DM60-GM WHEELCHAIR CONTROLLER INSTALLATION MANUAL
Contents
1. overriding the electrical control then to conform with TUV requirements the wheelchair is to have microswitches that allow the controller to detect the released state The microswitches are to be open circuit when the park brakes are manually released or disengaged and closed circuit when the manual override 15 removed and the park brakes can be controlled electrically In this configuration if the park brakes are manually overridden the controller if on will flash the status indicating on off lamp and not nergis th motors When the manual override is removed the park brakes are controlled by the wheelchair controller being released when th wheelchair is driven and engaged when the wheelchair has stopped The on off lamp is lit continuously Each 24 Volt park brake coil is to be connected to a park brake output from the controller via a 4 5 pin Beau connector A microswitch is to be connected in series with each park brake coil see figure 1 The microswitches are to be open circuit when the park brakes are manually overidden and closed circuit when the manual override is removed Fehler Textmarke nicht definiert LEFT RIGHT MOTOR MOTOR SOCKET SOCKET PIN 14 PIN 13 MICROSWITCHES LEFT 5 7N RIGHT PARKBRAKE PARKBRAK Figure 0 24 VOLT PARK BRAKE COIL CONNECTION DIAGRAM 5 6 INHIBITING THE CONTROLLER WHILE CHARGING The DM60 GM has only the inhibit input2. rel connectors are housed on the controller and comprise ug left and right motor socke rogramming sockets as shown in figure 2 150 incorporates the circuit breaker for remote loom The controller the battery liability lts The safety logic includes a battery isolate relay monitor that enables the user to verify normal relay operation at turn on It also continuously monitors the relay contacts and shuts down the controller if a relay fault is detected Verification of operation of the relay monitor relay and relay drive circuitry is performed by the user at turn on and is described in section 8 0 User Test Procedure 2 2 POWER STAGES The power stages use PWM to control the voltages to the motors High current field effect transistors switch motor currents at an ultrasonic frequency in a full bridge configuration achieving efficiency and ruggedness Fast current limiting circuitry protects the transistors against short circuits and stalled motors Fehler Textmarke nicht definiert 2 3 LOAD COMPENSATION Load compensation nsures xact motor control compensating for variations in motor loading under different wheelchair driving conditions Motor currents are continuously monitored and the output voltages adjusted to compensate for the voltage drop in the motors due to the current flowing through the motor resistance Load compensation ensures that the powe
3. mounting bushes The screw length should be chosen to screw into the blind threaded bushes to a maximum thread depth of 10mm The orientation of the controller is not critical although the label 15 positioned for vertical mounting The controller case is air cooled and therefore air is to be al case 5 0 lowed to freely pass over at least one side of the ELECTRICAL INSTALLATION Conne ctions to the battery motors and park brakes are made via polarised connectors 5 1 BATTERY SUPPLY The DM60 GM controller is designed to be used with heavy duty deep cycle lead acid batteries with capacity rating greater then 20 amp hours Use of batteries with capacities less than this is not recommended 5 2 BATTERY OVERLOAD PROTECTION A resettable thermal circuit breaker is incorporated in the controller to protect the wheelchair s electrical system and the user 5 3 BATTERY WIRE AND MOTOR WIRE RATINGS The following MINIMUM wire rating should be used for the indicated wheelchair loom wire lengths Battery wires Motor wires lt 400mm gt 400mm lt 400mm gt 400mm 5 mm 6 mm 4 mm 5 mm Add 0 5mm for every 500mm longer than 400mm Fehler Textmarke nicht definiert NOTE These minimum wire sizes will ensure that power loss in the wiring is not excessive Using a larger size wire will further improve efficiency 5 4 MOTOR TYPE Good load compensation requires that the level o
