Ascendor PLG7 Product information sheet
Maintenance and Service Manual Version 2.14 Page 3
Contents
1. Introduction.....................................................................................................................................................5
2. Health and safety regulations..........................................................................................................................5
2.1 General information................................................................................................................................5
2.2 Safety precautions before starting service work.....................................................................................5
2.3 Storage of the lift unit without a battery charge ....................................................................................6
3. Removal of the front plastic cover ..................................................................................................................6
4. Service schedule..............................................................................................................................................6
4.1 Function control of handheld or wall mounted remote control.............................................................6
4.2 Function control using the onboard control ...........................................................................................6
4.3 Function control for safety equipment ...................................................................................................7
4.4 Function control for mechanical parts and software..............................................................................7
4.5 Travel rail service.....................................................................................................................................7
4.6 Platform stair lift service .........................................................................................................................7
4.7 Documentation........................................................................................................................................8
4.8 Tools required for maintenance..............................................................................................................8
4.9 Inspection through elevator-inspector....................................................................................................8
4.10 Recommended spare parts set................................................................................................................9
5. Position and function of the switches b1 to b28...........................................................................................10
6. Trouble shooting guide..................................................................................................................................13
7. Failure code motor controller .......................................................................................................................15
8. Description of the PLC diagnostic system......................................................................................................16
8.1 Normal condition...................................................................................................................................16
8.2 Input-Output status of the PLC..............................................................................................................16
8.2.1 PLC Inputs..........................................................................................................................................17
8.2.2 PLC Outputs .......................................................................................................................................17
8.3 Operation time counter/Power blackout counter/Battery voltage......................................................17
8.4 Onboard control ....................................................................................................................................18
8.5 Monitoring of platform motor...............................................................................................................18
8.6 Analog PLC, Flasher................................................................................................................................18
9. Fuses..............................................................................................................................................................19
10. Opening the platform without remote control.........................................................................................19
11. Adjusting settings ......................................................................................................................................20
11.1 Adjusting the platform ..........................................................................................................................20
11.2 Setting the safety bar slip clutch ...........................................................................................................20
11.3 Adjust horizontal position of safety bars...............................................................................................20
11.4 Adjusting of the access ramps...............................................................................................................21
11.5 Memorising remote controls.................................................................................................................21
Page 4 Version 2.14 Maintenance and Service Manual
12. Remove / replace components .................................................................................................................23
12.1 Disassembling the PLG7 safety catcher.................................................................................................23
12.2 Reset of the PLK8 safety catcher...........................................................................................................24
12.3 Testing the PLK8 safety catcher.............................................................................................................25
12.4 Removing the drive motor and gearbox................................................................................................25
12.5 Removing the safety bar motors...........................................................................................................26
12.6 Removing the PLG7 limit switches ........................................................................................................26
12.7 Removing the PLK8 limit switches.........................................................................................................26
13. Instruction for the transfer of a new PLC program ...................................................................................27
14. Wiring diagram main circuit board............................................................................................................28
14.1 LEDs on main circuit board....................................................................................................................30
15. Wiring diagram..........................................................................................................................................31
16. Service plan................................................................................................................................................43
The further parts of the original user manual are:
•Part 1: Operating Manual
•Part 2: Assembly Instruction
Maintenance and Service Manual Version 2.14 Page 5
1. Introduction
The equipment tools described in this Maintenance and Service Manual were those available at the time of
writing. Due to the continual development and improvement of our product we reserve the right to alter the
contents and technical data without consultation or prior warning.
A precondition for the uninterrupted operation of this stair lift, free of any technical problems is the strict
compliance with the content of this manual.
The manufacturer strongly recommends that the lift receives a routine service according to the service
schedule (see chapter 4) at least once a year.
This part of the user manual is dedicated to trained service technicians who are used to the service and
maintenance work of this product.
2. Health and safety regulations
2.1 General information
All service or maintenance work on the platform lift may only be executed by trained personal.
! N O T E !
In the interest of your own well being and the safety of third parties, please observe international health and
safety regulations and the applicable national laws at all time.
! A T T E N T I O N !
