m4 Motor Installation Manual

Contents

1 Introduction .................................................................... 1

2 General Description ....................................................... 1

3 Electrical and Mechanical Specification ...................... 2 3.1 Standards Compliance .................................................................... 3 3.2 Typical Performance Characteristics.............................................. 4 3.3 Mechanical Characteristics............................................................. 4

4 Installation ...................................................................... 6 4.1 Mounting......................................................................................... 6 4.2 Connections and Wiring ................................................................. 9 4.3 Testing........................................................................................... 11

5 Operation of Clutch...................................................... 11

6 Maintenance and Servicing......................................... 12 6.1 Replacement of Motor Brushes .................................................... 13 6.2 Replacement of Park Brake Friction Element .............................. 15 6.3 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

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.

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.

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]

Left motor

Forward

Right motor


2

A powerful permanent magnet, coupled with Dynamics controllers will ensure remarkable speed regulation along with high efficiency. Hardened worm and spur gears, a one-piece worm and armature shaft, and a fully sealed gearbox combine for a long motor life. The motors are easily mounted to a 1 (25.4mm) tubular frame using the cast brackets. The motor may support other mounting arrangements, please contact Dynamic Controls for details.

3 Electrical and Mechanical Specification

Motor type Permanent magnet commutator 24 V DC Bearings Ball bearings Parking brake type Electro-mechanical 24 V DC No load current 3.3 A maximum Continuous current 8.0 A Power output maximum 230 W @ 65 RPM Torque Constant 1.1 Nm/A Max Torque 44 Nm when used with 40A controller

55 Nm when used with 50A controller Parking brake holding torque Greater than 50 Nm at output shaft No load speed at output shaft 120 rpm nominal Gear ratio i = 32.88 Insulation Class F Motor resistance 250 mOhm Weight 5.5 kg Motor frame finish Black Typical backlash 1.5 Protection class IP 54 Recommended wheel size 31.75 cm (12.5") Basic dimensions Refer to drawing

To improve controllability at load speed, a load compensation setting of approximately 165 is recommended for Dynamic Controls wheelchair controllers.


3

3.1 Standards Compliance

Dynamic Controls products built today allow our customers vehicles to conform to national and international requirements. In particular to the standards listed below. 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. No component compliance certificate issued by Dynamic Controls relieves a wheelchair/scooter manufacturer from compliance testing their particular vehicles. All motor mounting configurations must be tested with the complete wheelchair in order to comply with ISO standard 7176-8. If Dynamic Controls controllers are fitted to vehicles or applications other than wheelchairs and scooters, testing to appropriate standards for the particular application must be completed as ISO7176 may be inappropriate.

ISO7176 - Standard for Wheelchairs Successfully tested on representative wheelchairs.

Standard Reference

Part Section Reference

ISO 7176 3 Efficiency of Brakes ISO 7176 8 Static Impact and Fatigue Strength ISO 7176 9 6.1 Effects of Rain ISO 7176 9 6.3 Climatic Conditions ISO 7176 14 6.3 Electrical Isolation of Wheelchair ISO 7176 14 6.5 Interchangeability of Connectors * ISO 7176 14 6.6 Attachment and Positioning of Wires * ISO 7176 14 6.7 Protection From Non-insulated Parts ISO 7176 14 6.14 Stalled Condition Protection ISO 7176 14 7 Non-powered mobility Test ISO 7176 14 8 Safety Guard Test ISO 7176 14 10 Forces Needed to Operate Control ISO 7176 21 5.2.1 Radiated Emissions (in combination with

CISPR 11) ISO 7176 21 5.2.2 ESD

* Refer to Section 4.2.


4

3.2 Typical Performance Characteristics

0.0

10.0

20.0

30.0

40.0

50.0

60.00 5 10 15 20 25 30 35 40

Torque [Nm]

Curr

en

t [AD

C]

Effic

ien

cy

[%]

0

50

100

150

200

250

300

Ou

tput

Pow

er

[W]

Spee

d [1/

min

]

Current

Output PowerEfficiency

Speed

The maximum shaft speed of 120 rpm gives a normal speed of 7.2 kph with 12.5 inch outside diameter wheels.

