2000/3000 Ergo Express Carts - Clinical Engineering

Operation and Service Manual:
2000/3000 Ergo Express Carts
Document No. 54572-001, Rev. N 05/26/10
System Information and Operation
24/7 Technical Service Hotline
(888)639-5438

Introduction
Document No. 54572-001, Rev. N 05/26/10
Table of Contents
Introduction………………………………… 2
Safety………………………………...…….. 3
Daily Inspection………………………...….. 3
Basic Operation………………………...…... 4
User Interface Details……………...…….. 5
Safety and Operational Features……..…….. 6
Troubleshooting……………………..…….. 7
U.I. Programming…………………..……… 7
Wiring Diagram…………………..……..…. 10
Parts Diagram……………………..….……. 11
Parts List………………………….......……. 11
Warranty……………………………...……. 12
Your 2000/3000 Cart is a electrically powered vehicle that can accommodate a variety of
equipment. For an understanding of efficient and safe operation of the cart, it is important
that you read this manual.
This Ergo Express powered cart uses a microprocessor based controller to operate all
functions, including drive speed, drive direction, a motor speed governor, a battery
charge meter, and an automatic motor brake. Additionally the microprocessor controls
many functions that may not be readily apparent to a user, such as load compensation,
acceleration control, emergency stop behavior, and motor current limiting.
If you have any questions, call PHS West, 24/7 at (888)639-5438
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Document No. 54572-001, Rev. N 05/26/10
Safety
• Before servicing disconnect the power at the batteries, and unplug the chargers.
• All batteries are sealed, and maintenance free. Do not open the batteries.
• Never operate the cart if your visibility is obstructed.
• Always use safety straps while towing other equipment.
• Use caution when operating the cart on steep inclines.
• Never carry riders on the cart.
• Use the motion alarm in congested areas.
• Never leave the cart unattended while the parking brake is disengaged.
• Turn the power off when leaving the cart unattended.
Daily Inspection
Include the following checks in a daily inspection:
a) Visually check the caster wheels for damage.
b) Check the battery charge indicator. Operating the cart with a very low charge can
damage the batteries.
c) If equipped with safety straps, check that they are functioning and secure.
d) Ensure that the power cord is secured in the electrical cabinet.
e) Check the emergency stop switch for operation.
f) Visually check the cart for any other external damage.
g) Visually check the power cord and plug to monitor normal wear and tear. If the cord or
plug is found to have damage from normal wear and tear. Remove from service and
replace immediately per your normal protocol.
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Basic Operation
Document No. 54572-001, Rev. N 05/26/10
Figure 1 – Electrical Cabinet Interior
1. Turn the key counter clockwise to the on position. Check the battery level indicator to
verify the batteries have an adequate charge. Check the reverse indicator to determine the
direction the cart will travel when the throttle is engaged.
2. Slowly engage the throttle lever (either side, but not both) until the cart begins to move.
Position yourself behind the UI with both hands on the handle grips. Use the fingers from
one hand to operate the throttle.
The two throttle levers on the user interface are used to control the speed of the drive motor. When either is
engaged, the cart will move in the direction determined by the reverse indicator lamp. Both levers perform the
same, functioning as proportional speed controls. Engaging the throttle fully gives full speed. Engaging it halfway
results in half speed, ect.
3. The blue mushroom switch on the front of the user interface is an emergency stop switch.
When activated the cart will immediately stop. The cart will not operate if this switch is
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held closed.
4. The motion alarm button toggles the audible motion alarm. When set to the ‘on’ position,
the control will beep while the cart is in motion. The indicator lamp next to the horn button
is illuminated when the warning horn is on.
User Interface Details
Document No. 54572-001, Rev. N 05/26/10
Figure 2 – The Ergo Express User Interface
Key switch
The ON/OFF key-switch located on the side of the UI acts as the main power switch.
Turning the key-switch from OFF (O) to ON (I) causes microprocessor to initialize. If
the cart is left unattended for several minutes, the microprocessor will enter sleep mode
and power itself off. To exit sleep mode, toggle the key-switch to the off position, then
to on.
Throttle Lever
The two throttle levers on the user interface are used to control the speed of the drive motor.
When one is engaged, the cart will move in the direction determined by the reverse indicator
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lamp (see reverse button). Both levers perform exactly the same function.