This lift is manufactured in compliance with the relevant international and national health and safety
directives. However that alone cannot guarantee safety and security. Incorrect operation or misuse of this
product can eventually cause heavy injuries of the user or third parties and result in damage to the lift and its
surroundings.
2.2 Safety precautions before starting service work
Ensure that the lift is disconnected from the main supply and
take precautions to prevent an accidental restart. In addition,
the batteries must also be disconnected before carrying out any
form of maintenance or service work.
Please take these following steps:
•Unplug the battery charger from the main supply. If the
charger is positioned in the wall mounted box, open the
cover and unplug the charger.
•Disconnect the batteries by unplugging the shown
connector.
! ATTENTION !
Disconnect the batteries before starting any form of service work!
Page 6 Version 2.14 Maintenance and Service Manual
2.3 Storage of the lift unit without a battery charge
If the lift is not installed immediately after dispatch, the batteries must be disconnected from the circuit.
Please take the lift out of the wooden transport box, then open the platform and remove the front plastic
cover (see chapter 3).
Now disconnect the battery connector (as shown in the picture on previous page).
For a long-term shutdown of an already installed lift unit, consider please chapter 7 „Electrical operation“in
the operating manual.
3. Removal of the front plastic cover
For many service tasks its necessary to
remove the front plastic cover.
Please take these following steps:
Remove the two lateral screws on the
bottom of the front plastic cover.
Remove also the two screws of the handle
bar (the handle bar is either fixed on the
front or top side of the lift).
If a folding seat is fixed to the lift, it must be also removed.
Pull now on the bottom the cover a little bit to the front and take off the cover to the top.
! A T T E N T I O N !
The cable for onboard controls is attached to the cover. Please unplug the cable at the small circuit board
before you take off the cover completely. The emergency stop button can be bridged by connecting the short
ribbon cable.
4. Service schedule
During maintenance please fulfil following checks.
4.1 Function control of handheld or wall mounted remote control
•Travel UP / DWON
•Platform open / close
•Function test of the key switch (only for wall mounted remote controls)
4.2 Function control using the onboard control
•Travel UP / DOWN
Maintenance and Service Manual Version 2.14 Page 7
4.3 Function control for safety equipment
•Limit switch TOP
•Limit switch BOTTOM
•Pressure sensitive contact panel (platform underside)
•Emergency stop button
•Switch function test of the access ramps open (travel up / down)
•Switch function test of the access ramps closed (travel up / down)
•Volume test for acoustic alarm
•Shutdown when safety bars are opened while the lift is in motion
•Emergency travel release button (safety bars half open)
•Emergency folding button (see chapter 10)
•Shutdown when current overload at platform motor
•Check of PLK8 safety catcher (see chapter 12.3)
4.4 Function control for mechanical parts and software
•Access ramps open and close completely
•Safety bars open and close completely
•Platform open and close completely
•Check battery charger function
4.5 Travel rail service
•Check all fixing screws, tighten if necessary
•Clean brass charging contacts
•Check abrasion / wear of the rack
•Clean handrail and rack with slightly greasing stainless steel spray
4.6 Platform stair lift service
•Remove front plastic cover (see chapter 3)
•Make a visual inspection of all screw connections
•Check if gear wheel of safety bar shaft and collars are securely tightened
•Check if the fixing screws of the safety bar motors are securely tightened (on the backside of the lift
the topside plastic cover must be removed)
•Check if threaded pins on switch-cam are securely tightened
•Lubricate the gear wheels, eccentric tappet for Bowden cable with a lubrication spray
•Remove the batteries individually, disconnect them and check correct charge (U > 12 V)
•Check if moving magnets can move freely and easily
•Make a visual inspection of all electrical connections
•Check all cables for chafe marks or signs of wear
•Check front plastic cover for damage (Sticker, handle bar)
•Check safety bars for ease of movement
•Check platform and access ramps for freedom of movement
•Replace 9V battery in handheld and wall mounted remote controls
•Check that switch of battery charger is in position “B” (only for charger type Fronius / Red)
Page 8 Version 2.14 Maintenance and Service Manual
4.7 Documentation
After all previous mentioned checks are finished fill out the service plan.
