Contents1 Introduction .................................................................... 1 2 General Description ....................................................... 1 3 Electrical and Mechanical Specification ...................... 2 3.1 3.2 3.3 4 Standards Compliance .................................................................... 3 Typical Performance Characteristics.............................................. 4 Mechanical Characteristics............................................................. 4 Installation ...................................................................... 6 4.1 4.2 4.3 Mounting......................................................................................... 6 Connections and Wiring ................................................................. 9 Testing........................................................................................... 11 5 Operation of Clutch...................................................... 11 6 Maintenance and Servicing ......................................... 12 6.1 6.2 6.3 Replacement of Motor Brushes .................................................... 13 Replacement of Park Brake Friction Element .............................. 15 Spare Parts Numbers..................................................................... 17 7 Intended Use and Regulatory Statement ................... 17 8 Safety and Misuse Warnings....................................... 18 9 Warranty........................................................................ 20 10 Sales and Service......................................................... 21 GBK90001, Issue 6. May 2003 1 Introduction This manual provides installation and maintenance information for the Dynamic Motor Type M4. This manual should be read in conjunction with the installation manual for all other components of the control system including controller, remote, programmer, and accessories. All manuals must be read and understood before commencing installation. For more information contact Dynamic or an agent as listed in section 10. Dynamic Controls welcomes feedback from its customers on its products and documentation. If you would like to comment on this manual or the product it describes, please contact us at any of the addresses at the back on this manual or by email at: [email protected] 2 General Description The 24V Dynamic Motor is specifically designed for use on power wheel chairs. The motor incorporates a metal cased park brake. The park brake assembly and brushes are protected by a metal cover. The motor frame is integral with the cast aluminum gearbox housing producing a strong and compact unit. An easily operated lever disengages the spline clutch for manual pushing of the chair. Use of a spline clutch ensures minimal backlash. Forward Left motor 1 Right motor a one-piece worm and armature shaft. coupled with Dynamic’s controllers will ensure remarkable speed regulation along with high efficiency.4mm) tubular frame using the cast brackets.5º IP 54 31. 3 Electrical and Mechanical Specification Motor type Permanent magnet commutator 24 V DC Bearings Parking brake type No load current Continuous current Power output maximum Torque Constant Max Torque Ball bearings Electro-mechanical 24 V DC 3.75 cm (12.1 Nm/A 44 Nm when used with 40A controller 55 Nm when used with 50A controller Greater than 50 Nm at output shaft 120 rpm nominal i = 32.5") Refer to drawing Parking brake holding torque No load speed at output shaft Gear ratio Insulation Motor resistance Weight Motor frame finish Typical backlash Protection class Recommended wheel size Basic dimensions To improve controllability at load speed.88 Class F 250 mOhm 5.GBK90001.5 kg Black 1.0 A 230 W @ 65 RPM 1. The motor may support other mounting arrangements. The motors are easily mounted to a 1” (25. a load compensation setting of approximately 165 is recommended for Dynamic Controls wheelchair controllers. Hardened worm and spur gears.3 A maximum 8. please contact Dynamic Controls for details. and a fully sealed gearbox combine for a long motor life. May 2003 A powerful permanent magnet. Issue 6. 2 . In particular to the standards listed below. ISO7176 .3 6.Standard for Wheelchairs Successfully tested on representative wheelchairs.2.1 6. Issue 6.2. However the performance of motor / controller systems fitted to wheelchairs and scooters is very dependant on the design of the scooter or wheelchair so final compliance must be obtained by the vehicle manufacturer for their particular vehicle. 