Drive Unit e-drive1 Installation instructions 04/2014 English translation of the original German installation instructions
Contents Foreword... 3 Availability... 3 Structural features in the text... 3 Copyright... 3 Manufacturer's address... 3 Safety... 4 Intended use... 4 Basic safety notices... 4 Qualifications of personnel... 5 Personal protective equipment... 5 Structural features of notices warning of danger... 6 Structural features of notices warning of damage... 6 Description of the device... 6 Scope of delivery and device overview... 6 Task and function... 8 Assignment of the connection socket... 9 Name plate... 9 Technical data... 10 Transporting the device... 11 Preparing installation... 11 Creating the prerequisites for installation... 11 Mounting the interface... 12 Unpacking the device... 13 Installing the device... 13 Fastening the device... 13 Connecting the device... 14 Commissioning the device and testing its functioning... 14 Commissioning the device... 14 Setting the micro switch... 15 Testing the functioning of the emergency release... 16
Foreword Foreword These installation instructions are to help you install the electrical drive unit e-drive 1 properly, safely, and economically. The e-drive 1 is intended for installation on a carriage that has been prepared for this purpose. In these installation instructions, it will be called "device" for brevity. These instructions are intended for any person who installs, connects or services this device, particularly fitters employed at the manufacturer of the carriage. All such persons have to take notice of and understand the contents of these installation instructions. Observing these installation instructions helps to prevent danger and increases the lifespan of the device. In addition to the notices in these installation instructions, always adhere to the legal and other regulations that are valid at the installation site, e.g.: Accident prevention regulations Regulations for safe and proper work Availability These installation instructions are a component of the device. Always store them with the device's documentation. Ensure that they are available to the user. If you transfer this device to another owner, you have to transfer these installation instructions as well. Further documents, for example the manufacturer's declaration of incorporation, are also part of these installation instructions. Structural features in the text Defined structural features are assigned to the various elements within these installation instructions. A distinction can therefore be easily made between the following elements: Normal text Lists Action steps. These tips contain additional information, such as special information on the simple installation of the device. Copyright These installation instructions contain information that is subject to copyright. These installation instructions may not be copied, printed, or filmed in any form, nor may they be reproduced, processed, replicated, or distributed either completely or in extracts using another process, without prior written approval from TENTE-Rollen GmbH. 2014 TENTE-Rollen GmbH All rights reserved. Manufacturer's address If you require further information, please contact the manufacturer: TENTE-ROLLEN GmbH Herrlinghausen 75 D-42929 Wermelskirchen Telephone: +49 (0) 21 96 / 99-0 Telefax: +49 (0) 21 96 / 99-127 E-mail: info@tente.de Internet: www.tente.com Information on the responsible sales partner can be found on the Internet at www.tente.com. 3
Safety Safety Intended use The electrical drive unit is used for the controlled movement of carriages or hospital beds. It is only intended for commercial use indoors on flat and dry floors. Intended use also includes observing and following all the information in these instructions, in particular safety notices and technical data. Any other use of the device is not use as intended. The following activities in particular are not intended. Use of the device in areas where there is a risk of explosion Use of the device privately Use of the device as a brake Use of the device outdoors, on loose and unstable surfaces, as well as driving over obstacles, e.g. edges or drain covers Use of the device in combination with a control unit that has not been approved by the manufacturer for use with the device Use of the device after modifications Disassembling the device Use of the device by non-authorised persons Basic safety notices Avoiding the risk of fatal injuries Fatal injuries from electric shock are possible if the device is connected incorrectly. Only connect the drive unit according to the provided electrical connection diagram. Avoiding the risk of serious injuries Risk of shearing between fastening plate and device housing when lifting the drive roll. Never reach between fastening plate and device housing. Risk of shearing on the interior parts of the device. Never reach inside the device, in particular when it is connected to the control unit. Risk of crushing by the interior parts of the device. Never reach inside the device, in particular when it is connected to the control unit. Risk of injury when drive roll is moving. Never reach between the fastening plate and device housing during operation. Only install the device according to the drawings in these installation instructions. Ensure that a danger symbol for crushing is attached to the side of the carriage during installation. The device may only be operated when the danger symbols are easily recognised. Risk of injury on rotating parts due to body parts being drawn in. Never touch rotating parts. Wear tight-fitting working clothes when operating the device. Do not wear loose jewellery. Protect long hair by wearing a hair net. It is possible to break bones when opening the emergency release with force. Only open the emergency release according to the notices in these installation instructions. Serious injuries may be caused by parts under spring pressure when disassembling the device. Never disassemble the device. 4