4. on the program socket and this is unsuitable for inhibiting the controller when a charger is plugged in An alternative to using the controller s inhibit is to open circuit the logic supply when the charger is plugged in at the remote or a separate key plug This could be done for example by connecting one pin of the charger socket to the battery supply and the other to the ON OFF switch in the remote When the key plug is installed these pins are shorted enabling the controller 6 0 INSTALLATION TEST PROCEDURE The object of this test in the wheelchair wiring batteries after installation Fehler looms Textmarke nicht definiert is to ensure that there controller is no remote To prevent uncontrolled wheelchair movement it is recommended that the drive wheels of the wheelchair be supported off the ground before the following procedure t Procedu Plug fault 15 Tes Ts swi and 2 3 tching Check th carried out in the e ON OFF switch in remote re the on tha Swi the wheel DM60 GM controller and switch on ON by lchair s wheels are not rotating tch control ller off at the remote off lamp is on and is not flashing Hold the joystick fully forwards and switch on Check that the wheels do not rotate and that the warning beeper inside the contr
5. AM 10 22 The DM60 GM wheelchair controller is a dual channel high control the Volt current S witching controll Speed and direction of two wheelchair conjunction wit control The modulation PWM to voltage to the motors It is controller uses motors r designed twenty four ES designed to h a separate remote with a built in joystick pulse width ultrasonic efficiently control the be DC power used in power and The DM60 GM features a microcomputer for flexibility and making the safety controllers can be adjus enhanced becau Flexibility is field programmable ted with separate joystick and intern nables th achieved by and performance parameters Programmer Safety is se the microcomputer continuously monitors the output voltages and currents internal voltages al circuits An independent safet to test the bat wheelchair user relay drive circuitry at monitors the r elays during opera A battery pl and p a turn on and tion ts ty circuit tery isolate continuously current and a fuseholder for the logic supply 2 0 FEATURES 2 1 CONTROL AND SAFETY LOGIC All contro microcompu 1 functions are performed by 8 bit ter with digital precision and Redundant checking by the microcomputer enhances safety by minimising the risk of undetected system faul
6. DM60 GM WHEELCHAIR CONTROLLER INSTALLATION MANUAL Reference Number 24456 8 March 2006 DYNAMIC CONTROLS LTD 7 Craft Place Ph 03 338 0016 Christchurch Fax 03 338 3212 New Zealand CONTENTS PAGE 155 INTRODUCTION 2 FEATURES 2 1 CONTROL AND SAFETY LOGIC 2 2 POWER STAGES 2 3 LOAD COMPENSATION 2 4 PRECISE CONTROL ON SLOPES 2 5 USER CONTROLS 2 6 STATUS INDICATION 2 7 CONNECTORS 2 8 SAFETY and FAULT CHECKS 2 9 PERFORMANCE CUSTOMISATION 3 HANDLING 4 MOUNTING ELECTRICAL INSTALLATION BATTERY SUPPLY BATTERY OVERLOAD PROTECTION BATTERY WIRE AND MOTOR WIRE RATINGS MOTOR TYPE PARK BRAKE CONNECTIONS O1 O1 O1 O1 10 TI 14 WHEELCHAI NG THE CONTROLLER WHILE CHARGING INSTALLATION TEST PROCEDURE R TEST PROCEDURE USER TEST PROCEDURE CARE AND MAINTENANCE 17 20 APPENDIX 1 APPENDIX 2 APPENDIX 3 0 TROUBLESHOOTING DM60 GM TECHNICAL SPECIFICATION RECOMMENDED REMOTE SPECIFICATION ASSOCIATED INFORMATION Os O1 PP BWW CO I r2 III 20 LIST of ILLUSTRATIONS Figure 1 24 VO LT PARK BRAKE COIL CONNECTION D Figure 2 DM60 GM CONTROLLER CONFIGURATION GM CONNECTOR PINOUTS Figure 3 DM60 1 0 INTRODUCTION AGR
7. are removed if the wheelchair is equipped with them 3 2 Check that the battery charger is not plugged TIS 3 4 power indicating Sa 3 6 4 The joystick 4 1 4 2 De The Ss batteries 5 2 9283 up 6 The 6 1 connections 6 2 gearbox if 6 3 Check that the motor connectors are plugged in If the fault has been removed switching the off then on again will clear the fault condition If the fault persists charge batteries If the fault still persists call the service agent ON OFF lamp is on controller clicks when deflected but the wheelchair does not move Check that both the drives from the motor are engaged Check that motor connectors are plugged in Fehler Textmarke nicht definiert wheelchair lacks power The batteries are Recharge the nearly flat The batteries are Have the batteries and faulty charger checked The park brakes are Check for heat build dragging in brakes after one minute driving have brakes serviced if necessary chair does not drive straight One motor is Check motor disconnected One motor and or Check motor and gearbox is faulty consult servic agent necessary Park brake dragging 5 3 Fehler Textmarke nicht definiert l1 0APPENDIX 1 DM60 GM CONTROLLER TECHNICAL SPECIFICATION Revision B September 29 1990 11 1Specification DM60 GM conforms to the following specification
