Contents

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

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

Electrical and Mechanical Specification ...................... 2

3.1
3.2
3.3

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

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

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

Intended Use and Regulatory Statement ................... 17

Safety and Misuse Warnings....................................... 18

Warranty........................................................................ 20

10

Sales and Service......................................................... 21

GBK90001, Issue 6. May 2003

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:
info@dynamic-controls.co.nz

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

Right motor

GBK90001, Issue 6. May 2003

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.

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
3.3 A maximum
8.0 A
230 W @ 65 RPM
1.1 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 = 32.88
Class F
250 mOhm
5.5 kg
Black
1.5
IP 54
31.75 cm (12.5")
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, a load compensation setting of

approximately 165 is recommended for Dynamic Controls wheelchair controllers.

GBK90001, Issue 6. May 2003

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

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

6.1
6.3
6.3
6.5
6.6
6.7
6.14
7
8
10
5.2.1

ISO 7176

21

5.2.2

* Refer to Section 4.2.

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

GBK90001, Issue 6. May 2003

3.2

Typical Performance Characteristics

60.0

300

50.0

250
Efficiency

200

30.0

150
Current

Speed

40

35

0
30

0.0
25

50

20

10.0

15

100

10

20.0

Output Power [W] Speed [1/min]

40.0

Current [ADC]

Efficiency [%]

Output Power

Torque [Nm]

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

Mechanical Characteristics
44.5

1 x 45

+ 0

13.50 - 0.2
A

40.2

Se c t i on A- A

6 -0.05

-0.02

30

17 -0.05

3.3

3.5

Output Shaft and Keyway Detail

GBK90001, Issue 6. May 2003

17.7

36.8

22.9

R1
2.7
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 :

302.5 0.5

88

134

43

0.5

40

24V

113

Nm

79
51.00

43.44
47.0

52.80

3 x M 6- 7 H

107.00

36.6

25.4

Mad e i n C h in a
Fo r D Y NA M I C

110.0
124.0
138.0

44.50.2

R 14
.2

D es ig n ed fo r P ow er Wh e el ch a ir s

.0)

64.0

0
(2

77.0

7.0

)
3.0
(1

30.2

10.4

10
0
64

General Arrangement and Major Dimensions of the Dynamic Motor

(Left).
All dimensions in mm.
5

GBK90001, Issue 6. May 2003

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.

GBK90001, Issue 6. May 2003

3
7

11

9
1
5
4
2
6

10

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 ftlb) 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.

GBK90001, Issue 6. May 2003

M6 x 25 socket head
screw. (3 places)

M6 x 40 socket head
screw. (3 places)
6 x 6 x 40 keyway

M8 x 20 hex head

M6 x 25 socket head screw

and nylock nut. (2 places)
Front of chair
Chair frame - 25.4mm tube

Anti-tip wheels can

be installed here

Mounting on Tube Type Frame

GBK90001, Issue 6. May 2003

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, (ISO717614 section 6.5).

Blue -

Red +

Blue -

Red +

Forward
movement

Shown with
DX style plugs.

Left motor

Right motor

GBK90001, Issue 6. May 2003

Wire
Color

Wire size

Connector Rating

Red to +
Blue to Right motor Red to +
Blue to Park brake
Black

2.5 mm2

10 A continuous
or higher
10 A continuous
or higher
0.5 A continuous
or higher

Left motor

2.5 mm2
0.5 mm2

Wheel Rotation
(viewed from
axle)
Counterclockwise
Clockwise

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

DX-PM Motor Connector Housing

or GCN 60146

DX-PM Left Motor Connector Housing

or GCN 60147

DX-PM Right Motor Connector Housing

GCN 0787

DX-PM Motor Connector Boot

GCN 0781

DX Innergy Contact Female

GCN 0794

DX Positronic Contact Female

GCN 0790

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GBK90001, Issue 6. May 2003

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.

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

WSP90007

TM

WSP90008 - Right Motor label

TM

11

WSP90008

GBK90001, Issue 6. May 2003

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.

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GBK90001, Issue 6. May 2003

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.)

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GBK90001, Issue 6. May 2003

Screws
securing cover

Cover

Remove screw
(Tighten firmly)

Pull spring back

Slide brush out

Replacement of Motor Brushes

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GBK90001, Issue 6. May 2003

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.

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GBK90001, Issue 6. 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)

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GBK90001, Issue 6. May 2003

6.3

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

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. 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.
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GBK90001, Issue 6. May 2003

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.

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GBK90001, Issue 6. May 2003

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.

19

GBK90001, Issue 6. May 2003

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.

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GBK90001, Issue 6. May 2003

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:

21