GZS Bed Mover Operating Manual

Gzunda GZS Bed Mover-Operating Manual

Contents Introduction... 5 Operating instructions... 6 Controls... 6 Using the GZS... 9 Hitching and unhitching to a bed... 9 Sleep Mode... 10 Charging... 10 Maintenance... 11 Batteries... 11 Brakes... 11 Motor... 11 Electronic speed control... 11 Fuses... 12 Circuit breaker... 13 Cleaning... 13 General... 13 Disposal of components or material... 13 Warranty... 14 Maintenance... 14 Misuse... 14 General wear items not covered under warranty... 14 Appendix 1: Machine rating conditions... 15 Appendix 2: Fault codes... 16 Appendix 3: Motor brush replacement... 17

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Appendix 5: Charging procedures for SLA batteries... 20 Charging Setup... 20 During Charging... 20 Charger Manual... 20 Appendix 6: Spare Parts List... 21 EC Declaration of Conformity... 23 Service Log... 24

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Gzunda GZS Bed Mover-Operating Manual

Introduction The GZS is a battery powered mobile towing unit to assist in the movement of heavy beds and trolleys eliminating back or shoulder strain. It is designed to save operator effort when pushing or pulling beds and trolleys. The GZS includes the latest developments in DC motors with automatic electromagnetic park braking, as well as a high capacity programmable controller. Features include quiet operation, ease of handling, high manoeuvrability, low maintenance, and the ability to handle heavy loads. The GZS slows and parks automatically when the twist grip is released. Under typical operation, the GZS battery capacity should be adequate for a day’s operation. Overnight charging is recommended, and in high use situations additional “top-up” charging is advised. It is recommended to use the charger supplied with the GZS when charging the sealed maintenance free batteries. This charger is especially designed to set the charge rate, prevent gassing, and automatically cut switch to “trickle charge” when charging is complete. All bearings are pre-lubricated and sealed and should not require attention in normal use. Regular maintenance requirements on the vehicle are therefore minimal and are covered in this manual. As with any machinery, safety considerations demand that the GZS be handled with caution, and only operated by trained and authorised personnel. In addition, all loads must be placed securely on the bed or trolley, and the bed or trolley securely locked to the GZS. The GZS must only be operated by trained and authorised personnel.

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Operating instructions Controls

Controls Control panel

Hitch handle

Hitch strap

Charger socket

Brake release key switch

6

Circuit breaker See page 13

Gzunda GZS Bed Mover-Operating Manual

Control panel

Hitch controls

Power and battery level indicators

Emergency stop

Key switch

Horn

Safety brake

Speed selection

Throttle grip

Key switch The key switch must be turned clockwise to switch the GZS on. When on, the LED status indicator will be illuminated. If a fault occurs with the electronics, this LED light will flash an error code (refer to Appendix 2). It is important to note that the unit should be switched off and the key removed, whenever it is not in use. This eliminates the risk of unauthorised movement and also prevents an unnecessary use of battery power. Safety brake (emergency back-off bar) When the safety brake is activated (depressed) while in motion, the GZS will behave in one of two ways. 1. In reverse (towards the operator), the GZS will stop and then move away from the operator for a short distance. 2. In the forward direction, the GZS will come to a smooth stop. The GZS will need to be reset by activating reverse throttle momentarily. The GZS can then be driven forward. Any accessories installed that prevent the safe operation of the safety brake may create a crush hazard for the user.