3.3 Mechanical Characteristics

Output Shaft and Keyway Detail

1 x

45

30

3.5

40.213.50 + 0- 0.2

44.5

17

-0.

02-0.

05

A A

Sect ion A-A 6 0

-0.

05


5

79

22.9

134

107.

00

17.7 36.8

44.5

0.

2

25.4

43

640

10

0.5

302.

5

0.5

88

113

For

De

sig

ned

for

Po

we

r W

heel

cha

irs

DY

NA

MIC

Ma

de i

n C

hin

a

Part # : WMT

Ser ia l #:

Vol ts : D C 24V

RP M: 110 min imu m

Sta lled Torque : 40

In su lat ion Class : F

Amps : 8A Cont inuous

B rak e Vo l tage : DC 24V

N m

R 12.70

52.80

110.03 x M6-7H

124.0

47.0

30.27.

0

64.0

77.0

138.0

(13.0

)

(20.0

)

R 14.2

36.6

10.4

51.00 43.44

General Arrangement and Major Dimensions of the Dynamic Motor (Left).

All dimensions in mm.


6

4 Installation

This motor is to be used on power wheelchairs in conjunction with appropriate electronic controllers to ensure safe operation. This motor must also be used in pairs (2 motors) on each wheelchair. 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. In any mounting scenario, the motor is to be mounted horizontally. The most commonly used method is shown (see following pages). 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. Note that different length screws are used with each mounting option.

Slightly open the screws on the clutch release side of the gearbox. 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). Readjust if necessary.

Tighten the screws in the order indicated to ensure correct pressure is put onto the gasket.


7

6

1

2

54

3

11

78

10

9

Note that different length socket head screws are used with each option. Ensure that the motor is firmly secured and that the axle is accurately

aligned. The mounting must conform to the static and dynamic load requirements

of the chair (refer to ISO 7176-8). When fitting the wheel, apply a chemical thread lock such as Loctite 222

to the wheel screws and tighten the screws to a torque of 14 Nm (10.3 ft-lb) to 18 Nm (13.3 ft-lb). Frequent checks to ensure the wheels are secure are recommended. When replacing, use only grade 8.8 screws.

All alternative-mounting methods must be tested and proven by the wheelchair manufacturer to ensure relevant standards compliance.


8

M6 x 25 socket headscrew. (3 places)

M6 x 40 socket headscrew. (3 places)

M8 x 20 hex head

6 x 6 x 40 keyway

Front of chair

Chair frame - 25.4mm tube

M6 x 25 socket head screwand nylock nut. (2 places)

Anti-tip wheels canbe installed here

Mounting on Tube Type Frame


9

4.2 Connections and Wiring

Each motor has four wires of two different sizes that require connection. 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.

Note: Reverse motor polarity and left and right motor swap are fully programmable (software) options in all Dynamic wheelchair controllers. However the cables must be mounted in a way that the connectors for left and right motor cannot be swapped, (ISO7176-14 section 6.5).

Left motor

Forward

Shown withDX style plugs.

Right motor

movement

Red +

Blue -

Blue -

Red +


10

Wire Color

Wire size Connector Rating Wheel Rotation (viewed from

axle) Left motor Red to +

Blue to - 2.5 mm2 10 A continuous

or higher Counter-

clockwise Right motor Red to +

Blue to - 2.5 mm2 10 A continuous

or higher Clockwise

Park brake Black 0.5 mm2 0.5 A continuous or higher

Different connectors are available and should be chosen to suit the application, wire size, and current requirements. When all wiring is completed the loom must be fastened to the frame to minimise strain on the connections. Lift the wheels before making the battery connection and check the drive system is functioning correctly. Ensure that the wheelchairs power system is equipped with a circuit breaker according to ISO7176-14. For compatibility reasons, left and right motor connectors are identical. The use of polarized connectors is recommended in order to reduce the risk of interchanging connectors.