8. arke nicht definiert 8 Turn the maximum Speed control knob full anti clockwise and repeat 5 93 Turn the maximum speed control knob fully clockwise Driv th wheelchair full speed forward and then move the joystick fully reverse Check that the wheelchair decelerates smoothly in a straight line before stopping and moving backwards 10 Repeat test 9 but move the joystick from full speed reverse to forward Note Deceleration in reverse is less than forward 11 Drive the wheelchair slowly forward and then switch the controller off Check that the wheelchair immediately stops 12 Hold the joystick slightly forward about 25 of available travel in the forward direction and switch on Check that the wheelchair does not drive Release the joystick for 2 3 seconds and then check that the wheelchair drives normally 13 Drive the wheelchair up a ramp with 1 in 6 gradient and attempt to accelerate from a slow speed Check the wheelchair can climb at a normal speed 14 Reverse down the ramp with a 1 in 6 gradient Check the wheelchair can be controlled and brakes as expected 15 While driving the wheelchair slowly up the ramp release the joystick Check that the wheelchair does not roll back excessively for the type of wheelchair and transmission arrangement before the park brakes operate 16 Continue driving up and down the ramp four times and check the controller s case temperature is not excessive for the type
9. cated by encoded flashing of the lamp The fault code except code 1 is the number of flashes where the number depends on the fault of fast flashes followed by a long OFF period This sequence repeats while the controller is left on The number of flashes can be counted to determine the fault code Fault code 1 produces continual flashing with a short on and off period and may be caused by switching the controller on with joystick deflected less than 50 of maximum travel Controller will not drive until joystick is returned to neutral for 2 seconds Greater than 50 deflection enables test mode see section 8 0 attempting to driv th wheelchair with an overcharged battery The controller enables driving when the voltage drops below the maximum battery voltage Fehler Textmarke nicht definiert Electronic circuitry protects against the following failure hazard or overload conditions Te Battery connected with wrong polarity 2 Microcomputer master clock bus or software failure 34 Overheating under heavy loads such as occur when the wheelchair motors are stalled for an extended period Note Stalling the motors for a long time may damage the motors wiring or batteries 2 9 PERFORMANCE CUSTOMISATION The Dynamic Controls Programmer enables the user to customise the performance of the DM60 GM controller to his or her needs Eight different parameters ca
10. definiert DESCRIPTION BATTERY FUSE BATTERY MOTOR MOTOR 16 DI ID 15 14 TL E 13 DESCRIPTION BATTERY FUSE BATTERY MOTOR MOTOR 16 DI ID 15 14 13 16 lil 15 14 iil 13 BATTERY BATTERY BATTERY PLUG Figure 3B DM60 GM CONNECTOR PINOUTS PART B Fehler Textmarke nicht definiert
11. e gaiter itself will very likely fall into the joystick mechanism resulting in rapid deterioration of the joystick It will also allow moisture into the joystick and remote 3 Protect the controller and remote from liquid spillage Should a liquid be spilt on to the controller or remote wipe off with an absorbent cloth as soon as possible 10 0 TROUBLESHOOTING These instructions are designed to assist in diagnosing a problem after the controller and remote has been installed on a wheelchair If after diagnosing the likely cause and following the suggested action the problem persists then an authorised servic person should be called Fehler Textmarke nicht definiert Tx On lamp in the remote does not light when the controller is turned on at the remote 1 1 Possible connection Check that the battery problem connector is correctly plugged into the controller and that the battery connections have not been reversed Check the cleanliness of the battery connections and clean if necessary 2 Batteries very flat Recharge the batteries 3 Lamp blown Check that the wheelchair drives normally Replace bulb On lamp in the remote flashes slowly once per second 2 1 Batteries are nearly Recharge the batteries flat Se Lamp flashes rapidly twice per second 3 1 Check park brake manual overrides one for each park brake
