Vancare C450 User manual

Technical
Manual
Troubleshooting
Repairs
Replacements
C450/ C625
by 9$1&$5(
VANCARE, INC.
1515 1ST STREET, AURORA, NE 68818 | T [phone] F [phone]
[e-mail] | www.vancare.com
Manufactured for:
C-450/C-625 Technical Manual
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Table of Contents
C-450/C-625 Lift
Symptoms and Problems
Finding the Problem –Before Getting Inside 3
Pneumatic Systems 4
Electrical Systems 5
Mechanical Systems 8
Basic Instruction Sheets
B1 - Getting Access to the C-450/C-625 11
Pneumatic Instruction Sheets
P1 - Replace Airline Tubing 13
P2 - Replace Grommet 14
P3 - Faulty PCB (Main + Aux) Air Switches 15
Electrical Instruction Sheets
E1 - Test and/or Replace Batteries 16
E2 - Replace combined PCB & Adaptor Board (Printed Circuit Board) 17
E3 - Replace Charger Adaptor Board 19
E4 - Repair/replace C-450/C-625 Charger and End Stop 20
E5 - Repair C-450/C-625 Charger Contact Strips and Wire Harnesses (LED) 21
E6 - Repair C-450/C-625 Constant Charger System 22
E7 - Adjust/Replace UP/DOWN Micro Switch Assembly 23
E8 - Repair/Replace Emergency Shut-off with Pull Cord 25
Mechanical Instruction Sheets
M1 - Replace Lifting Strap –Frayed, Stress Streaks, Length 26
M2 - Replace Trolley Wheels 27
M3 - Replace Traversing Drive Motor, Traversing Gear and Traverse Idle Gear 28
LCD Display & Programming Functionality 29
Tool List 34
Wiring Diagrams
D1 - Main PCB (Printed Circuit Board) and Adaptor Board Schematic Diagrams 35
Service Parts List 36
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SYMPTOMS AND PROBLEMS
Finding the Problem – Before Getting Inside
Please note that the majority of technical problems that can occur with the C-450/C-625 occur
with external system components. The following are the key components to check before
removing any lift cover:
Charger and Charge Connections
Hand Control and Airline Problems
Twisted Strap or Slack Tape Issues
External Thermal Breaker
Review Trouble Shooting Points in Owner’s Manual
The ceiling lift is a pneumatically operated electro-mechanical device. To diagnose performance
interruption it is useful to think of the product as three separate systems:
1. Pneumatic System
Hand Control Unit
Airline Tubing (2, 4, 6-way)
Grommet Connectors
Connector Pins
Air Tubes
Air Receiver Mechanism
2. Electrical System
Charger and Charger Connections
Combined PCB & Adaptor Board –Printed Circuit Board
Wire Harnesses
Microswitch Up Limit Switch
Microswitch Down Limit switch
Quick Disconnects
LED Indicator & LCD Display
Electric ON/OFF, Emergency Lowering and Emergency Shut-Off
3. Mechanical System
Carry Bar or Lifting Hook
Lifting Strap
Tape Switch Assembly
Motors and Gears
Trolley Wheels and Chain Drives
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Pneumatic Systems
The pneumatically operated functions control on/off, up, down and, where applicable, the side-to-
side traversing motion of the lift and/or gantry. A methodical check of the pneumatic system starts
from the hand control and works forward through the pneumatic switches on the circuit board.
1. Hand control & Airline
•
2. Air tubes
•Re-attach the hand control airline to the lift. (The airline end plug has a cap that has a
raised ridge on one face. The raised cap ridge aligns with and slides over the ridge on the
grommet. Correct insertion can thus be verified by touch and by sight.) Check to see that
the air tubes have been routed free and clear. If not routed properly, air tubes can get
trapped by wires, other lift components or the lift cover.
•Check to see that the air tubes are correctly connected to the circuit board switches. The
two air tubes attached to the main board are color coded to correspond to the colored
stickers on the switches. The two air tubes attached to each of the traversing boards are
connected on the principle of “nearest tube to nearest switch.”
•Next detach one air tube at a time from the circuit board. Check for leaks in an air tube by
pressing the function key corresponding to that air tube (the function is indicated on the
color coded stickers on the switches), then pinch the open end of the air tube between two
fingers, then release the function button. The button should stay down when the button is
released. Repeat for each air tube.
•Air tubes are fragile. In detaching and re-attaching air tubes, do not press on the air tubes
with fingernails and be careful not to pierce the tubes with the connector pins.
If NO air leak is found then proceed to check the electrical system.
Unplug the hand control airline from the lift and check for blockage of the airlines by
pressing each of the function buttons in turn. A small blast of air can be felt from the brass
pins at the end of the curly cord.
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Electrical Systems
Ensure that the batteries are charged. Turn the lift on & look at the LCD reading to check the
battery charge level. If the batteries are not charged, put them on charge before servicing the
equipment or connect a fresh set of batteries. If the charger indicator does not give any reading,
batteries can be tested “outside the system” with a load tester or, again, a fresh set of batteries
should be hooked up. An occasional battery problem is acid leaks at the vents. Sometimes a leak
shows up as corrosion of the battery leads.
Do a preliminary inspection of the circuit boards for burn marks or burns odours. A single or
series of components may have failed. The PCB will have to be replaced.
When an electrical problem seems to be the cause of the malfunction, it is important to first check
that all the wire harnesses are plugged in. Secondly it is important to check all wire harnesses for
cuts and/or exposed wires. If this is found, the wire harness must be replaced.