Reverse Button
The Reverse button acts as a direction toggle, allowing a user to operate the cart in
either the forward or reverse direction. If the reverse lamp is illuminated, the cart will
travel in the reverse direction. The reverse direction is to your back when you are
facing the UI with both hands on the handle grips.
Speed Selector Pushbuttons
The speed selector buttons act as a speed governor. The speed setting determines the
top speed of the cart when the throttle is fully engaged. If you feel that the cart’s full
speed velocity is too fast, you can reduce it by adjusting the speed buttons. The speed
indicator ladder is positioned next to the speed control buttons, and displays speed
governor setting.
Motion Alarm Pushbutton
The motion alarm is a beep that will sound while the cart is in motion. The button with
the ‘horn’ symbol is used to toggle the alarm on and off. An indicator lamp is
illuminated when this feature is activated. When the cart is initially powered on, the
motion alarm is toggled on by default.
Battery Charge Level display
The battery level indicator on the UI indicates the level of charge on the cart’s batteries.
When all the indicator bars are illuminated, the battery is fully charged. When only one
bar is illuminated, the battery charge is very low. The display will start flashing when the
charge is critically low. Operating the cart when the batteries are low can damage the
batteries.
Blue Stop Button
The blue mushroom switch is an emergency stop switch. When activated, the cart will
immediately stop. The cart will not operate if this button is held closed.
Safety and Operation Features
The UI is equipped with a number of internal features to enhance the operation of the
system.
• Throttle Engaged during Power Up: To prevent abrupt startups, the cart will not
operate if the throttle is depressed while the key-switch is turned on. The throttle must
be in the neutral position when the control is turned on.
• Sleep Mode: The control system utilizes a power saving mode designed to conserve
battery life. If the system does not detect user input for several minutes, the controller
will power itself off. To exit sleep mode, turn the key switch to the off position, and then
to on.
Parking Brake: The cart automatically engages a motor brake when the drive wheels
are not being powered, even while the system power is off. If the cart must be moved
manually (by pushing for example), the motor brake must be physically disengaged.
Refer to figure 2 for the over-ride lever location. While the brake is physically
disengaged, the cart will not operate, and a fault code will flash on the UI.
Document No. 54572-001, Rev. N 05/26/10
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Document No. 54572-001, Rev. N 05/26/10
Figure 3 – Brake disengagement lever position
Throttle lock-out during charging: If the system is charging, the throttle levers will be
disabled. If the throttles are engaged while charging a fault code will be displayed on
the UI.
Anti Runaway If for any reason, the parking brake lever is released, and the cart rolls
away, the controller will automatically limit the speed of the cart. This function operates
even if the cart is powered off.
Start Compensation – The controller will sense when the cart is stopped on an inclined
surface, and provide additional power when started to prevent roll back.
Troubleshooting
In its power on sequence, the control will perform a self diagnostic check, and report
fault codes if any are detected. The codes are flashed in the battery charge display,
and can be interpreted using the table below. There are three states provided by the
battery charge display. These are...
Steady ON - Indicates “normal” status and will glow steady during most operations.
Steady OFF - Indicates Power is off. There is no battery power.
Flashing – The display will flash an error code. See the table below.
Error Codes
In regular operation with no faults present, the battery charge display will be illuminated
steadily. If during operation the controller detects a fault, the display will flash a code to
indicate the type of fault. The display will flash the first number of the code, pause for
approximately one second, and then flash the second part of the code. Count the
flashes to determine the fault code. The controller will continually repeat the flash code
until powered off.
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Fault Code Example: Two flashes followed by a pause, and then two more flashes
indicates a fault code 2-2 "Motor Open" condition (see the fault code table).
When a fault is corrected, the controller must be reset by turning the key-switch to the off
position, and then back to the on position. If the display continues to flash, either the fault
has not been corrected, or another problem exists. See the fault code table for more
information on faults.
Table 1 - Fault Codes
Error
Code
Document No. 54572-001, Rev. N 05/26/10
Problem Possible Causes
1-1 Brake Short Shorted brake, loose/broken
connection to brake, faulty U.I
module
1-2 Brake Open Brake shorted to case,
missing/open brake, loose/broken
connection to brake, faulty U.I.
module
2-1 Motor Short Defective motor, loose/broken
connection to motor, faulty U.I.
module
2-2 Motor Open Defective motor, loose/broken
connection to motor, brake
manually released, faulty U.I.
module
2-3 Power Relay
Defective batteries, faulty U.I.