You find the plan at the end of this manual (see chapter 16).
You should also write down the current hour counter and power blackout counter on the day of service.
To read this information please see chapter 8.3.
4.8 Tools required for maintenance
•Set of Allen keys
•Current analyser / measuring device (Multimeter)
•Set of TORX (star head) keys / screwdriver
•Sealing tape
•various screw drivers (magnetic)
•cleaning towels
•set of open ended wrenches
•slightly greasing stainless-steel spray
•various pliers
•lubrication spray
4.9 Inspection through elevator-inspector
In addition to the maintenance work carried out by service technicians the lift must be inspected once a year
by authorised elevator inspector. The inspector must be tasked by the operator.
In the course of the yearly inspection all safety equipment must be checked according to chapter 4.3.
! N O T E !
Only required if directed by national law!
Maintenance and Service Manual Version 2.14 Page 9
4.10 Recommended spare parts set
We recommend taking a set of spare parts with you at all service operations.
Part number
Quantity
Description
XT401187
1
Bowden cable
KT000700
1
Radio receiver board 433,075MHz
XT401195
1
Main circuit board
10401
1
Wireless handheld transmitter
XT401467
2
Holder charging point, extra long
XT401547
2
Cover charging point, extra long
XT401516
1
Brass charging point
KT000436
2
Brass screw M4x16 for charging point PLG7
KT000479
2
Brass screw M4x30 for charging point PLK8
XT401223
1
Platform motor
KT000081
1
Safety catcher
KT000061
4
Battery 12V 7,2Ah
KT000239
3
Fuse 30 A
KT000297
3
Fuse 40 A
KT000407
3
Fuse 7,5A
KT000016
3
Miniature switch with roller lever
KT000017
2
Miniature switch, positively driven NC contact
KT000037
1
Limit switch up/down FR 555 1M1
KT000090
3
Miniature switch for contact tray, outdoor unit
XT401338
10
Rubber buffer for contact tray
KT000446
2
Proximity switch curve-travel
XT501093
5
Distance for bracket PLK8 3mm
XT501094
5
Distance for bracket PLK8 5mm
XT501095
5
Distance for bracket PLK8 1,5mm
XT401766
5
Distance for bracket 3mm PLG7
XT401767
5
Distance for bracket 1,5mm PLG7
XT401774
5
Distance for bracket 5mm PLG7
KT000247
3
Plastic cap stanchion, tube 60x60mm
KT000622
3
Plastic cap stanchion, tube 80x60mm
KT000315
2
Plastic cap hexagon nut, wrench size 17
KT000316
2
Plastic cap hexagon nut, wrench size 19
XT401528
2
Cover charging point PLG7
KT000607
1
Charger Soneil
XT401529
4
Rail end cap 42,4x3,2mm stainless steel
KT000432
5
Hexagon bolt M10x30 stainless steel
KT000429
5
Hexagon socket bolt ISK M10x30 stainless steel
If you find a broken spare part during service you can order it with the part number by your distributor.
You find a list of all spare parts in the spare parts catalogue.
Page 10 Version 2.14 Maintenance and Service Manual
5. Position and function of the switches b1 to b28
No.