Safety Avoiding the risk of slight injuries Cuts may be sustained on sharp edges on the device. Wear protective gloves during all work on the device. Crushing is possible when actuating the emergency release. Only actuate the emergency release according to the notices in these installation instructions. Wear sturdy protective gloves when testing the functioning of the emergency release. Crushing may be caused if the device collides with persons. During operation, ensure that no persons remain in the carriage's direction of travel. Avoiding damage to property and malfunctions Damage to property is possible when an unsuitable control unit is used. Only use control units that have been approved by the manufacturer for use with this device. Damage to property may be caused when the cable of the control unit is not fastened. Ensure that the cable of the control unit is securely fastened to the carriage. Qualifications of personnel Installation may only be performed by specialist personnel. The specialist personnel must have knowledge and experience in the following areas: Installation of carriages, for example hospital beds Mounting additional electrical equipment onto carriages (specialist electricians) Creating connections for the types of equipment used All notices in these installation instructions and the included documents Personal protective equipment During all work on the device, ensure that protective clothing suitable to the respective task is worn. The protective clothing has to be chosen according to the risk that is expected for the task. The protective clothing must protect against the following risks in particular: Injuries to the body Hand injuries Injuries to the feet A malfunction may be caused by the plug on the control unit becoming loose. Secure the plug after connecting the device with two hexagon socket head screws in the threaded holes intended for this purpose. A malfunction may be caused by insufficient fastening. Tighten the screws fastening the device with the specified torque. Damage and malfunctions may be caused by use outdoors. Soiling and wetness can affect functioning and lead to the device being damaged. Only use the device as intended. Damage may be caused by unsuitable cleaning agent. Only use cleaning agent that does not damage the construction material of the device. Please contact your sales partner for more information. 5
Description of the device Structural features of notices warning of danger DANGER Notices containing the word DANGER warn of a hazardous situation which may possibly lead to death or severe injuries. Description of the device Scope of delivery and device overview The device is supplied packaged and ready for installation. The control system, current supply and mounting material are not included in the scope of delivery. WARNING Notices containing the word WARNING warn of a hazardous situation which may possibly lead to death or severe injuries. CAUTION Notices containing the word CAUTION warn of a situation which may lead to slight or moderate injuries. Structural features of notices warning of damage ATTENTION! These notices warn of a situation that leads to damage. 6
Description of the device 1 2 3 4 5 9 28 7 6 No. Part 1 Name plate 2 Connecting socket for the control unit 3 Fastening plate 4 Micro switch 5 Housing 6 Drive wheel 7 Travel motor 8 Threaded holes for securing the connecting plug of the control unit 9 Emergency release lever 7
Description of the device Task and function The device is used for the controlled movement of carriages. It is installed under the carriage and connected with a suitable control unit and a power supply. In the idle position/basic position, the drive wheel is raised to the top end position (see the following illustration). When the control unit is actuated, the drive wheel lowers to the ground (see illustration, right) and the travel drive is switched on. The micro switch monitors the basic position of the drive wheel. You can push the micro switch to adjust it to the control unit. The device has a defined main direction of travel (see arrow). In the opposite direction, the device is only used for manoeuvring slowly. You can use the device both as a starting-up aid and as a continuous travel aid. When used as a starting-up aid, the drive wheel is lowered and switched on for a few seconds. This helps to overcome the starting-up resistance. Afterwards, the drive wheel is lifted up again. The carriage then has to be pushed manually. When used in continuous operation, the drive wheel is lowered and driven for as long as the drive is switched on. Afterwards, the drive wheel is lifted up again. The device does not require maintenance. Only the manufacturer may replace components and carry out repairs. Remove the device in the reverse order of how it was installed on the carriage. Send the complete device to your sales partner. The emergency release is used to lift up the drive wheel in the event of a control unit fault. To cancel the emergency release, turn on the control unit after removing the fault and actuate the travel drive for three seconds. The drive wheel remains in the basic position. The device only operates normally again the next time the travel drive is actuated. 8
Description of the device Assignment of the connection socket Connection socket type: TYCO 350782-1, 09-pin. UMNL CAP HSG Name plate The following information is located on the name plate: Manufacturer's address Serial number Supply voltage 3 2 1 Protection class 6 5 4 9 8 7 Pos. Component Connection 1 Travel motor 24 VDC, Plus 2 Position switch Ground 3 Actuator 24 VDC, Plus 4 Position switch Maximum 24 VDC, Plus 5 Resistance Maximum 24 VDC, Plus 6 Not assigned 7 Actuator Ground 8 Not assigned 9 Travel motor Ground 9