12. f compensation is matched to the wheelchair motors Insufficient compensation will result in loss of performance and the wheelchair will exhibit the following symptoms Have some uncontrolled movement when parking a slope 2 Exhibit poor steering response on undulating surfaces Shs Feel sluggish Matching low series resistance motors is especially important because of the motor s responsiveness to small changes in voltage and may result in unstable or jerky wheelchair operation if the load compensation is not matched to the motors Consult the factory to discuss your application 5 5 PARK BRAKE CONNECTIONS A parking brake output is provided on pin 13 of each motor connector These pins are for the TUV compliant DM60 GM controller connected inside the controller to separate park brake drives which are separately monitored The park brake outputs are controlled by the microcomputer actuating releasing the park brakes when th motors are driven The outputs can supply up to 1 Amp at 24 Volts for each outputs They current limited to protect against short circuits The wheelchair s park brakes are to be of the fail safe type ngaged when electrically de energised and released when energised Fehler Textmarke nicht definiert IMPORTANT If the wheelchair has manual park brake release mechanisms that mechanically disengage the park brakes
13. figuration It is recommended that the remote used with the DM60 GM controller is to have the following user controls joystick on off switch high intensity incandescent lamp to indicate on off BDI and error status and a maximum Speed control A battery gauge or voltmeter is also recommended l2 2Joystick The joystick is to be fully proportional 2 axis inductive Flightlink model a Type number JSAXTDC Restrictor Plate Flat diamond 13 0APPENDIX 3 ASSOCIATED INFORMATION The following documents can be used in conjunction with the Programmer when programming a DM60 GM 1 DM Series Controller Feature Curves Reference number 25179 2 Programmer Operating Manual Reference number 25181 Fehler Textmarke nicht definiert PROGRAM REMOTE LOOM SOCKET SOCKET MOUNTING HOLES PER SIDE BAT PLU BATTERY PARK BRAKE CIRCUIT BREAKER FUSE Figure 0 DM60 GM CONTROLLER CONFIGURATION Fehler Textmarke nicht definiert Figure OA PIN DESCIPTION GROUND SWITCHED 24V INHIBIT 1 e 8 4 5 6 7 8 9 10 11 12 13 14 DM60 GM CONNECTOR PINOUTS PART GROUND NC SERIAL CLOCK SERIAL DATA PROGRAM SOCKET DESCRIPTION SWITCH 1 JOYSTICK 12V NC JOYSTICK SPEED JOYSTICK 6V JOYSTICK DIRECTIO SWITCH 2 POT SPEED SWITCH LAMP JOYSTICK GROUND NC REMOTE LOOM SOCKET Fehler Textmarke nicht
14. he controller will click when the controller is turned on Leave controller switched on 3 Move joystick slightly forward Check that the park brakes on both motors are energised and are heard to click The controller s relays will also click 4 Drive wheelchair slowly with small joystick deflections in the forward reverse left and right directions Check for precise control Dis Drive wheelchair at maximum speed full joystick deflections in the forward reverse left and right directions Check speeds feel correct for the wheelchair 6 Drive the wheelchair at full reverse speed Check that initially the wheelchair does not deviate from a straight line in reverse by more than 20 of the distance travelled Note 1 This characteristic depends on the channel balance in the controller and wheelchair motor matching A wheelchair with well matched motors better the 1 speed matching must be used for this test to have any value Note 2 Rear wheel drive wheelchairs tend to have an unstable characteristic in reverse which due to inertia causes the wheelchair to tighten the turn when it starts to turn and eventually to drive in circles dis Drive with joystick in full forward on the flat of the joystick s restrictor plate Check that the wheelchair can be steered to the left and to the right while still on the flat Fehler Textm