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Throttle grip The throttle grip provides variable speed control. Releasing the grip stops the unit. An automatic park brake is applied after a short delay after the grip has returned to its neutral position. Under no load, the park brake will maintain the GZS in a stationary position. Under load, the brake may not be capable of holding the system stationary, particularly on a sloping surface. Speed selection The speed selection will always start in the slow position. Select a speed that you are comfortable using. The speed can be changed whilst driving. It is advisable that you use a slow speed setting when approaching a bed or trolley to hitch, entering a confined area, a place with slippery or slightly sloped floor surfaces, turning, or reversing. Battery level indicator The battery level indicator indicates the amount of charge left in the batteries. When it appears to be running low, return the GZS to the closest charging station to charge the batteries. Being aware of the level of charge of the batteries will eliminate the possibility of running low on power whilst away from the charging station. Red light only indicates no usable battery power remaining. Isolation from supply mains The unit is not directly incorporated with means of isolation from supply mains. An appliance coupler is used on the unit to be connected to the battery charger only but not the supply mains directly. Horn Push to sound the horn, release to turn off. Brakes Two braking systems operate in the GZS. Firstly, when the throttle grip is released the GZS is slowed electronically with dynamic braking until the GZS and the accompanying load stops. In addition, after a short delay an automatic mechanical brake is activated to park the GZS. Brake release In the case where the unit cannot be turned on due to a flat battery, use the brake release located at the back of the machine, next to the charging socket. Use this key switch to override the motor park brake. The machine can now be manually pushed to a different location. Remove the key from the Park brake release and immediately place the machine on charge when unit is at the charging station. Confirm the charger has begun to charge the batteries and leave on charge for a minimum of 8 hours. If the machine is still not working call an Electrodrive service agent.

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Gzunda GZS Bed Mover-Operating Manual

Using the GZS Safety check Before using the GZS, the operator should complete the following safety check. 1. The charger is disconnected from the GZS. 2. The safety brake bar works 3. The battery condition indicator shows adequate charge. 4. The braking system is in operation, so that when stopped, the unit cannot be manually moved, and that the unit slowly moves when the throttle grip is gently rotated. 5. The GZS hitch is not damaged and securely latches onto the bed frame. Safe operation 1. The unit, when attached with a hospitable bed, may present a hazard to other staff and moving hospital equipment during an emergency. Setting the proper speed and use of the horn to attract attention is advised in such cases. 2. Even though the electromagnetic or other interference of the GZS is not significant, it may still have an impact on some high accuracy hospital equipment. It is advised that you do not park or keep the GZS too close to this kind of equipment when they are in use. 3. Always begin driving the GZS in SLOW speed to ensure you maintain control. The GZS has an intuitive control system, so it becomes easier to use the more you use it. Select a speed that is suited to the competency of the operator. If unsure, start with SLOW speed then adjust up accordingly.

Hitching and unhitching to a bed Hitching to a bed The GZS is fitted with an actuator-controlled hitch. The hitch is controlled from the control panel. 1. Adjust the height of the hitch so that it is aligned vertically with the bed frame. 2. Release the locks on the hitch strap (handles in the raised position). Pull the straps out from the hitch box, and strap around the bed frame. Pulling the bed gently against the GZS at this stage will improve the hitching. Push the handles down to lock the strap. You will feel the resistance on the handle indicating a firm grip of the bed. 3. Ensure to do this on both sides. 4. Ensure that the castors on the bed are in the neutral position and that the bed is not plugged into the wall or connected to external equipment.

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The bed is ready to be moved. Unhitching from a bed 1. Confirm the GZS and bed are stationary, and on level ground. 2. Apply bed brakes. 3. Release the hitch straps and unhook from the bed. The GZS can now be taken to the charging station, or to the next bed. Always park the GZS in a safe place.

Sleep Mode After a period of 30 minutes of inactivity, the GZS will switch into a sleep mode to extend battery life. To resume operation, simply reset by turning key OFF then ON.

Charging 1. Use only the supplied battery charger to charge the unit. 2. Always position the unit to allow enough space to connect or disconnect the battery charger from the wall socket. 3. Always position the unit to allow enough space to connect or disconnect the unit from the battery charger. For detailed charging procedures refer to Appendix 6.