Description of the device Technical data Dimensions and weight Length Width Height in basic position Installation height Wheel diameter Wheel width Wheel tyre Weight Max. 315 mm (emergency release actuated) 190 mm 145 mm 170 mm 125 mm 35 mm Rubber, non-marking Approx. 6 kg Characteristic values Maximum work load (weight of the carriage to be moved) Maximum lifting force/downforce Maximum speed Operating modes Driving directions Ground clearance Maximum floor unevenness Emergency release Constant transverse force during floor contact Protection type Dependent on the operating mode and driving resistance at the place of use (your sales partner will supply you with further information) 400 N 4 km/h S4: Starting-up aid (delivery state) S1: Continuous travel aid (optional) Forwards and reverse 30 mm ±15 mm Mechanical 400 N IPX4 (splash water from all sides) Permitted ambient conditions Working temperature 5 to 40 C Permitted storage temperature 20 to 50 C Air humidity 90 %, non-condensing Audible acoustic energy IEC 60601-2-52, Section 201.9.6.2.1 Switching Driving 80 db(a) 45 db(a) 10
Transporting the device Travel motor Nominal voltage Nominal current Nominal output Nominal torque 24 V DC 7.0 A 73.1 W 4 N m Nominal speed 174.5 min 1 Actuator Nominal voltage Nominal current Nominal output Nominal torque 24 V DC 3.5 A 14.8 W 4 N m Nominal speed 35.3 min 1 We reserve the right to implement technical changes. The device consists of different metal types and electronic components. Contact your sales partner for more detailed information on the construction materials used. Transporting the device Transport the device in the original packaging. If the original packaging is not available, package the device so that it is protected against moisture and mechanical damage. Preparing installation Creating the prerequisites for installation Ensure that the carriage onto which the device should be installed fulfils the following prerequisites: The treads and the roll resistance of the carriage's rollers have to be aligned to the moving mass. Please contact your sales partner if you have questions about this. An interface with corresponding threaded holes or through holes has to be provided on the carriage. The interface must be designed so that the forces expected from the drive can be easily transferred during operation. The design also has to take into account the lifting force of the device. Your sales partner will support you with the design. The distance between the floor and interface has to be 170 mm. The interface has to be mounted so that the device's main direction of travel is aligned with that of the carriage. The following prerequisites also need to be fulfilled if used as a drive for hospital beds: The requirements of IEC 60601-52 are fulfilled. At least four hospital bed rollers with the function "total locking" are provided. The roller system has central locking. 11
Preparing installation The control unit, which is not included in the scope of delivery, has to be approved for use by the manufacturer. Please contact the manufacturer if you wish to use a control unit that is not supplied or approved by the manufacturer. Attaching the interface to a hospital bed The interface on the hospital bed has to be arranged so that the drive wheel (1) of the device is aligned centrally to the hospital bed rollers (2). Mounting the interface 2 2 The arrangement of the interface differs depending on its intended use. When using the device on hospital beds, the interface has to be mounted centrally between the hospital bed rollers. When using the device as a drive for carriages, the interface can be mounted offset from the centre. The central arrangement is more favourable however. = = 1 2 2 = = Contact your sales partner if you have questions on the arrangement of the interface. Ensure that the following preparations have been taken at the interface: The interface must fulfil the prerequisites mentioned in the previous section. The interface must have three holes of 9 mm diameter or three M8 threaded holes in order to fasten the device. The screw-in depth must be at least 10 mm. The arrangement of the fastening holes depends on the main direction of travel (see arrow). Fasten the interface to the desired position. Attaching the interface to other carriages The interface on the carriage has to be arranged so that the drive wheel of the device is aligned parallel to the transport device rollers. The following points have to be observed when aligning the drive wheel. If the alignment is offset from the centre and there is unequal weight distribution on the carriage, then the carriage can be lifted on one side when the drive wheel is lowering. Contact your sales partner in this case. The further the drive wheel is mounted to the outside of the carriage, the greater the risk of crushing when it is lifting or lowering. = = 60 Fasten the interface to the desired position. 100 12
