GZS Bed Mover Operating Manual OM0003E-4

GZS Bed Mover Operating Manual

General ...15   Warranty ...16   Appendix 1-Machine rating conditions ...17   Appendix 2-Fault codes ...18   Appendix 3- Motor brush replacement ...19   Appendix 4 – Wiring diagram ...20   Appendix 5-Charging Procedures for SLA batteries ...21   Charging Setup ...21   During Charging ...21   Charger Manual ...21   Appendix 6 – Spare Parts List ...22   Service Log...25   Service recommendations ...25  

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Controller See page

Hitch Handle Hitch Bar

Hitch Strap

Battery charger socket

Circuit Breaker Brake Release Key switch

Model Operating capacity

GZS 600 kg

Voltage

24 V

Top speed

4 km/h

Variable speed

YES

Park brake

YES

Programmable

YES

Horn

Standard

Emergency stop

Standard

Safety bar

Standard

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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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. The power supply is specified as part of GZS, 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 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. The training material is supplied together with this manual; user is advised to go through this manual and the training material in details before operation of the unit.

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Environmental Conditions Operating Conditions The GZS is intended to be operated in an indoor environment within prescribed environment conditions: • • •

Rated operating temperature range: Recommended 5°C to 40°C (41°F to 104°F) Rated operating humidity range: a relative humidity range of 30 % to 75 %; Rated operating pressure range: an atmospheric pressure range of 70,0 kPa to 106,0 kPa;

Transport and Storage Electrodrive recommends that the machine is shrink wrapped during transportation or during long term storage to prevent damage from moisture or dust. If stored for an extended period of time, the machine should be stored in a cool dry place and the batteries should be disconnected. Periodic charging of stored batteries recommended if storage exceeds two months If transporting on a pallet, the GZS should be firmly attached with straps. It should be centred on the pallet to ensure no part of the machine extends outside the pallet perimeter to prevent potential damage • • •

Rated Transport and Storage temperature range: Recommended -5°C to 50°C (23°F to 122°F) Rated Transport and Storage humidity range: a relative humidity range of 30 % to 80 %; Rated Transport and Storage pressure range: an atmospheric pressure range of 50,0 kPa to 106,0 kPa; Ensure the unit is not parked in a manner that obstructs access, causes a tripping hazard or any other safety related issue.

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Operating Instructions Controls Control handle position pin

Hitch Direction Control Key Switch Power & Status Indicator

Emergency Stop Battery Level Indicator Speed Governors Horn Throttle Safety Bar

Key Switch (ON / OFF) Turn the key as indicated 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 code1. 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.

1: Refer to Appendix 2

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Safety bar When the safety bar is activated (depressed) while in motion, the GZS will behave in one of two ways. • •

In reverse (towards the operator), the GZS will stop and then move away from the operator for a short distance. 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 back-off safety bar may create a crush hazard for the user.

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 governor 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 the operator select a slow speed when approaching a bed or trolley to hitch, entering a confined area, a place with slippery or slightly sloped floor surface, 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 (Standard) Push to sound the horn, release to turn off.

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

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.

Park Brakes Release In the case where the unit cannot be turned on due to a flat battery, use the park brake release on the back of the machine adjacent to the charger socket to override the motor to release the park brake, the machine can now be manually pushed to a different location. Immediately place the battery on charge when unit is moved to charging station.

Driving Safety check Before using the GZS to move beds the operator should complete the following feature check: 1. 2. 3. 4.

The charger is disconnected from the GZS. The Safety Bar functions as intended. The battery condition indicator shows adequate charge. 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 lever is gently squeezed. 5. The GZS hitch is not damaged and securely latches onto the bed frame. Safety Operation When using the GZS to move the beds, the operator is advised to drive with caution in below cases: 1. The unit, when attached with a hospitable bed, may present a reciprocal interference hazard to other moving hospital equipment when everyone has to move quickly in an emergency case, the proper speed, use of the horn and special attention is advised to the operator in such cases. 2. Even though the electromagnetic or other interference of GZS is not significant, it may still have some impact on some of the high accuracy hospital equipment or facilities. It is advised not to park or keep the GZS too close to this kind of equipment when they are in use. 3. Always begin in SLOW speed to ensure you maintain control of the GZS. 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, begin in the ‘slow’ speed then adjust up accordingly.

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Connect/Disconnect the unit to a bed Hitching to a bed The GZS is fitted with an actuator controlled hitch. The hitch is controlled from the control panel. • •

• • •

Adjust the height of the hitch so that it is aligned vertically with the bed frame. 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. Lock the handles by moving them the lower position. You will feel the resistance in the handle indicating a firm grip of the bed. Ensure to do this on both sides. 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 equipments. The bed is ready to be moved.

