GZS Bed Mover Operating Manual

GZS Bed Mover Operating Manual

GZS Bed Mover Operating Manual—OM0003E/4 © Electrodrive

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

Contents Contents ........................................................................................................................................... 2 Introduction ...................................................................................................................................... 5 Environmental Conditions .............................................................................................................. 6

Operating Conditions ..................................................................................................................... 6 Transport and Storage ................................................................................................................... 6

Operating Instructions .................................................................................................................... 7 Controls .......................................................................................................................................... 7

Key Switch (ON / OFF) ............................................................................................................................. 7 Safety bar ................................................................................................................................................. 8 Throttle grip ............................................................................................................................................... 8 Speed selection ........................................................................................................................................ 8 Battery level indicator ............................................................................................................................... 8 Isolation from Supply Mains ...................................................................................................................... 8 Horn (Standard) ........................................................................................................................................ 8

Brakes ............................................................................................................................................ 9 Park Brakes Release ..................................................................................................................... 9 Driving ............................................................................................................................................ 9

Safety check ............................................................................................................................................. 9 Safety Operation ....................................................................................................................................... 9

Connect/Disconnect the unit to a bed .......................................................................................... 10 Hitching to a bed ..................................................................................................................................... 10 Unhitching from a bed ............................................................................................................................. 10

Sleep Mode .................................................................................................................................. 10 Charging ...................................................................................................................................... 10

Maintenance ................................................................................................................................... 11 Batteries ....................................................................................................................................... 11 Hub motor .................................................................................................................................... 12 Brakes .......................................................................................................................................... 12 Motor ............................................................................................................................................ 12 Electronic speed control ............................................................................................................... 12 Fuses ........................................................................................................................................... 13 Circuit breaker .............................................................................................................................. 14 Cleaning ....................................................................................................................................... 15 Disposal of components or material ............................................................................................. 15

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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

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Controller See page

Hitch Handle

Hitch Strap

Hitch Bar

Battery charger socket

Circuit Breaker

Brake Release Key switch

Model GZS

Operating capacity 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

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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.

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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.

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Operating Instructions

Controls

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

Control handle position pin

Hitch Direction Control

Key Switch

Power & Status Indicator

Emergency Stop

Battery Level Indicator

Speed Governors

Horn

Throttle

Safety Bar

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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.

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.

Any accessories installed that prevent the safe operation of the back-off safety bar may create a crush hazard for the user.

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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. The charger is disconnected from the GZS. 2. The Safety Bar functions as intended. 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 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.

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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.

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

Always park the GZS in a safe place.

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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.

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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

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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. 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.

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


JDYX, JDYX2

UL - IEC 60127

1A Fuse (control circuit)

Bussmann AGC Series Rated 1A, 250 V speed—F


JDYX, JDYX2

UL TUV, VDE, CSA

IEC 60127

All the fuses can only be replaced with the same model or equivalent.

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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.

The controller is also equipped with safety shut-down capabilities and will limit the battery current as well as detect low battery voltage.

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.

Circuit Breaker

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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.

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.

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.

Electrodrive can provide parts and service support on request.

Call +61 3 9300 8500 or email [email protected]

mailto:[email protected]

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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.

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.

Do not modify this equipment without authorization of the manufacturer.

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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.

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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 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

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

• 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

The motor brushes are located under the brush retaining band

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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.

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.

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Appendix 6 – Spare Parts List