15. n customised by plugging into a programming socket in the controller and setting the desired level using the controller s joystick The parameter level is displayed by the Programmer s meter Programmer Function Mode 1 Overall Sets all of the following adjustable parameters to give an overall response damped to H accelerat ct H decelerat ct ranging from slow and very fast and very responsive 2 Forward Sets maximum forward speed 3 Reverse Sets maximum reverse speed 4 Turn Sets maximum turning rate 5 Accel Sets forward and reverse on 6 Decel Sets forward and reverse on 7 Turnaccel Sets turning acceleration 8 Turndecel Sets turning deceleration Refer to the Programmer operating manual for details 3 0 HANDLING The DM60 GM controller is a sophisticated electronic assembly and should be handled carefully Ta Do not subject to unnecessary Or excessive mechanical shocks 233 Do not connect anything to the controller unless it is in accordance with an approved wiring diagram 3 Do not make any wiring connections or modifications while the battery is connected Fehler Textmarke nicht definiert 4 Do not subject to temperatures outside these ranges In Storage 35 to 60 Deg C While Operating 10 to 50 Deg C 4 0 MOUNTING The DM60 GM controller is designed to be mounted using M5 Screws into the
16. of wheelchair and never exceeding 65 degrees C 17 Switch the controller off Fehler Textmarke nicht definiert 8 0 USER TEST PROCEDURE I S RECOMMENDED THAT IHE FOLLOWING PROCEDURE 15 PERFORMED DAILY BY THE WHEELCHAIR USER PRIOR TO USING THE WHEELCHAIR EQUIPPED WITH DM60 GM CONTROLLER THIS RECOMMENDATION IS TO BE INCORPORATED IN THE USER S MANUAL La When the controller is off hold the joystick on the remote fully forward and then switch on 2 The beeper inside the controller will sound if the battery isolate relays and relay driver circuitry operate normally The absence of this sound signifies potentially serious failure the controller In the case of failure switch the controller off and contact a wheelchair service agent ce Switch off 4 The wheelchair is now ready for normal operation and can be switched on normally without deflecting the joystick 9 0 CARE AND MAINTENANCE Ta Do not leave the DM60 GM controller exposed to direct sunlight for long periods This may overheat the case which absorbs heat very well and reduce the available motor currents and hence the ability of the wheelchair to climb obstacles or ramps 2 Do not continue to use the remote if the rubber joystick gaiter has holes or cracks in it Extraneous material possibly from th
17. oller sounds See section 8 0 User Test Procedure Turn the controller off then on again 4 Move joystick forward and check that both wheels start to turn and accelerate smoothly in the FORWARD direction 5s Move joystick backward and check that both wheels start to turn and accelerate smoothly in the BACKWARD direction 6 Move joystick to the right and check that the right wheel runs in the backwards direction and the left wheel in the forwards direction ls Move joystick to the left and check that the right wheel runs in the forwards direction and the left wheel in the backwards direction Upon the successful conclusion of these tests lower the wheelchair to the ground and carry out the wheelchair test procedure below 7 0 WHEELCHAIR TEST PROCEDURE This suggested wheelchair test is designed to test for satisfactory performance of the controller remote motors and wheelchair wiring Before starting the tests ensure that the wheelchair batteries are in a good state of charge Fehler Textmarke nicht definiert Ia Turn maximum speed control knob in remote fully clockwise if fitted 2 Turn the controller on at th remote then off and on several times without touching the joystick Check that the parking brakes are NOT energised even momentarily The park brakes will click when energised or de energised Note The relays inside t
18. over an ambient temperature range of 10 to 50 Degrees Celsius and relative humidity of 10 to 80 percent Abbreviations A Ampere V Volts C Celsius kHz kilohertz max maximum minimum 11 2Supply Battery Voltages a Operating Voltage 24V Nominal b Maximum supply voltage for safe controller operation 28V c Absolute max supply voltage averaged over 10 mSec interval during battery charging 32V d Minimum supply voltage for operation after Isolate relay engaged 19V e Minimum supply voltage for battery isolate relay to engage 22V f Battery Discharge Indicator steady state trip voltage 2 33 23V Calibrated g Motor Voltage Rollback Battery Saver 21 19V 11 3Logic Supply Current see note 1 300mA max 11 4Motor drive or braking current each channel Maximum controlled current Current limited 60A 5A b PWM frequency 20kHz 20 10 Fehler Textmarke nicht definiert 11 5Thermal rollback and cutout protection a Rollback trip case temperature 55 deg C b Cutout temperature case temperature 70 10 5 deg C Time to reach cutout limit at 25 Deg ambient temperature motor stalled 2 Mins minimum 11 6Joystick interface parameters refer note 2 Speed channel a b c e a b c Neutral offset 30mV max Maximum input voltage FORWARD 1 00V Absol