Function
b1
b2
b14
wireless remote controls
1 –UP button
2 –DOWN button
3 –folding
b3
b4
b3
b4
1 –limit switch top PLG7
2 –limit switch bottom PLG7
3 –limit switch top PLK8
4 –limit switch bottom PLK8
Positioned on the back side of the lift at
PLG7 and PLK8 units
b5
b5.1
b6
b6.1
b7
b8
b9
b10
1 –safety bar switch top / middle
position
2 –safety bar switch top / middle PLC
3 –safety bar switch bottom / middle
position
4 –safety bar safety switch
5 –safety bar switch top / down
position
6 –safety bar switch bottom / down
position
7 –safety bar switch top / high position
8 –safety bar switch bottom / high
position
Positioned behind the front plastic
cover on the upper component
b11
b12
b13
b21
1 –UP button internal control
2 –DOWN button internal control
3 –emergency stop button
4 –emergency call button
1
2
3
1
3
2
1
2
4
3
1
2
4
3
1
2
3
4
5
6
7
8
Maintenance and Service Manual Version 2.14 Page 11
b15
1 –safety catcher PLG7
2 –safety catcher PLK8
Positioned on the back side of the lift at
PLG7 and PLK8 units
b17
b18
b19
b20
b22
b26
1 –ramp safety switch top
2 –ramp safety switch bottom
3 –platform switch up (white colour)
4 –platform switch down (black colour)
5 –weight control equipment
6 –emergency drive
Positioned behind the front plastic
cover on the bottom side near the
motor
b17.1
contact strip top
(optional)
b18.1
security contact-tray
(7 pcs. overall)
Positioned at platform underside
b17a
b18a
1 –contact strip backside PLK8, top
2 –contact strip backside PLK8, bottom
1
2
1
2
4
3
5
6
X
X
X
X
X
X
X
1
2
X
Page 12 Version 2.14 Maintenance and Service Manual
b23
roll monitoring PLK8 safety catcher
b24
b25
b25.1
1 –3rd stop
2 –curve speed reducer 1
3 –curve speed reducer 2
Positioned on the back side of the lift
(only for PLK8 units)
b27
b28
1 –Emergency close platform
2 –Emergency open platform
1
2
3
2
1
X
Maintenance and Service Manual Version 2.14 Page 13
6. Trouble shooting guide
Solution
Release the emergency stop button
(turn button to the left)
Use the emergency drive button and move the lift in
direction of the upper station.
After the safety catcher has been activated the device must
be checked and if necessary replaced by a technician.
Remove obstacle and make sure that the access ramp and
contact tray can be moved easily.
Move the lift with UP or DOWN button to a charging station.
Check power supply
Move the lift with UP or DOWN button to a charging station.
Remove obstacle,
If necessary check the current value on the PLC display (see
chapter 8.5)
Close safety bar by pressing UP or DOWN button.
The lift can only be operated via onboard control with
opened platform.
Can be changed in PLC menu (see chapter 8.4)
Call service technician
Possible cause of problem
Emergency stop button has been pushed
Safety catcher is activated
Obstacle is activating the contact tray
(platform underside) or access ramp
Lift is not parked in a charging station
Battery charger is not plugged in or
broken
Empty or low batteries
Obstacle blocks movement of safety bar
or platform
Safety bar has been opened by hand
Incorrect operation
Upper and lower limit switch are pressed
at the same time
Display prompt
Fault 1
Emergency Stop or Emergency Brake
Fault 2
Loading ramp or contact sensor strip
Fault 3
Low voltage or no charge
Fault 4
Platform or safety bars are
overloaded
Fault 5
Safety bar manually opened
Fault 6
Only use onboard control
Fault 7
Both limit switches activated
Page 14 Version 2.14 Maintenance and Service Manual
Solution
Replace 7,5 A fuse (see Chapter 9)
Check freedom of movement of safety bars and / or
platform motor operation.
Straighten lever of b19 switch, or replace the switch
Reduce weight on the platform
Adjust or replace roll monitoring sensor.
Press “fold platform” button for at least 2 seconds
Check if dirt or water activates the sensor button
Push RESET button on F1 fuse main switch (see Chapter 9)
Call service technician
Call service technician
Possible cause of problem
Short circuit of platform or safety bar
motor
Lever switch b19 bent or broken
Lift is too heavily loaded
The monitoring roll of the safety catcher
is not running or only sporadically.
Lift is mounted distorted to the rails.
Monitoring sensor is broken.
Platform is not closed completely
Onboard control button is activated at all
times.
Short circuit
PLC is defective
Low battery voltage
Display prompt
Fault 8
Fuse F2 is broken
Fault 9
Weight overload
Fault B
Roller monitoring safety catcher
Fault C
Platform is not completely closed
Fault D
Onboard control up/down permanent
activated
Lift does not work
No prompt on the PLC display
Maintenance and Service Manual Version 2.14 Page 15
7. Failure code motor controller
When a problem concerning the motor controller occurs, a blink code (0 or 1) will also be visible on the Ready-
LED on the main circuit board.