To build a single connector:

Part Number Description Qty per motor

GCN 0790 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


11

4.3 Testing

When the installation of the motors and control system are complete the system may be tested. While testing, the following points should be noted: A circuit breaker must be included in the power circuitry; Lift the wheels off the ground; Do not arc cables to check for power; Use a multimeter to check the voltage.

5 Operation of Clutch

When it is desired to manually push the chair the clutch is easily disengaged. Simply turn the lever on each motor. When engaging the clutch rock the chair slightly.

Labels are available for indicating the status of the clutch lever.

WSP90007 - Left Motor label

WSP90008 - Right Motor label

TMWSP90007

TMWSP90008


12

6 Maintenance and Servicing

This motor is a low maintenance motor and apart from periodic inspections, 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 system regularly. Check for loose, damaged or corroded connectors and terminals Replace damaged cabling. Check motor mountings for tightness. Clean motor and control system components with a damp cloth. The cover may be removed to check the brush length, which should be

greater than 10 mm. Check for oil or grease leaks around the seals, output shaft, and clutch

lever. Check for damage on motor or wheelchair indicating external impact. Check motor for increased backlash or play, excessive noise or other

indications of increased wear of the gear. Where any doubts exist, contact your nearest Service Centre or Agent.

Warning: Do not use the motor is there is any indication of damage or excessive wear such as: damage to the case, excessive noise, grease leakage, increased backlash or play, abnormal response, heating, smoke or arcing.

Ensure that the motor is securely fastened to the frame and the wheel securely fastened to the motor.


13

6.1 Replacement of Motor Brushes

Each motor contains two carbon brushes which may require replacement after prolonged operation. Brush replacement is a simple operation:

Disconnect the motor. Remove the end cover to allow access. Remove the screw holding the brush wire. It is important not to let the

screw fall into the motor as the magnets contained will make removal of the screw extremely difficult.

Use a small hook as a tool to hold back the spring and slide out the brush.

Check the commutator for excessive wear or unusual burns or erosion marks.

Reverse the above processes to install the new brush, ensuring that the brush is still able to slide in the brush guide.

Ensure the springs seat properly on the brush and the brush wire is placed according to the drawing.

Note: The brush wire must not contact the aluminum end bell. Ensure correct insulation between motor case and motor wires (refer ISO 7176-14).

Always replace all the brushes in both motors at the same time. Run brushes in for 12 hours in the forward direction at about half speed.

Ensure that the parkbrake is released when operating the motor. (This reduces brush bounce which causes arcing, which in turn produces RFI and audible noise.)


14

Replacement of Motor Brushes

Cover

Screwssecuring cover

Slide brush out

Pull spring back

Remove screw(Tighten firmly)


15

6.2 Replacement of Park Brake Friction Element

Each park brake assembly contains a friction element which may require replacement. Poor park brake holding ability indicates the need for replacement of the friction element. Alternatively the entire park brake assembly can be replaced.

Disconnect the motor. Remove the cover to allow access. Remove the screws holding the park brake assembly to the end bell. Avoid excess strain on the wires. Remove the screws holding the park brake assembly together. Remove the friction element and replace. Reverse the process to install the new friction element. Secure the park

brake assembly to the end bell. Check park brake pull-in and drop-out voltages. (Coil cold.)

8 volts < brake pull-in voltage < 16 volts. The brake must drop out without hesitation at 1.5 volts minimum. Too large a gap between the steel brake disk and the coil housing will cause the brake pull-in voltage to be too high. Remove some shim washers to reduce the park brake pull-in voltage.

Check the armature rotates freely with the park brake disengaged.

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.

Always replace the friction elements in both motors at the same time. Replace cover after checking all parts are correctly positioned.