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Gzunda GZS Bed Mover-Operating Manual

Maintenance Batteries If the GZS is not being used for an extended period of time, it should be connected to the battery charger to check the battery level on a regular basis, and placed on charge overnight if required. This will ensure the batteries are kept in good condition. The batteries are sealed and maintenance free. DO NOT attempt to open these batteries. If the GZS is not charged as above, the batteries may be exhausted and have dropped below the charging threshold of the battery charger. The supplied charger cannot begin to charge the batteries unless they have a small amount of charge. If this occurs, contact Electrodrive or your local service agent. A sign that the batteries need replacing is when they no longer hold charge. Irregular charging may cause premature battery failure. The battery can only be replaced by a qualified technician.

Brakes The park brake does not require regular maintenance. If the GZS is not remaining stationary when in the OFF position, contact Electrodrive or your local service agent.

Motor Motor brushes should be inspected every six months and replaced as required (see Appendix 3 for instructions).

Electronic speed control This unit is factory programmed, and is not serviceable by the customer. The LED status indicator on the membrane console flashes to indicate a fault with the controller. The number of flashes will refer to a particular fault (see Appendix 2). Contact Electrodrive or your local service agent for diagnosis and advice.

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Fuses The control circuit is protected against inadvertent current overloads with a 1 Amp fuse. The charger circuit is protected by a 10 Amp fuse. These fuses are located next to the electronic controller on the electrical panel (see below).

The fuses can only be replaced by qualified personnel or technician, refer to below fuse specifications for replacement guide. All the fuses can only be replaced with the same model or equivalent.

Fuse Type

Technical Data

CCN

Conformity Standard (FUS)

10A (charger circuit) Bussmann AGC Series

Rated 10A, 250V, speed-F, breaking capacity-H

JDYX, JDYX2

UL (FUS), IEC 60127 TUV, VDE, CSA

3A (Deadman circuit) Bussmann AGC Series

Rated 3A, 250V, speed-T, breaking capacity-H

DYX, JDYX2

UL (FUS)

1A (control circuit) Bussmann AGC Series

Rated 1A, 250V, speed-F, breaking capacity-H

DYX, JDYX2

UL (FUS), IEC 60127 TUV, VDE, CSA

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IEC 60127

Gzunda GZS Bed Mover-Operating Manual

Circuit breaker The GZS is fitted with a self-resetting circuit breaker in case of momentary overload. This switch can be found next to the brake release. If the circuit breaker continues to trip multiple times in succession, test the machine, as the motor may be damaged. Continued use could damage the unit further. The controller is also equipped with safety shut down capabilities and will limit the battery current as well as detect low battery voltage.

Cleaning To clean exterior of machine wipe surfaces down with a warm damp cloth. A mild detergent may be used for hard to remove grime. Do NOT use chemical solvents, highly concentrated caustic soda or abrasive cleaning agents. These may damage the surface quality and may affect the integrity of polyurethane and machine lubricant properties.

General Any damage audible or visible to the GZS should be addressed at the time of discovery. When not in use the unit should be stored in a cool dry place. Please ensure it is not parked in a manner that obstructs access, cause a tripping hazard, or any other safety related issue.

Disposal of components or material All replaced or damaged components should be disposed or recycled properly based on its category.

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Warranty Electrodrive Pty Ltd warrants that this product is free from defects in materials and workmanship for a period of twelve months from the date of dispatch from the Electrodrive plant. If a defect is reported, Electrodrive will repair or replace the defective part, at its own discretion. This warranty does not apply if the GZS has been misused, damaged, or modified in any way. Please be aware that modifications and misuse will void your warranty. The following activities (including, but not limited to) are examples of these:

Maintenance §§ The machine is re-wired by an unauthorized service agent §§ The motor controller is re-programmed by an unauthorized service agent §§ There are modifications done to the body or frame of the machine §§ Use of non-specified parts §§ The machine is serviced by an unauthorized service agent

Misuse §§ Shunting loads at speeds in excess of 2 km/h §§ Overloading the unit either during towing or lifting §§ Carrying people or other foreign objects §§ Exposed to rain of other precipitation §§ Using the emergency Back-off system to change direction regularly §§ Exposed to a corrosive environment §§ Driven off road-potholes, gravel, etc. §§ Driven on slopes with a steeper gradient than 1:12 §§ Not being charged adequately §§ Using the emergency stop button as an ON/OFF button