Installing the device Unpacking the device CAUTION Cuts may be sustained on sharp edges on the device. Wear protective gloves during all work on the device. Take the device out of the packaging. Check the device for transport damage. Contact you sales partner if you discover transport damage. Installing the device In order to fasten the device to the carriage, proceed as follows: Turn the two screws (2) slightly into the threaded holes of the interface. Or Attach the two screws (2) slightly with the nuts to the interface. Push the device with the open holes of the fastening plate (3) over the two pre-mounted screws. Insert the third screw through the hole (1) of the fastening plate and attach this to the interface. Tighten the three screws with a torque of 20 N m. 1 To install the device on the prepared carriage, you will require the following: This device (drive unit) Torque wrench with a setting range to 20 N m 2 Three M8 screws of minimum strength class 8.8 (DIN EN 24017). Select the length of the screws according to type of fastening (threaded holes or through holes in the interface) If fastening with through holes, three M8 nuts of strength class 8 3 The corresponding tool depending on the fastening type Fastening the device CAUTION Cuts may be sustained on sharp edges on the device. Wear protective gloves during all work on the device. 13
Commissioning the device and testing its functioning Connecting the device DANGER Risk to life from electric shock if device is connected incorrectly. Connect the device only according to the electrical connection diagram on page 9. ATTENTION! Material damage or malfunctions on the device due to incorrect assignment of the connections. Make sure that the assignment of the control system and device connections correspond. Proceed as follows in order to connect the control unit to the device: Remove the two M4 x 6 cylinder screws (1). Insert the connection plug of the control unit into the connection socket of the device until it latches in. Secure the position of the connection plug with the two M4 x 6 cylinder screws (1). Tighten the cylinder screws by hand. Commissioning the device and testing its functioning Commissioning the device WARNING Risk of shearing between fastening plate and device housing when lifting the drive roll. Never reach between the fastening plate and the device housing. The further out on the carriage the drive wheel is mounted, the greater the danger of crushing when lifting and lowering the drive wheel. WARNING Risk of shearing on the device's internal components. Never reach inside the device when it is connected to the control system. Ensure when operating with hospital beds that the complete hospital bed fulfils the requirements of the following standards: IEC 60601-1:2005 (electrical safety) IEC 60601-1-2:2005 (electromagnetic compatibility) IEC 60601-2-52:2010 Corrigendum 1 (Particular requirements for the basic safety and essential performance of medical beds) ATTENTION! 1 When the arrangement is offset from the centre and there is unequal weight distribution on the carriage, then the carriage can be lifted on one side when the drive wheel is lowering. Ensure that the carriage is evenly loaded. 14
Commissioning the device and testing its functioning Commission the device as described in the instruction manual on the connected control unit. Setting the micro switch By setting the micro switch you can adapt the device to different control units. For this, you will need a screw-driver that is suitable for the type of screw used. The micro switch switches off the actuator for lifting the drive wheel. By pushing the micro switch (2), you can set how high the drive wheel will be lifted: To lift the drive wheel higher, push the micro switch downwards. To lift the drive wheel less, push the micro switch upwards. The manufacturer recommends setting the micro switch so that the top edges of the housing (3) are parallel to the interface (1) in the basic position. ATTENTION! Incorrect setting of the micro switch causes malfunctions when resetting the emergency release. Ensure the correct setting of the micro switch. Set the micro switch as described in the following section. If you have any queries contact your sales partner. Ensure that the device is disconnected from the power supply. Release the two screws (2). Push the micro switch (1) to the desired position. Tighten the two screws (2) by hand. Connect the device to the power supply. Check if the drive wheel is lifted into the basic position. Repeat the setting if the drive wheel is not lifted as desired. WARNING Risk of crushing by the interior parts of the device. Never reach inside the device when it is connected to the control unit. Remove the connection plug of the control unit before working on the device. 15
Commissioning the device and testing its functioning Testing the functioning of the emergency release Test the functioning of the emergency release after commissioning. During this test the device has to be in the same position as during operation. Switch off the control unit. CAUTION Risk of crushing when actuating the emergency release. Ensure that no body parts can become caught between lever and device housing or carriage when actuating the emergency release. Wear protective gloves when actuating the emergency release. To actuate the emergency release and lift the drive wheel, pull the lever downwards with force until you can feel it latch in. To cancel the emergency release, turn on the control unit after removing the fault and actuate the travel drive for three seconds. The drive wheel remains in the basic position. The device only operates normally again the next time the travel drive is actuated. Switch on the control unit. Actuate the travel drive for three seconds. The emergency release is cancelled. Actuate the travel drive again. The drive wheel is lowered in normal operation. If this is not the case, proceed as follows: If necessary, switch off the travel drive. Ensure that the connection is correct and the control unit is functioning properly. Ensure the correct position of the micro switch. Repeat the functional test. Contact your sales partner if the device is not functioning properly. The drive is lifted into the basic position. The lever stays locked in the lower position. WARNING Risk of bones being broken or crushing injuries when releasing the latched-in lever by force. Only release the lever as described here. 16