3 Section Reference Efficiency of Brakes Static Impact and Fatigue Strength Effects of Rain Climatic Conditions Electrical Isolation of Wheelchair Interchangeability of Connectors * Attachment and Positioning of Wires * Protection From Non-insulated Parts Stalled Condition Protection Non-powered mobility Test Safety Guard Test Forces Needed to Operate Control Radiated Emissions (in combination with CISPR 11) ESD .6 6.7 6.3 6.1 ISO 7176 21 5.14 7 8 10 5. May 2003 3.5 6. Standard Reference Part ISO 7176 ISO 7176 ISO 7176 ISO 7176 ISO 7176 ISO 7176 ISO 7176 ISO 7176 ISO 7176 ISO 7176 ISO 7176 ISO 7176 ISO 7176 3 8 9 9 14 14 14 14 14 14 14 14 21 6. All motor mounting configurations must be tested with the complete wheelchair in order to comply with ISO standard 7176-8.1 Standards Compliance Dynamic Controls products built today allow our customer’s vehicles to conform to national and international requirements.2 * Refer to Section 4. No component compliance certificate issued by Dynamic Controls relieves a wheelchair/scooter manufacturer from compliance testing their particular vehicles. If Dynamic Controls controllers are fitted to vehicles or applications other than wheelchairs and scooters.GBK90001. testing to appropriate standards for the particular application must be completed as ISO7176 may be inappropriate.2. 50 .3 3. Mechanical Characteristics 44.0 15 100 10 20.2 Typical Performance Characteristics 60.02 Ø30 A Ø17 -0.2 A 40.0 150 Current Speed 40 5 35 0 30 0.05 3.2 Se c t i on A.0.5 Output Shaft and Keyway Detail 4 .0 25 50 20 10.0 0 Current [ADC] Efficiency [%] Output Power Torque [Nm] The maximum shaft speed of 120 rpm gives a normal speed of 7.05 -0.0 Output Power [W] Speed [1/min] 40.5 1 x 45° + 0 13.GBK90001.2 kph with 12. May 2003 3. Issue 6.5 inch outside diameter wheels.A 0 6 -0.0 250 Efficiency 200 30.0 300 50. 44 47.2 10. All dimensions in mm.2 R 14 .4 Mad e i n C h in a Fo r D Y NA M I C 110.5±0.0 (Ø1 30.GBK90001.4 10 0± 64 General Arrangement and Major Dimensions of the Dynamic Motor (Left). 5 .7 36.0 0 (Ø2 77.0 7.00 43.6 Ø25.7 H 107.0 138.7 0 Par t # : W MT S er i al #: Vol ts : D C 2 4 V Am ps : 8 A Co ntinuo us B r ak e Vo l tag e : DC R P M: 1 1 0 m i ni mu m S ta ll e d Tor que : In sul at i on Cl as s : 302.0 ) 3.5 ± 0.80 3 x M 6. Issue 6.0 52.0 44. May 2003 17.2 D es ig n ed fo r P ow er Wh e el ch a ir s .5 40 24V 113 Nm F 79 51.8 22.0 124.9 R1 2.0) 64.5 88 134 43 0.00 36. the motor is to be mounted horizontally.GBK90001. This motor must also be used in pairs (2 motors) on each wheelchair. Mounting of the motors to the frame of the chair should be done in the following sequence: • Mount the motor to the frame leaving the screws loose. • Tighten the screws in the order indicated to ensure correct pressure is put onto the gasket. Issue 6. 6 . • Fasten all screws hand tight then check the alignment of the output shaft and the consistency of the gap between the clamp and the top plate (this must include both screws used on the vertical tube clamp). In any mounting scenario. The most commonly used method is shown (see following pages). Readjust if necessary. • Slightly open the screws on the clutch release side of the gearbox. May 2003 4 Installation This motor is to be used on power wheelchairs in conjunction with appropriate electronic controllers to ensure safe operation. Installing a the motor requires the following steps: • Mounting • Connections and wiring • Testing 4.1 Mounting There are a variety of methods for mounting the motors. Note that different length screws are used with each mounting option. Issue 6. apply a chemical thread lock such as Loctite 222 to the wheel screws and tighten the screws to a torque of 14 Nm (10. • When fitting the wheel.3 ft-lb).3 ftlb) to 18 Nm (13. • Ensure that the motor is firmly secured and that the axle is accurately aligned. 7 . May 2003 3 7 8 11 9 1 5 4 2 6 10 • Note that different length socket head screws are used with each option. • The mounting must conform to the static and dynamic load requirements of the chair (refer to ISO 7176-8).GBK90001. Frequent checks to ensure the wheels are secure are recommended. • All alternative-mounting methods must be tested and proven by the wheelchair manufacturer to ensure relevant standards compliance.8 screws. When replacing. use only grade 8. 