General wear items not covered under warranty §§ Tyres, tubes and castors §§ Drive wheels, motors and motor brushes §§ Hand grips

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Gzunda GZS Bed Mover-Operating Manual

Appendix 1: Machine rating conditions

1230

800 (GSZIN) 900 (GZSUS)

1245

Model

920 (GSZIN) 1015 (GZSUS)

Safe Working Load

Max Load

GZSIN (International)

600 kg

600 kg

GZSUS (US)

600 kg

600 kg

The GZS has been designed to move the rated weight capacity on a level firm surface. Variations in the working environment may impede the performance of the GZS. Such parameters include (but are not limited to) the following: Ramps and sloped surfaces Soft surfaces (for example carpet) Slippery surfaces (gravel, water, oil, etc on the ground) It is important that the GZS NOT to be operated outside of the recommended conditions.

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Appendix 2: Fault codes Fault Code

☼ ☼

Explanation

Causes

Over-temperature cutback

Machine overloaded Park brake not releasing properly Short in motor or wiring

☼ ☼☼

High ambient temperature Throttle pot fault

Throttle pot wires open or shorted Faulty throttle pot

☼ ☼☼☼

Speed governor fault

☼ ☼☼☼☼ ☼ ☼☼☼☼☼ ☼☼ ☼ ☼☼ ☼☼ ☼☼☼ ☼ ☼☼☼ ☼☼

Battery voltage too low

Battery voltage < 17 V

Battery voltage too high

Battery voltage > 36 V

☼☼☼ ☼☼☼

Pre-charge fault

☼☼☼ ☼☼☼☼

Park brake fault

Faulty speed governor pot

Main contactor controller failure Contactor driver fault HPD present > 10 seconds

Throttle out of adjustment

Park brake fault

Park brake coil open circuited Controller failure

☼☼☼☼ ☼☼

Low battery voltage Controller failure

☼☼☼ ☼☼☼☼☼ High pedal disable (HPD) ☼☼☼☼ ☼

Speed governor wires open or shorted

Park brake coil shorted Controller failure Throttle not in neutral when Keyswitch turned on

Current sense fault

Short in motor or wiring Controller failure

Motor voltage fault

☼☼☼☼ ☼☼☼ EEPROM fault ☼☼☼☼ ☼☼☼☼ Output section fault

Short in motor or wiring Controller failure Controller failure Short in motor or wiring Controller failure

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Gzunda GZS Bed Mover-Operating Manual

Appendix 3: Motor brush replacement The motor brushes are located under the brush retaining band.

1. Remove the rear cover of the GZS. 2. Remove the brush retaining band from the motor. 3. Take out the old brushes. There are 4 brushes to replace. 4. Insert new brushes and replace brush retaining band. 5. Replace cover.

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Appendix 4: Wiring diagram

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Appendix 5: Charging procedures for SLA batteries §§ Always charge batteries when work is complete and the equipment is not required for use. §§ Opportunity charging is NOT recommended. This can also shorten battery life. §§ Never leave batteries in a discharged state as this will shorten the batteries life. §§ For maximum battery life, a battery must be recharged to 100% capacity. Recharging less than 100% may result in premature battery failure. Batteries are not covered under warranty if they are not recharged properly. §§ If batteries are disconnected from the machine and not used for lengthy periods of time, it is recommended to give them a maintenance charge once every 2 months.

Charging Setup §§ Ensure you have the correct charger for the batteries. The correct voltage and current is important to ensure the full life of the batteries. §§ Check all connections are tight and in good condition. §§ The green charger LED will illuminate to confirm charging is in progress. §§ If charger lights do not come on, call your service technician. §§ When charger is plugged in, drive function of machine is automatically inhibited.