19. r instance The on lamp will flash if the controller is turned on while charging Fehler Textmarke nicht definiert See Safety and Fault checks section 2 8 2 7 CONNECTORS A 5 pin Beau plug provides battery input there are separate 4 pin with fifth polarising pin female Beau connectors for the motors and park brake outputs a single 7 pin DIN programming socket and an AMP 14 pin CPC connector for the remote These connectors are shown in figure 2 with pin outs in figure 3 The recommended wiring to the battery and motor connections and park brake 18 described in section 5 Electrical Installation 2 8 SAFETY and FAULT CHECKS The microcomputer checks for the following conditions and may remove the drive to the motors actuate the parking brake output s stopping the wheelchair and indicate a fault by flashing the status lamp if any of these conditions are detected Fault Code Description ds Battery voltage too high greater than 28V OR joystick deflected less than 50 of travel when controller turned on 2 Park brake s fault cm Battery voltage too low less than 22V 4 joystick signal speed or direction outside its normal Operating range 3 Left and right motor voltages not consistent with joystick demand controller fault 6 Controller battery isolate relay fault d Controller memory fault The particular fault is indi
20. r to the motors suits the driving conditions whether on thick pile carpets polished floors or driving across a slope 2 4 PRECISE CONTROL ON SLOPES Due to load compensation and an adaptive park brake delay the DM60 GM controller minimises uncontrolled movement of a wheelchair when parking on a slope ensures maximum user control 2 5 USER CONTROLS The DM60 GM is designed to be used in conjunction with user controls mounted in a separate remote unit that connects to the controller via the remote cable The normal user controls are ON OFF switch inductive joystick and maximum Speed pot The maximum speed can be set by a potentiometer the remote and the BDI ON and fault status indicated by an incandescent lamp or LED The specification of the joystick is given in appendix 2 2 6 STATUS INDICATION The lamp located on the right side of the remote front of the joystick as shown in figure 1 indicates the controller status as follows Tx Lamp on continuously All systems normal controller ready Di Lamp flashing slowly once per second Battery state of charge is low Recharge battery as soon as possible Bie Lamp flashing quickly twice per second Wheelchair system battery motor parking brake or controller fault has been detected Driving inhibited Note The park brake output may be open circuited to inhibit the controller when charging the battery fo
21. ute max input voltage FORWARD 1 06V Maximum input voltage REVERSE 1 10V Absolute max input voltage REVERSE Transfer function Customisable See Set Up Box manual Direction channel Neutral offset 30mV max Maximum input voltage left amp right qc FSN Absolute max input voltage left amp right Transfer function Customisable See Set Up Box manual Fehler Textmarke nicht definiert Reference amp Supply Rail a b 12V rail voltage 12V 4 12V rail output current 20 mA max 6V REF voltage 12V L811 2 1 6V REF input amp output current 1 uA max 11 7Fuse Holders Logic Supply Fuse Rating 2A 11 8Parking Brake Outputs a Maximum continuous current high side source 1 2A b Operating delay after motor V 0 0 2 Sec 11 90utput connectors a Battery 4 5 pin Beau Male b Motors and Parking brakes 4 5 Pin Beau Female c Programming input 7 Pin DIN d Remote 14 pin AMP CPC 11 10 Dimensions a Height 163mm b Length 280mm Thickness 57mm Fehler Textmarke nicht definiert 11 11 Environmental a Operating temperature range 10 to 50 Deg b Storage temperature range 35 to 60 Deg C c Humidity relative 10 to 80 d Enclosure rating Splash proof 12 0APPENDIX 2 RECOMMENDED REMOTE SPECIFICATION 12 1Con
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