Index Part Number Description

1 EDACTLA23 Actuator LA23 suit GZS hitch

2 EDWIRLA23 Actuator cable loom

3 EDWIRLA23LCK Actuator cable lock

4 EDBATGEL33AH Battery 12v 33Ah suit GZS

5 EDCIREXT18 Circlip External 18mm


7 EDBRG206PILHOU Bearing housing suit GZS steer column

8 EDBRG20630ID Bearing suit GZS steer column

9 EDBRGROLTAP40ID Bearing GZS Hub motor bearings

10 EDTGDQ75BSN Cable control thread guard 30mmID

11 EDSEAGZS GZS Base bearing seal

12 EDSTKGZSKIT GZS decal set

13 EDMOTHUB300WS2 Hub motor 300W

14 EDSPRPLG7MM GZS Handle position locking plunger

15 EDEL3285 Double Sided Tape

16 EDWHLJB125 GZS Tyne castor WHLJB125

17 EDFABGZS00001 GZS front tyne cover

18 EDAXBGZS GZS tyne castor bush

19 EDM6X59XZP Chicago bolt 59mm long

20 EDMJQ75G GZS tyne buffer castor MJQ75G

21 EDFABGZS00002 GZS hitch slider

22 EDFABGZS00003 GZS base top cover

23 EDFABGZS00004 GZS top back cover

24 EDFABGZS00005 GZS base front cover

25 EDFABGZS00006 GZS base back cover

26 EDFABGZS00007 GZS Top front middle cover

27 EDPINGZSPIVOT GZS column pivot pin

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28 EDCONGZSPROG Controller 1228 programmed to suit GZS

29 EDEL2855 Actuator current cut off PCB

30 EDEL2500 Fuse Holder panel mount

31 EDEL2710 Spare Key Electrodrive - Tugs

32 EDEL1901 30A DC Circuit Breaker

33 EDEL3190 Socket - 3 pin - Chassis mount (Charger)

34 EDEL3272 Solenoid 24V 65Amp Continuous UL approved

35 EDCAPULGZS UL Compliance Capacitor

36 EDBKTCAPMNTGZS UL Compliance Capacitor mount

37 EDSUBGZSHNDASY GZS tiller head assembly

38 EDSUBGZSTHRTASY GZS throttle assembly

39 EDBRGROL20ID32OD GZS external throttle bearing 20mmID

40 EDPINGZSTHROT GZS throttle shaft

41 EDBRGROL17ID30OD GZS internal throttle bearing 17mmID


43 EDCIRINT32 Circlip internal 32mm

44 EDEL2822 microswitch-SM-1040

45 EDEL3015 Potentiometer - 5K Self Return ing wig wag Pot

46 EDSWTMCRTHRT UL deadman throttle microswitch


48 EDSPRGZSBACKOFF GZS backoff bar tension spring

49 EDEL2380 Emergency Stop Button Complete (Large)

50 EDEL2710 Spare Key Electrodrive - Tugs

51 EDEL2851 PCB Membrane control board

52 EDGM1801 Handgrips - to suit GZ10 [Lock on style] Handgrips (Silver)

53 EDEL2835 Nylon Mounting Spacer male/Fem ale M3

54 EDMCHGZSBACKOFF GZS backoff buffer pad

55 EDSTKGZSMEM GZS membrane control panel

56 EDPINGZSKNL GZS Knuckle pivot pin

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57 EDFABGZS00008 GZS base wheel cover

58 EDFABGZS00009 GZS hitch rail

59 EDPINGZSSLIDEPOST GZS hitch slider post

60 EDFABGZS00010 GZS base top front cover

61 EDWIRGZSKIT GZS wiring loom kit

62 EDHT1810-017-D Flex hitch to suit GZS

63 EDBA1105 GZS Battery Charger

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Service Log

Service recommendations To ensure your GZS is kept in a safe and reliable condition, it is important to maintain a preventative maintenance program. Maintain a log of the service work on the cards following, and always use an Approved Electrodrive Service Agent to conduct the works. The service personnel will be provided with all necessary documents and components in service repair, including but not limited to, circuit diagrams, component part lists, descriptions, service checklists and spare parts.

6 month service

Date of service Service agent

Machine serial number

Summary of works

Next service due:

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12 month service



Summary of works

Next service due:

18 month service



Summary of works

Next service due:

27



2 year service



Summary of works

Next service due:

2½ year service



Summary of works

Next service due:

28



3 year service



Summary of works

Next service due:

3½ year service



Summary of works

Next service due:

29



4 year service



Summary of works

Next service due:

4½ year service



Summary of works

Next service due:

30



5 year service



Summary of works

Next service due:

Documents

GZS Bed Mover Operating Manual