During Charging §§ Ensure there is enough airflow to help keep the batteries as cool as possible. §§ If the batteries are swollen turn off immediately and call your service technician. §§ Always leave batteries on charge until the charge is COMPLETE. This is indicated when charger LED turns off.

Charger Manual Please read BA1105-Battery Charger Operating Manual for more information.

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Gzunda GZS Bed Mover-Operating Manual

Appendix 6: Spare Parts List Part Number

Description

EDACTLA23

Actuator LA23 suit GZS hitch

EDWIRLA23

Actuator cable loom

EDWIRLA23LCK

Actuator cable lock

EDBATGEL33AH

Battery 12V 33Ah suit GZS

EDCIREXT18

Circlip External 18 mm

EDCIREXT12

Circlip External 12 mm

EDBRG206PILHOU

Bearing housing suit GZS steer column

EDBRG20630ID

Bearing suit GZS steer column

EDBRGROLTAP40ID

Bearing GZS Hub motor bearings

EDTGDQ75BSN

Cable control thread guard 30 mm ID

EDSEAGZS

GZS Base bearing seal

EDSTKGZSKIT

GZS decal set

EDMOTHUB300WS2

Hub motor 300W

EDSPRPLG7MM

GZS Handle position locking plunger

EDEL3285

Double Sided Tape

EDWHLJB125

GZS Tyne castor WHLJB125

EDFABGZS00001

GZS front tyne cover

EDAXBGZS

GZS tyne castor bush

EDM6X59XZP

Chicago bolt 59 mm long

EDMJQ75G

GZS tyne buffer castor MJQ75G

EDFABGZS00002

GZS hitch slider

EDFABGZS00003

GZS base top cover

EDFABGZS00004

GZS top back cover

EDFABGZS00005

GZS base front cover

EDFABGZS00006

GZS base back cover

EDFABGZS00007

GZS Top front middle cover

EDPINGZSPIVOT

GZS column pivot pin

EDCONGZSPROG

Controller 1228 programmed to suit GZS

EDEL2855

Actuator current cut off PCB

EDEL2500

Fuse Holder panel mount

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Part Number

Description

EDEL2710

Spare Key Electrodrive-Tugs

EDEL1901

30A DC Circuit Breaker

EDEL3190

Socket-3 pin-Chassis mount (Charger)

EDEL3272

Solenoid 24V 65Amp Continuous UL approved

EDCAPULGZS

UL Compliance Capacitor

EDBKTCAPMNTGZS

UL Compliance Capacitor mount

EDSUBGZSHNDASY

GZS tiller head assembly

EDSUBGZSTHRTASY

GZS throttle assembly

EDBRGROL20ID32OD

GZS external throttle bearing 20 mm ID

EDPINGZSTHROT

GZS throttle shaft

EDBRGROL17ID30OD

GZS internal throttle bearing 17 mm ID

EDCIREXT16

Circlip External 16 mm

EDCIRINT32

Circlip internal 32mm

EDEL2822

microswitch-SM-1040

EDEL3015

Potentiometer-5K Self Returning wig wag Pot

EDSWTMCRTHRT

UL deadman throttle microswitch

EDCIREXT20

Circlip External 20 mm

EDSPRGZSBACKOFF

GZS backoff bar tension spring

EDEL2380

Emergency Stop Button Complete (Large)

EDEL2851

PCB Membrane control board

EDGM1801

Handgrips-to suit GZ10 [Lock on style] Handgrips (Silver)

EDEL2835

Nylon Mounting Spacer male/female M3

EDMCHGZSBACKOFF

GZS backoff buffer pad

EDSTKGZSMEM

GZS membrane control panel

EDPINGZSKNL

GZS Knuckle pivot pin

EDFABGZS00008

GZS base wheel cover

EDFABGZS00009

GZS hitch rail

EDPINGZSSLIDEPOST

GZS hitch slider post

EDFABGZS00010

GZS base top front cover

EDWIRGZSKIT

GZS wiring loom kit

EDHT1810-017-D

Flex hitch to suit GZS

EDBA1105

GZS Battery Charger

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