Short
2-4 PSL Motor
Short
4-2 Charge Mode
Time Out
5-3 Throttle Failband
module
PSL Motor, loose/broken
connection to PSL motor, faulty
U.I. module
Bad charger cable, bad batteries,
bad charger
Throttle control pot is off
center/open, loose/broken
connection/cable, faulty U.I.
module
U.I Module Programmability via a hand-held Programmer
Certain parameters (such as acceleration and deceleration rates) can be changed with the
use of a hand-held programmer. If you are unhappy with certain controller behavior, contact
PHS West to discuss adjustments. Our technicians can send you a programmer, and guide
you through reprogramming the control. Examples of parameters that can be adjusted
include…
• Forward speed maximum
• Reverse speed maximum
• Forward acceleration rate
• Forward deceleration rate
• Reverse acceleration rate
The UI display will briefly flash when the power is turned on. This is
normal, and does not indicate a fault.
The UI display will flash to indicate a full charge while the batteries are
being charged. This does not indicate a fault.
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• Reverse deceleration rate
• Time required to activate sleep mode
• Throttle release deceleration (completely releasing the throttle vs. incrementally varying the
throttle)
• Brake onset delay
• Low battery shut-down voltage setting
• Load speed compensation (to maintain speed under increasing loads)
• Throttle gain in the forward and reverse directions (motor response to throttle levers)
Separate documentation is available for programming the UI module.
Warning! Changing the programming on the microprocessor could damage your cart, and may
invalidate the warranty. ALWAYS contact the PHS West hotline at (888) 639-5438 if you wish to
modify the program.
Document No. 54572-001, Rev. N 05/26/10
Figure 4, 2000/3000 Wiring Schematic
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Document No. 54572-001, Rev. N 05/26/10
Figure 5, Explode View
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Table 2 – Parts List
Item Quantity P/N Description
1 4 51392-001 Caster, HD, 8"
2 1 54166-001 Housing, Electrical
3 1 55823-001 Bracket, Battery, Right
4 1 53139-001 DIN Rail, 35mm
5 1 53142-001 Breaker 50A
6 2 53140-001 End Stop, DIN Rail
7 3 53138-001 Terminal Block, Single Circuit
8 1 53867-001 U.I. Module
9 1 53590-001 Throttle Assy
10 1 53599-001 Base, U.I. Module
11 1 53707-001 Cover, U.I. Module
12 1 55256-001 Switch, Key
13 1 57889-001 Switch, Blue Mushroom
14 1 54450-001 Harness, Charger
15 1 55822-001 Bracket, Battery, Left
16 1 54090-001 Faceplate, UI
17 2 54392-001 Grip, Handle
18 4 54131-001 Terminal Block, 2 Circuit
19 1 54385-001 End Plate, 2 Circuit Block
20 2 53137-001 End Plate, 1 Circuit Block
21 1 51455-001 Door w/Hinge
22 1 51497-001 Handle, Pull
23 1 51573-001 Cover, Electrical Outlet
24 1 52499-001 Lock, Tube
25 2 54414-001 Charger, 24VDC, 3A
26 1 54421-001 Harness, AC w/Power Cord
27 2 51399-001 Battery, 12VDC, 33AH
28 1 51762-001 Retract Pan, Transaxle
29 1 53021-001 Motor, Transaxle
30 2 51415-001 U-Bracket, Transaxle Mount
31 2 52925-001 Shoulder Bolt,3/8-16 X 0.75
32 2 52733-001 Retaining Ring, 3AMI
33 2 52672-001 Spacer
34 2 52680-001 Key 3/16 x 1 3/4
35 2 52229-001 Wheel, 8" Foam Filled
36 1 52232-001 Actuator Linear 1.75"
37 4 53629-001 Bumper, Corner Grey
38 - 54191-001 Bumper, Top Grey
39 1 52588-001 Brake Assy, 5/8 HP Motor
40 1 53021-001 Transaxle Assy, 5/8 HP
41 1 52699-001 Ground Strap
42 - 53069-001 Bumper Base
43 2 53013-001 Bearing, Flanged, 1/2 x 3/8
44 2 52732-001 Nut, Jam, 1/2-20
45 2 52679-001 Wave Washer
Document No. 54572-001, Rev. N 05/26/10
PHS WEST, Inc.
11283 River Road NE, Hanover, Minnesota 55341
888-639-5438
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