Unhitching from a bed • • • •

Confirm the GZS and bed are stationary, and on level ground Apply bed brakes. 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 switches into 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 Detailed charging procedures Refer to Appendix 7

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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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 become exhausted and drop 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. Battery can only be replaced by qualified personnel or technician, refer to below battery specifications for replacement guide.

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Hub motor To replace the Hub motor, contact Electrodrive or your local service agent.

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 required2.

Electronic speed control This unit is factory programmed, and is not serviceable by the customer. The status indicator on the controller console flashes to indicate a fault with the machine. The number of flashes refers to the particular fault3. Contact Electrodrive or your local service agent for diagnosis and advice.

2: Refer to Appendix 3 for instructions 3: Refer to Appendix 2 for fault codes

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

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. The 3A fuse provides supply to the neutral position of motor isolation circuitry. 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

Manufacturer/ Trademark

Type/Model

Technical Data

Product Category CCN

Marks of Conformity (Required for FUS)

Marks of Conformity (All Others)

Standard (edition or year)

10A Fuse (charger circuit)

Bussmann

AGC Series

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

JDYX, JDYX2

UL

TUV, VDE, CSA

IEC 60127

3A Fuse (Deadman circuit)

Bussmann

AGC Series

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

JDYX, JDYX2

UL

-

IEC 60127

1A Fuse (control circuit)

Bussmann

AGC Series

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

JDYX, JDYX2

UL

TUV, VDE, CSA

IEC 60127

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Circuit breaker The GZS is fitted with a resettable circuit breaker in case of momentary over-load. This switch can be found next to the fuses as shown.

Circuit Breaker

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.

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Cleaning To clean exterior of machine wipe surfaces down with a warm damp cloth. A mild detergent may be used for harder 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.

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

General Any damage to the GZS, audible or visible, 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, causes a tripping hazard, or any other safety related issue. Electrodrive can provide parts and service support on request. Call +61 3 9300 8500 or email [email protected]

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Warranty Electrodrive Pty Ltd warrants that the GZS is free from defects in materials and workmanship for a period of twelve months from the date of dispatch from the Electrodrive plant at 10A Burwood Ave, Sunshine North, Victoria. 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. Do not modify this equipment without authorization of the manufacturer.

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 (Electrodrive genuine parts) The machine is serviced by an unauthorized service agent

Misuse • • • • • • • • •

Shunting loads at speeds in excess of 2.0kph Overloading the unit either during towing or lifting Carrying people or other foreign objects except in the case of transporting patients on a hospital bed Exposed to rain or other precipitation Using the emergency backoff system to change direction regularly Exposed to a corrosive environment Driven off road – potholes, gravel, etc Not being charged adequately Using E-stop as an ON/OFF button

General wear items not covered under warranty • • • • •

Castors Tubes Hub motor Hand grips Motor brushes

If you are interested in extending your warranty period through a regular service program, please contact Electrodrive on 03 9300 8500. Note that batteries are not included.

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Appendix 1-Machine rating conditions The GZS has been designed to move the rated capacity on a level firm surface. Variations in the working environment may affect 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.

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

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

Speed governor wires open or shorted Faulty speed governor pot

☼ ☼☼☼☼

Battery voltage too low

Battery voltage <17V

☼ ☼☼☼☼☼

Battery voltage too high

Battery voltage >36V

☼☼ ☼

Main contactor controller failure

☼☼ ☼☼

Contactor driver fault

☼☼☼ ☼

HPD present > 10 secs

Throttle out of adjustment

☼☼☼ ☼☼

Park brake fault

Park brake coil open circuited Controller failure

☼☼☼ ☼☼☼

precharge fault

Low battery voltage Controller failure

☼☼☼ ☼☼☼☼

Park brake fault

Park brake coil shorted Controller failure

☼☼☼ ☼☼☼☼☼

High pedal disable (HPD)

Throttle not in neutral when Keyswitch turned on

☼☼☼☼ ☼

Current sense fault

Short in motor or wiring Controller failure

☼☼☼☼ ☼☼

Motor voltage fault

Short in motor or wiring Controller failure

☼☼☼☼ ☼☼☼

EEPROM fault

Controller failure

☼☼☼☼ ☼☼☼☼

Output section fault

Short in motor or wiring Controller failure

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Appendix 3- Motor brush replacement Remove the rear cover of the GZS as shown below:

The motor brushes are located under the brush retaining band

• • • •

Remove the brush retaining band from the motor Take out the old brushes. There are 4 brushes to be replace Insert new brushes and replace brush retaining band Replace cover

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

Appendix 4 – Wiring diagram

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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GZS Bed Mover Operating Manual

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. Turn GZS circuit breaker to ON position to begin charging. 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 see charger manual overleaf for further details.

GZS Bed Mover Operating Manual-OM0003E/4 Electrodrive | 2A Ayton Street, North Sunshine VIC Australia 3020 | www.electrodrive.com.au

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