, a steering release microswitch, one or two drive motors with integral
park brakes, a 24 V battery supply, and optional 24 V lights.
The DX system will comprise of a minimum of a DX Remote, a DX Power Module, a
SLM and may also have up to 13 other DX modules.
The DX BUS is used to control and monitor all DX Modules. The DX Power Module has
two identical DX BUS connectors and is connected in a chain type arrangement with
the SLM. The SLM can be powered from an independent 24 V power supply, but low
power steering requirements can be powered from the DX BUS 24 V supply. The
lighting can also be supplied from the DX BUS, or from the 24 V wheelchair battery.
See section 5.4.3 and 5.4.4.
In a servo system, the speed and direction data from a DX Remote is passed to the
SLM rather than directly to the DX Power Module. The SLM processes the speed data
and then sends it directly to the DX Power Module. The direction signal is processed
by the SLM and applied to the servo steering motor. A position sense potentiometer
tells the SLM the steering position.
A microswitch is attached to the steering clutch so that when the clutch is released
for manual wheelchair manoeuvring, the system is inhibited and will not drive. When
the clutch is restored, the system must be turned off then on again to drive.
The DX System allows up to five preset Drive Programs to be selected, depending on
the type of remote. Each Drive Program contains an associated Steering Program
that defines the maximum steering lock available for safe driving at different speeds.
The SLM controls the steering lock to conform to the Steering Program, and also
controls the speed output, so that the speed cannot exceed that allowable for a
particular lock.
The SLM can control a full lighting system of sidelights (front and rear) and indicator
lights (left and right). The activation of the lights is via the DX Remote.
The SLM can be used with a two channel (70 or 90 A per channel) DX Power Module
(DX2-PMAxx) or a single channel 160 A DX Power Module (DX-PMB2-S). If only one
drive motor is used in the system then the DX-PMB2-S should be used.
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GBK60027 DX-SLM Installation Manual Issue 5
3.1 General Features
The SLM has the following general features:
•Servo output capable of supplying 5 A continuous and 30 A peak to a 24 V
servo actuator.
•Fully DX BUS compatible.
•Two identical DX BUS sockets for Daisy Chain connection to the DX System.
•Powered by a 24 V wheelchair battery via the DX BUS connection, or directly
from the battery for high current applications.
•Fully programmable for optimum driving performance.
•Electromagnetically compatible:
-not susceptible to high levels of RFI
-emitting low levels of RFI
-protected against high levels of ESD.
•Compact case for mounting under the wheelchair seat.
3.2 Safety and Protection Features
The SLM has the following safety and protection features:
•Motor current limit and current limit timeout set to prevent overheating of
motors.
•Thermal protection to reduce current limit.
•Short circuit protection of all inputs and outputs except between motor and
battery negative while driving.
•Open circuit motor detection when not driving.
•Driving is inhibited if steering clutch is disengaged.
•Over voltage, under voltage and reverse battery protected.
•Detection of broken steering position feedback potentiometer connections or
short circuit of the potentiometers' terminals.
•Driving inhibit if Steering Module is not connected and responding.
•Compliance with ISO 7176 requirements.
•Controlled power down in event of DX BUS disconnection or communication
failure.
•Hazard lights can be operated by an external switch.
•Hazard lights will operate automatically if communication with the DX Remote is
lost while turned on.
•Indicator flash rate will double if a rear indicator bulb has failed (incandescent
lamps only).
•Sidelights will come on if battery charger is over-charging the batteries or during
regenerative braking if the battery cannot absorb the regenerated power.