LED CODES
Explanation
LED off
No voltage or controller broken
continuously on
Controller ready, no failure
1.1
Reduction due to excessive or insufficient temperature
1.2
Travel control failure
1.3
Limiting potentiometer failure
1.4
Failure caused by low voltage < 17 V
1.5
Failure caused by voltage overload > 31 V
2.1
Main contactor unit failure
*
2.3
Main contactor broken
2.4
Main contactor unit short circuit
2.5
*
3.1
Collision protection activated longer than 10 seconds
3.2
Brake circuit failure
*
3.3
Fault while loading the condensers
3.4
Brake-circuit short circuit
3.5
Travel control collision protection is activated
*
4.1
Fault in current measurement
*
4.2
Fault in motor current
4.3
EEPROM failure
*
4.5
No connection to batteries (Fuse F3 broken)
* = can be deactivated by turning the main switch OFF and then ON
Note: the last three errors will be shown.
MOTORCONTR OK (green)
In addition a LED MOTORCONTR OK will
be visible on the printed circuit board
indicating errors by a flash code.
Page 16 Version 2.14 Maintenance and Service Manual
8. Description of the PLC diagnostic system
The lift unit is fitted with an acoustic alarm signal which will be activated in case of a failure during operation.
The failure can be identified by the information on the display and the appropriate counter measures listed in
chapter 6 should be taken.
8.1 Normal condition
To enter the main menu please press UP and DOWN button simultaneously for at least 5 seconds, or press the
A and B button simultaneously for at least 3 seconds.
For navigation in the main menu press the A or B button.
Choose your settings with + and –on the particular menu site.
Press ESC to leave the main menu.
8.2 Input-Output status of the PLC
After you have opened the main menu the Input-Output picture appears.
This is very useful for failure search.
In the course of trouble shooting with Ascendor telephone support you may be asked to handover this
information.
(I = Input, O = Output)
Input = top line
Output = bottom line
In this example the inputs 4, 5, and 6 (dark coloured numbers and letters) are activated.
This means that the lift is located in the lower stop and the platform is opened.
I-4 = limit switch BOTTOM (b4)
I-5 = platform switch (b20)
I-6 = emergency stop circuit (b13, b15)
Maintenance and Service Manual Version 2.14 Page 17
8.2.1 PLC Inputs
I-1 UP button
I-A upper safety bar down
I-2 DOWN button
I-B lower safety bar down
I-3 limit switch TOP
I-C 3rd stop
I-4 limit switch BOTTOM
I-D charging, weight control equipment
I-5 platform switch
I-E internal control
I-6 emergency stop circuit
I-F current measurement
I-7 motor ON
I-G roll monitoring (PLK8)
I-8 lower bar closed or platform closed
I-9 safety bars horizontal
8.2.2 PLC Outputs
O-1 disengage motor control
O-2 relay platform motor
O-3 safety bar motor top
O-4 safety bar motor down
O-5 reverse polarity relay K1
O-6 moving magnet
O-7 beeper (emergency call)
O-8 free
O-9 flasher (optical and acoustical warning signal)
O-A free
8.3 Operation time counter/Power blackout counter/Battery voltage
Operation time counter:
The operation time counter only counts whole driving
hours. Every movement on the lift (drive UP / DOWN,
fold platform ...) is part of the driving time.
Power blackout counter:
Records how often the PLC was switched off (due to
low batteries or power failure)
Battery voltage:
If the lift is parked at the station the charging voltage is shown.
When the lift is moving or standing between the stations the battery voltage is displayed.
The above shown PLC display shows following values:
Hour cou. = 0 Hours
Power off-counter = 1
Voltage = 26,49 V
Page 18 Version 2.14 Maintenance and Service Manual
8.4 Onboard control
Onboard controls prior:
0 = Onboard and remote control are coequal
1 = Onboard control has priority
Once this function is activated the UP and DOWN buttons
on the remote controls are only functional when the
platform is folded!
8.5 Monitoring of platform motor
Maximal current value (max.):
Protects the platform and safety bar motors from electrical
overload. If this value is exceeded, the power supply to
platform and safety bar motors will be switched off.
A value of 250 is recommended.