25. (3 places) M6 x 40 socket head screw. May 2003 M6 x 25 socket head screw.GBK90001. (3 places) 6 x 6 x 40 keyway M8 x 20 hex head M6 x 25 socket head screw and nylock nut.4mm tube Anti-tip wheels can be installed here Mounting on Tube Type Frame 8 . (2 places) Front of chair Chair frame . Issue 6. GBK90001. Blue - Red + Blue - Red + Forward movement Shown with DX style plugs. May 2003 4. However the cables must be mounted in a way that the connectors for left and right motor cannot be swapped. (ISO717614 section 6. Note that the red and blue wire connections will affect the direction the motor rotates. Refer to the diagram and the table to ensure motors work as a pair. Left motor 9 Right motor .5). Note: Reverse motor polarity and left and right motor swap are fully programmable (software) options in all Dynamic wheelchair controllers. Issue 6.2 Connections and Wiring Each motor has four wires of two different sizes that require connection. For compatibility reasons. Lift the wheels before making the battery connection and check the drive system is functioning correctly. May 2003 Wire Color Wire size Connector Rating Red to + Blue to Right motor Red to + Blue to Park brake Black 2.5 mm2 Wheel Rotation (viewed from axle) Counterclockwise Clockwise Different connectors are available and should be chosen to suit the application. wire size.5 A continuous or higher Left motor 2.5 mm2 0. Ensure that the wheelchair’s power system is equipped with a circuit breaker according to ISO7176-14.5 mm2 10 A continuous or higher 10 A continuous or higher 0. The use of polarized connectors is recommended in order to reduce the risk of interchanging connectors. left and right motor connectors are identical. Issue 6. To build a single connector: Part Number Description Qty per motor DX-PM Motor Connector Housing 1 or GCN 60146 DX-PM Left Motor Connector Housing 1 or GCN 60147 DX-PM Right Motor Connector Housing 1 GCN 0787 DX-PM Motor Connector Boot 1 GCN 0781 DX Innergy Contact Female 2 GCN 0794 DX Positronic Contact Female 2 GCN 0790 10 . When all wiring is completed the loom must be fastened to the frame to minimise strain on the connections.GBK90001. and current requirements. • Lift the wheels off the ground. the following points should be noted: A circuit breaker must be included in the power circuitry.Right Motor label TM 11 WSP90008 . Labels are available for indicating the status of the clutch lever. Issue 6. While testing.GBK90001. Simply turn the lever on each motor.Left Motor label WSP90007 • TM WSP90008 . • WSP90007 . 5 Operation of Clutch When it is desired to manually push the chair the clutch is easily disengaged. May 2003 4. When engaging the clutch rock the chair slightly. • Do not arc cables to check for power. • Use a multimeter to check the voltage.3 Testing When the installation of the motors and control system are complete the system may be tested. heating. • The cover may be removed to check the brush length. smoke or arcing. • Check for loose. Warning: Do not use the motor is there is any indication of damage or excessive wear such as: damage to the case. grease leakage. excessive noise.GBK90001. which should be greater than 10 mm. • Check for damage on motor or wheelchair indicating external impact. contact your nearest Service Centre or Agent. May 2003 6 Maintenance and Servicing This motor is a low maintenance motor and apart from periodic inspections. abnormal response. damaged or corroded connectors and terminals • Replace damaged cabling. • Check for oil or grease leaks around the seals. will require no further maintenance under normal conditions. The batteries should be disconnected during any maintenance procedure and in fact their complete removal from the chair may improve access. • Check motor for increased backlash or play. • Where any doubts exist. and clutch lever. increased backlash or play. Ensure that the motor is securely fastened to the frame and the wheel securely fastened to the motor. Issue 6. excessive noise or other indications of increased wear of the gear. 12 . • Clean motor and control system components with a damp cloth. • Check system regularly. • Check motor mountings for tightness. output shaft. • Use a small hook as a tool to hold back the spring and slide out the brush. • Remove the screw holding the brush wire. • Remove the end cover to allow access. which in turn produces