16

Cover

End Bell

Body of motor

Park brake assembly

Screws

Screws securing

securing cover

park brake assembly

Spring

Friction elementSteel brake disk

Coil housing

Shim washers

(Park brake Assembly)

Replacement of Park Brake Friction Element (Note: Armature and brushes not shown)


17

6.3 Spare Parts Numbers

Part Description Dynamic Part Number Qty Per Motor Left Motor Clutch Label WSP 90007 1 Right Motor Clutch Label WSP 90008 1 Brush Kit (two brushes) WSP 90101 1 End Cover with Screws WSP 90111 1 Key 6 x 6 x 40 mm (on shaft) WSP 90120 1 Wheel Securing Set (set screw & washers)

WSP 90130 1

Park Brake Assembly 24V WSP 90140 1 Park Brake Friction Element WSP 90150 1

7 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. 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. USA The Dynamic Motor Type M4 is a component of a Class II medical device (Powered Wheelchair) as detailed in 21 CFR 890.3860. Compliance and Conformance with Standards Appropriate to the device classification, the Dynamic Motor Type M4 is designed in accordance with the requirements of the European Medical Device Directive and the Quality System Regulations. The Dynamic Motor Type M4 has been designed and manufactured such that the wheelchair, along with applicable components and accessories, is capable of complying with the requirements of the MDD harmonised standards EN 12182 & EN12184 and the FDA consensus standard ISO7176 for performance. However, final compliance of the complete wheelchair system with international and national standards is the responsibility of the wheelchair manufacturer or installer.


18

8 Safety and Misuse Warnings

All warnings throughout this Manual must be read and understood. Warnings apply to unsafe practices which could result in personal injury or property damage. If in doubt ask for advice.

Users and Suppliers of Assistive Mobility products should give consideration to the possibility of a failure to operate, or an incorrect operation, by the product. Should an operator be left with limited or no mobility due to an equipment failure, they should still be able to summon assistance from where ever they may be.

The Dynamic Motors must not be used other than in the manner described in this manual otherwise injury or damage may result.

The Dynamic Motor meets IP54 for shower and dust protection and thus it is not suitable for driving through surface water.

Do not operate the equipment if it behaves erratically, or shows abnormal response, heating, smoke or arcing. Turn the equipment off at once and consult your Service Agent.

A warning must be conveyed to the wheelchair operator that the controller could cause the chair to come to a sudden stop. In situations where this could affect the safety of the user, this will require the fitting and wearing of a seat belt.

Ensure the wheelchair controller is turned off when not in use. The user must turn the system off while getting in and out of the

wheelchair. Do not operate the equipment if it shows abnormal noise, increased

backlash or it was damaged otherwise. Turn the equipment off at once and consult your Service Agent.

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.

Performance adjustments should only be made by professionals of the health care field or persons fully conversant with this process and the drivers capabilities. Incorrect settings could cause injury to the driver, bystanders, damage to the chair and surrounding property.


19

After the wheelchair has been set-up, check to make sure that the wheelchair performs to the specifications entered in the set-up procedure. If the wheelchair does NOT perform to specifications, turn the wheelchair OFF immediately and re-enter set-up specifications. Repeat this procedure until the wheelchair performs to specifications.

No connector pins should be touched, as contamination or damage due to electrostatic discharge may result.

In the event of a fault indicator flashing while driving, the user must ensure that the system is behaving normally. If not, the system must be turned off and a Service Agent called immediately.

Most electronic equipment is influenced by Radio Frequency Interference (RFI). Caution should be exercised with regard to the use of portable communications equipment in the area around such equipment. If RFI causes erratic behaviour, shut the wheelchair off immediately. Leave off while transmission is in progress.

Report any malfunctions immediately to your Service Agent.


20

9 Warranty

All equipment supplied by Dynamic Controls is warranted by the company to be free from faulty materials or workmanship. If any defect is found within the warranty period, the company will repair the equipment, or at its discretion, replace the equipment without charge for materials and labour.

The warranty is subject to the provisions that the equipment: Has been correctly installed; Has been used solely in accordance with this manual; Has been properly connected to a suitable power supply in accordance

with this manual; Has not been subjected to misuse or accident, or been modified or repaired

by any person other than someone authorised by Dynamic Controls. Has been used solely for the driving of electrically powered wheelchairs in

accordance with the wheelchair manufacturers recommendations.


21

10 Sales and Service

Dynamic has a global network of sales and service centres. Please contact your nearest Dynamic representative for Sales and/or Service advice, or contact us directly through our web site:

Documents

m4 Motor Installation Manual