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GBK60027 DX-SLM Installation Manual Issue 5
4Specifications
4.1 Electrical Specifications
Power Supply Input
Symbol
Parameter
Min
Nom
Max
Units
VBAT Battery voltage 18.0 24.0 32.0 V
IQQuiescent Current (No servo load) 150 mA
IOOperating Current (+ servo load) 250 mA
IDXBUS DX BUS Current (RMS Continuous to entire
system) 12 A
Servo Motor + / - Output
Symbol
Parameter
Min
Nom
Max
Units
SM+ Output Voltage (when not in current limit) VBAT-1.2V VBAT V
IAV Continuous Average Current (over
programmable time period) 5 A
Î Peak Output Current (for up to 5 seconds) 30 A
Servo Pot Input / Output
Symbol
Parameter
Min
Nom
Max
Units
SP+ Pot Supply + Output Voltage (Open circuit) 4.5 5.0 5.5 V
SP- Pot Supply - Output Voltage 0.0 V
ZSP+ SP+ Output impedance 950 1 K 1050 Ohms
ZSP-SP- Output Impedance 10 Ohms
ZSP Acceptable Pot Impedance 4 K 10 K 12 K Ohms
Steering Clutch Switch
Symbol
Parameter
Min
Nom
Max
Units
VLO Low level switch voltage
(Microswitch closed) 0 0.5 V
VHI High level switch voltage
(Microswitch open) 3.5 5.0 V
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GBK60027 DX-SLM Installation Manual Issue 5
Lighting Specification
Symbol
Parameter
Min
Nom
Max
Units
Turn Indicator Outputs (each output)
VTIO Output Voltage VBAT-1 VBAT-0.1 VBAT V
ITIO Continuous Output Current 2.3 2.5 A
Sidelight (Head / Tail Light) Output
VSLO Output Voltage VBAT-1 VBAT-0.1 VBAT V
ISLO Continuous Output Current 2.3 2.5 A
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GBK60027 DX-SLM Installation Manual Issue 5
4.2 Mechanical Specifications
Size: 210 * 123 * 38 mm
Weight: 0.530 Kg
Mounting: M5 screws four places, or placed in tray
Case material: Aluminium sheet, powder coat finish
Case sealing: Tamper proof, IP54 if mounted as per mounting instructions
SLM Configuration
4.3 Environmental Specifications
Symbol Parameter
Min
Max
Units
Operating ambient temperature range -25 50 °C
Storage temperature range -25 70 °C
Operating and storage humidity 0 90 %RH
Durability ISO7176 part 14
Vibration Specification 120 minutes @ 4 g’s random
vibration without damage
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GBK60027 DX-SLM Installation Manual Issue 5
5Installation
5.1 Introduction
Installing a SLM requires the following steps:
1. Mounting the SLM Refer Section 5.2
2. SLM Connection with the DX system Refer Section 5.3
3. SLM 21 Way Connector Refer Section 5.4
4. SLM Servo Connector Refer Section 5.5
5. Programming the SLM related parameters Refer Section 7.0
5.2 Mounting
Optimum mounting orientation
Fit the SLM with the top label facing up.
Unacceptable Mounting Orientation
Do not mount with connectors facing up.
Do not mount with the top label facing down.
Other orientations are acceptable.
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GBK60027 DX-SLM Installation Manual Issue 5
Securing the SLM
The SLM can be mounted using the four mounting holes and mounting screws
provided, or placed in a suitable tray. Do not use screws that protrude into the SLM
case by more than 12 mm.
The SLM must be mounted in a position that offers the maximum protection from
water and mechanical abuse. Since there are no user accessible controls on the SLM,
it can be mounted in a position which is inaccessible to the user e.g. under the seat.
Note:
For ease of diagnosis, it is recommended that the SLM be mounted where
the SLM Status LED can be seen without having to remove covers.
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GBK60027 DX-SLM Installation Manual Issue 5
5.3 SLM Connection with the DX System
5.3.1 DX BUS Connections
Note:
If only one DX BUS connector is used on the SLM and the remaining
connector is accessible to the wheelchair user, a GPL65009 DX BUS
Connector Cover should be fitted to the unused connector. This complies
with the ISO 7176-14 standard.
Like all other DX Modules, the SLM is connected to the DX system using the DX BUS.
Refer to the DX System Manual for more information regarding DX BUS cables.
Note:
The order and positioning of the SLM within the DX system is important and
must be based on the rules discussed in section 5.3.2 and 5.3.3.
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GBK60027 DX-SLM Installation Manual Issue 5
5.3.2 DX Module Interconnection Topology Options
The battery and DX Power Module combination are always considered the heart of a
DX system. Other DX Modules can be arranged in several ways:
Star DX BUS Topology
In-line DX BUS Topology
Mixed DX BUS Topology
DX
Power
Module DX
Module DX Module DX Module
DX
Module DX Module
DX
Module DX Module DX Module
DX
Module DX Module
DX
Remote
Battery
24V
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GBK60027 DX-SLM Installation Manual Issue 5
DX modules normally have one or two DX BUS sockets for system interconnections.
Smaller DX modules may have a permanently mounted cable terminated in a DX BUS
plug, rather than DX sockets.
The star and mixed topologies both require the use of one or more DX BUS Expanders
(DX-SKT-X3). The DX-SKT-X3 may be purchased from Dynamic Controls or a Dealer.
For lowest cost and simplicity the in-line topology is generally preferred, provided the
DX BUS length and voltage drop requirements described below can be met.
Warning:
If the SLM is between the Power Module and the Battery Charger:
1. Have as few as possible DX BUS cables between the SLM and the Power
Module.
2. The DX BUS cables between the SLM and the Power Module must not
total more than 1 metre.
This will avoid unintended interaction between the SLM and the Battery
Charger.
5.3.3 DX BUS Length and Voltage Drop Restrictions
Due to signal distortion that increases with increasing DX BUS length, the total length
of all DX BUS cables must not exceed 15 metres in any topology.