RFI and audible noise. ensuring that the brush is still able to slide in the brush guide. Issue 6. Note: The brush wire must not contact the aluminum end bell. Ensure correct insulation between motor case and motor wires (refer ISO 7176-14). • Reverse the above processes to install the new brush. Ensure that the parkbrake is released when operating the motor. It is important not to let the screw fall into the motor as the magnets contained will make removal of the screw extremely difficult. Brush replacement is a simple operation: • Disconnect the motor. • Check the commutator for excessive wear or unusual burns or erosion marks. • Always replace all the brushes in both motors at the same time.GBK90001. May 2003 6.1 Replacement of Motor Brushes Each motor contains two carbon brushes which may require replacement after prolonged operation. • Run brushes in for 12 hours in the forward direction at about half speed. (This reduces brush bounce which causes arcing.) 13 . • Ensure the springs seat properly on the brush and the brush wire is placed according to the drawing. GBK90001. May 2003 Screws securing cover Cover Remove screw (Tighten firmly) Pull spring back Slide brush out Replacement of Motor Brushes 14 . Issue 6. • Remove the friction element and replace. Note: Do not rely on the click sound because if the gap between the steel brake disk and the coil housing is uneven you may hear he click but the park brake may be only partly disengaged. • Remove the cover to allow access. Remove some shim washers to reduce the park brake pull-in voltage.) 8 volts < brake pull-in voltage < 16 volts. 15 . Issue 6. (Coil cold. • Always replace the friction elements in both motors at the same time. • Reverse the process to install the new friction element. • Remove the screws holding the park brake assembly to the end bell.2 Replacement of Park Brake Friction Element Each park brake assembly contains a friction element which may require replacement. Alternatively the entire park brake assembly can be replaced.GBK90001. • Remove the screws holding the park brake assembly together. • Avoid excess strain on the wires. May 2003 6. Secure the park brake assembly to the end bell. Too large a gap between the steel brake disk and the coil housing will cause the brake pull-in voltage to be too high. Poor park brake holding ability indicates the need for replacement of the friction element. • Check the armature rotates freely with the park brake disengaged. The brake must drop out without hesitation at 1. • Check park brake pull-in and drop-out voltages. • Disconnect the motor. • Replace cover after checking all parts are correctly positioned.5 volts minimum. May 2003 Screws securing cover Coil housing Spring Steel brake disk Friction element Shim washers Cover (Park brake Assembly) Screws securing park brake assembly Park brake assembly End Bell Body of motor Replacement of Park Brake Friction Element (Note: Armature and brushes not shown) 16 .GBK90001. Issue 6. USA The Dynamic Motor Type M4 is a component of a Class II medical device (Powered Wheelchair) as detailed in 21 CFR § 890. final compliance of the complete wheelchair system with international and national standards is the responsibility of the wheelchair manufacturer or installer. Issue 6. The motor is fitted with an integral park brake and intended for use with a wheelchair controller & appropriate overload protection device. Device Classification Europe The Dynamic Motor Type M4 is a component of a Class I medical device as detailed in the Council Directive 93/42/EEC concerning Medical Devices. is capable of complying with the requirements of the MDD harmonised standards EN 12182 & EN12184 and the FDA consensus standard ISO7176 for performance. May 2003 6. the Dynamic Motor Type M4 is designed in accordance with the requirements of the European Medical Device Directive and the Quality System Regulations. along with applicable components and accessories. Compliance and Conformance with Standards Appropriate to the device classification. 