If fault 4 –Platform or safety bars are overloaded –appears
on the PLC display this value may be altered in small
increments. The maximum value is 310.
Reduced (red): This value controls the smooth closing of the platform. We recommend a value between 50
and 180, depending on the platform size.
Current value (cur.): displays the actual current value of the platform motor.
Delayed running (delay): time delay switching off the platform motor (ensures that the motor is no longer
under load while folding down). This value should NOT be adjusted!
8.6 Analog PLC, Flasher
Analog PLC:
This value can be used to check if the signal from the remote
controls reaches the PLC.
UP or DOWN from onboard control:
Value = 1023-1024
Unfold or fold the platform:
Value between 300 and 700
UP or DOWN from remote control:
Value = 0
Flasher:
If the lift is equipped with an optical and acoustical warning signal it can be activated or deactivated with this
parameter.
Changing parameters:
The parameters shown on this page can be changed, please take the following steps:
•Choose the required parameter by pressing the + or –button and confirm with OK
•The chosen parameter is now flashing. By pressing the + or –button the value can be altered.
•To confirm the new value press OK again
Maintenance and Service Manual Version 2.14 Page 19
9. Fuses
The fuses are located in two positions on the lift; behind the front plastic cover next to the batteries
and under the top service hatch cover at the rear of the lift.
Push button
Platform OPEN
Platform motor
Fuse F2 - 7,5A
Main Power
Switch
Connection cable for
platform emergency opening
Battery overload
protection fuse 30A
Push button
Platform CLOSED
Drive motor
Fuse F3 - 40A
Fuse 2A with
RESET button
10. Opening the platform without remote controls
The platform can be opened without the aid of remote control.
First of all, open the service hatch cover on the top, rear of the lift.
There are two possible operating options:
•Open the platform with the push buttons (emergency folding)
•Open the platform with direct external electrical supply to the platform motor (e.g. battery of cordless
screw driver).
If the batteries are empty, bring the loose black cable with white terminal block (connection cable) directly
into contact with platform motor fuse or to the positive pole of the external power source.
If the batteries are charged, use the OPEN or CLOSE push buttons to operate the platform.
(This will also function when the remote controls are defective).
If the remote controls are at fault, connect the emergency power supply via black cable, directly to the 7,5A
Fuse. If the batteries are completely discharged, the emergency power supply cable must be connected to the
positive pole of the external power supply and the negative pole should be brought into contact with the
frame of the lift unit.
If the lift has not been correctly positioned at a charging station, it will automatically switch itself off after a
maximum of 10 hours in order to prevent a deep discharge of the batteries.
•To RESTART the lift unit, press the RESET button.
! ATTENTION ! Only use this solution when there is no voltage in the batteries!
•The platform can ONLY BE OPENED!
•Opening the platform with an emergency power supply, deactivates the safety limit switches!
As soon as the platform is horizontal, remove all power connections, otherwise the platform motor could be
subjected to an electrical overload!
Page 20 Version 2.14 Maintenance and Service Manual
11. Adjusting settings
11.1 Adjusting the platform
The pitch angle of the platform can be adjusted with the sheet metal plates.
These are located on the bottom of the aluminium profiles.
Turn the reverse plates 180 degrees for raising the platform height.
! A T T E N T I O N !
Adjust the switch b20 (platform horizontal) if necessary!
11.2 Setting the safety bar slip clutch
The slip clutch is located on the safety bar
motor shaft.
Remove the plastic cover on the backside of
the lift.
Set the safety bars to a horizontal position.
Use a 10mm open ended wrench to adjust the
clutch.
! A T T E N T I O N !
Only adjust the clutch slightly.
The collar may not be moved!
Please note that each safety bar has its own individual slip clutch.
11.3 Adjust horizontal position of safety bars
The safety bars can be adjusted with the aid of the stop
screws which are moved by the lifting magnets.
! A T T E N T I O N !
Safety bar switches b5, b5.1, b6, b6.1 may need to be
adjusted. Please note that it’s important to make only
very slight adjustments to these switches!
Stop screw
The safety bar base-setting is marked with a
black line.
Switch-cams are fixed with grub screws. To
adjust, first loosen grub screw, than turn the
cam.
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