Two of the DX BUS's four cores (DXB+ and DXB-) are used to supply power to the
modules and to the loads connected to them. A Positive Temperature Coefficient
(PTC) device in the Power Module limits the total DX BUS current to 12 A, this protects
the DX BUS wiring and connectors. The topology and cable lengths used may reduce
the DX BUS's upper limit to below 12 A.
For correct DX System operation the voltage drop on the DX BUS's DXB- wire due to
return currents, must not exceed 1.0 V between any two modules within the DX
System. Use a topology and module placement that reduces this voltage drop as low
as reasonably possible.
Voltage drops occur along the DX BUS due to the return of current to the battery
through the small but finite resistance of the DX BUS cable and connectors.
A DX BUS connector can be modelled as:
DX BUS Cable Model
Rct = contact resistance = 5 mOhm
Rca = cable resistance (B-) = 8.5 mOhm / metre
R
c
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R
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a(B-)
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GBK60027 DX-SLM Installation Manual Issue 5
Example:
Consider a Power Module connected to an SLM via five other DX Modules using 1
metre cables.
Example of DX Module interconnection
The total resistance of the 0 V return path, between the Power Module and SLM is:
6 X (2 * Rct + Rca) = 111 mOhms
This means that the maximum load that the SLM can drive and not exceed the1.0 V
drop requirement is 1 / 0.111 = 9 A.
If, for example, the servo motor and lighting that the SLM is required to drive has a
peak current of 10 A, the interconnection order of the DX modules will have to be
changed to place the SLM closer to the Power Module.
The above example illustrates a fundamental rule of DX Module interconnection: all
DX Modules that connect to high current loads (e.g. actuators / motors and lights)
must be connected as close to the Power Module as possible.
The above example is simplified and does not include current to other DX Modules.
The DX BUS maximum current rating of 12 A is for the entire DX System.
Operation of the SLM at its maximum rating of 30 A peak current is not possible from
the DX BUS supply. To supply greater than the 12 A DX BUS current see section 5.4.4.
DX
Module DX Module DX Module DX Module
DX
Module
Battery
24V
I
SLM
Servo Motor
DX Power Module
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GBK60027 DX-SLM Installation Manual Issue 5
This favours topologies such as:
Rationalised In-line Topology
Two-way star Topology
Multi-star Topology
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DX BUS Expander
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GBK60027 DX-SLM Installation Manual Issue 5
5.4 SLM 21 Way Connector
5.4.1 21 Way Connector Pin Definitions
Note: Other pins unused.
5.4.2 21 Way Connector Wires and Terminations
To build a matching connector
To build a matching connector to fit to the 21 way connector, the parts are :
DX 21W Plug Housing Part/Order Number GCN 0796*
DX 21W Boot Part/Order Number GCN 0795*
DX Positronics Contact, FC114N2 (Lge) Part/Order Number GCN 0793*
DX Positronics Contact, FC116N2 (Med) Part/Order Number GCN 0797
DX Positronics Contact, FC120N2 (Sml) Part/Order Number GCN 0794*
The DX Positronics Contacts are crimp terminals.
*Included in DX-SLM Loom Connector Kit Part/Order Number DXLOOM-SLM
1
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1
5
3
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2
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1
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1 DX BUS -
2 Side Lights -
3 Left Indicator -
4 Right Indicator -
5 Alternative Lighting +
6 Hazard In
7 Hazard Out
8 Battery -
9 Steering Power +
14 Battery - (spare)
15 DX BUS +
16 Lighting +
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GBK60027 DX-SLM Installation Manual Issue 5
Wire Sizes
The minimum wire sizes that must be used are:
Function
Wire Size (minimum)
Terminal Part*
DX BUS - 1.0 mm² FC116N2
Side Lights - 0.5 mm² FC120N2
Left Indicator - 0.5 mm² FC120N2
Right Indicator - 0.5 mm² FC120N2
Alternative Lighting + 1.0 mm² FC116N2
Hazard In 0.5 mm² FC120N2
Hazard Out 0.5 mm² FC120N2
Battery - 1.0 mm² motors < 10 A
2.0 mm² motors ≥10 A FC116N2 FC114N2
Steering Power + 1.0 mm² motors < 10 A
2.0 mm² motors ≥10 A FC116N2 FC114N2
DX BUS + 1.0 mm² FC116N2
Lighting + 1.0 mm² FC116N2
* Positronic Industries Ltd
5.4.3 Power Supply from the DX BUS
The DX BUS is suitable for powering low speed servomotors and lighting, where the DX
System current requirement is less than the 12 A DX BUS rating.
To power the lighting and servomotor from the DX BUS, links must be inserted to short
the DX BUS - pin to the Battery - pin, and the DX BUS + pin to the Steering Power and
Lighting + pins.
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