17 . However. The Dynamic Motor Type M4 has been designed and manufactured such that the wheelchair.GBK90001.3 Spare Parts Numbers Part Description Left Motor Clutch Label Right Motor Clutch Label Brush Kit (two brushes) End Cover with Screws Key 6 x 6 x 40 mm (on shaft) Wheel Securing Set (set screw & washers) Park Brake Assembly 24V Park Brake Friction Element 7 Dynamic Part Number Qty Per Motor WSP 90007 WSP 90008 WSP 90101 WSP 90111 WSP 90120 WSP 90130 1 1 1 1 1 1 WSP 90140 WSP 90150 1 1 Intended Use and Regulatory Statement Intended Use The Dynamic Motor Type M4 is a 24-volt DC permanent magnet motor intended for use on powered wheelchairs.3860. by the product. Incorrect settings could cause injury to the driver. heating. or shows abnormal response. • The user must turn the system off while getting in and out of the wheelchair. damage to the chair and surrounding property. • Do not operate the equipment if it shows abnormal noise. they should still be able to summon assistance from where ever they may be. increased backlash or it was damaged otherwise. • A warning must be conveyed to the wheelchair operator that the controller could cause the chair to come to a sudden stop. • The Dynamic Motors must not be used other than in the manner described in this manual otherwise injury or damage may result. Issue 6. bystanders. Should an operator be left with limited or no mobility due to an equipment failure. • The Dynamic Motor meets IP54 for shower and dust protection and thus it is not suitable for driving through surface water. • Ensure the wheelchair controller is turned off when not in use. 18 . Turn the equipment off at once and consult your Service Agent. May 2003 8 Safety and Misuse Warnings • All warnings throughout this Manual must be read and understood. this will require the fitting and wearing of a seat belt. If in doubt ask for advice. Turn the equipment off at once and consult your Service Agent.GBK90001. In situations where this could affect the safety of the user. • Users and Suppliers of Assistive Mobility products should give consideration to the possibility of a failure to operate. • Do not operate the equipment if it behaves erratically. • Performance adjustments should only be made by professionals of the health care field or persons fully conversant with this process and the driver’s capabilities. or an incorrect operation. smoke or arcing. • Do not operate the controller if the battery is nearly flat as a dangerous situation may result due to a loss of power in an inopportune place. Warnings apply to unsafe practices which could result in personal injury or property damage. Repeat this procedure until the wheelchair performs to specifications. • Most electronic equipment is influenced by Radio Frequency Interference (RFI). 19 . • In the event of a fault indicator flashing while driving. check to make sure that the wheelchair performs to the specifications entered in the set-up procedure. the system must be turned off and a Service Agent called immediately. If the wheelchair does NOT perform to specifications. If not. Issue 6.GBK90001. turn the wheelchair OFF immediately and re-enter set-up specifications. Leave off while transmission is in progress. If RFI causes erratic behaviour. as contamination or damage due to electrostatic discharge may result. • Report any malfunctions immediately to your Service Agent. Caution should be exercised with regard to the use of portable communications equipment in the area around such equipment. May 2003 • After the wheelchair has been set-up. shut the wheelchair off immediately. • No connector pins should be touched. the user must ensure that the system is behaving normally. • Has been properly connected to a suitable power supply in accordance with this manual. If any defect is found within the warranty period. the company will repair the equipment. or at its discretion. Issue 6. • Has been used solely in accordance with this manual. • Has not been subjected to misuse or accident. 20 . May 2003 9 Warranty All equipment supplied by Dynamic Controls is warranted by the company to be free from faulty materials or workmanship. or been modified or repaired by any person other than someone authorised by Dynamic Controls. replace the equipment without charge for materials and labour. The warranty is subject to the provisions that the equipment: • Has been correctly installed.GBK90001. • Has been used solely for the driving of electrically powered wheelchairs in accordance with the wheelchair manufacturer’s recommendations. Please contact your nearest Dynamic representative for Sales and/or Service advice.GBK90001. May 2003 10 Sales and Service Dynamic has a global network of sales and service centres. or contact us directly through our web site: 21 . Issue 6.