NOTE: All lifts will come with new combined (Main + Aux.)PCB’s, C-450/C-625 Manual has only 2
air switches on PCB, C-450/C-625 Power or Manual PT has 4 air switches on PCB and C-450/C-
625 Power X-Y or Power Turntable has 6 air switches on PCB.
1. The new combined board (main + auxiliary) on Manual and Power Traversing systems;
additional attached charger adaptor board on Manual Power Turntable or Power XY /
Power Turntable systems.
A. The new combined board (main + auxiliary) on manual and power traversing systems;
The white power plug, second from left, connects the batteries to the circuit board. The circuit
board is connected to the main motor via the white plug (for power switch cable) on the right most
side of the board. On the top of PCB side, first from right, the white plug connects to traverse
motor cable. The board and main motor plugs are shaped to prevent erroneous hook-up. The
battery cables are color-coded black and red to match the battery leads. Check to see that the
board, lift motor and battery plugs are properly connected.
The large 2-pin white plug in the middle of top PCB side, connects the charger to the PCB. The
3-pin white plug, first on the left, connects the LED indicator to the PCB. The 16-pin connector,
third from the left connects the LCD display to the PCB. The 4-pin white plug, second from the
right, connects the “slack tape” and “tape thickness” limit switches on the tape switch assembly to
the circuit board. Check to see that the functionality plugs are properly connected (when
connecting a plug, it is easy to miss a prong) and that the wires do not pull out of the functionality
plugs (if a wire does pull out, it was either connected incompletely or connected upside down).
B. Additional attached charger adaptor board on manual power turntable or power XY
power turntable systems.
On the top of PCB side, the white plug, first from right, connects Adaptor Board Cable for manual
power turntable system. The white plug, first from left, connects Adaptor Board Cable for power
XY or power turntable systems.
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Electrical Systems Front side of PCB #613880 Rev C
Charger Cable
Traverse Motor Cable (for Power lift) or
Adaptor Board Cable (for Manual Power
Turntable lift)
Adaptor Board Cable
(f or Power XY lift or Power Turntable lift)
DisplayBattery Cable
Power Switch Cable
Limit SwitchLED
Air Switch
Charger Adaptor Board #613882
Rev C
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Electrical Systems
3. If the batteries and circuit boards appear in order, no air leak is found and no fault is
found with the wiring
•Proceed to check that the lift and traversing motors are functioning by removing the
motor and battery leads and running jumper cables from the motor leads to the battery
leads. (Reversing polarity causes the motors run in reverse)
4. If the batteries and circuit boards appear in order, no air leak is found and no fault is
found with the wiring or with the motors
•The most likely cause of failure is a blown fuse on the circuit board. To confirm, check
the fuses on the board and verify they are both operable. If a fuse is blown replace it
with another 15 amp fuse and test the lift. Under no circumstances should a fuse with a
fuse rating other than 15 amps be used. Using such a fuse can result in damage to the
lift and /or personal injury. If the problem persists after testing, replace the circuit board.
If the problem still persists contact customer service at 1-800-265-0677.
•The other likely cause of failure is a circuit board failure that is not readily visible. To
confirm, connect the non-functioning lift to a board from service parts or from another
lift. (There is no need for a complete board installation: the replacement board used for
confirmation can be hooked up provisionally outside the lift.)
5. If the on/off buttons (and/or emergency lowering buttons) on both the hand control
and the lift do not work
•Check the Emergency Shut-Off with Pull Cord. If it has been activated during an
emergency, call customer service. If it has been activated accidentally push the button
towards the lift until you hear a click. This will allow you to operate the lift again. If the
lift still fails to operate examine the Emergency Shut-Off assembly to make sure it is not
obstructed and activates and deactivates the switch, repair as required. If the problem
persists, replace the Emergency Shut-Off switch.
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Mechanical Systems
1. If the lift goes down to the end of the strap and then goes up again with the up and
down functions reversed, the “slack strap” safety feature is not working:
•Because the roller assembly inside the tape switch assembly is stuck and is therefore
not activating the micro switch. Clean the inside assembly of all debris and make sure
all parts are loose. Then check for the click of the switch as the roller assembly comes
to the end of the slot. If there is no click, The 2 switch screws should be loosened and
the switch pushed closer to the tape switch roller. Make sure that nothing is stuck or
jammed in the assembly.
•Because the switch is too close to the roller assembly. The 2 switch screws should be
loosened and the switch pushed farther away from the tape switch roller.
•Because of a wiring problem. Check the wiring from the tape switch assembly to the
main circuit board.
•Because the micro switch is malfunctioning. Replace the switch.
2. The lift intermittently performs a pneumatically controlled function by itself
(pneumatically controlled functions are on/off, emergency lowering, up, down and,
where applicable, power traversing of lift and gantry)
•There is likely a slow leak in the pneumatic system. The first elements of the pneumatic
system to be checked are the grommets (there is one on the hand control and one on
the lift). For a complete check of the pneumatic system, see sections P1 to P4.
Frequent detachment and re-attachment of the airline or rough usage causes wear and
tear in the air holes of the grommets. Clients should NEVER use the hand
control/airline to pull the lift along the track.
3. The strap goes all the way into the gearbox
The “thick strap” safety feature is not working:
•Because the moving roller assembly does not activate the switch. Introduce a slight
bend in the metal strip (which activates the switch) such that activation takes place
when a double thickness of strap is forced between moving rollers inside the tape
switch assembly. Make sure that nothing is stuck or jammed in the assembly.
Bend the limit switch strip to
ensure activation
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Mechanical Systems
•Because of a wiring problem. Check the wiring from tape switch assembly to the main
circuit board.
•Because the Microswitch is malfunctioning. Replace the switch or re-align it.
4. The lift traverses poorly at specific points in the track system
Identify the points of blockage:
•Is the blockage at the seam of two pieces of track? Correct the vertical and/or
horizontal alignment.
•Is the blockage in a curved section? Check the curve for clearance. Curve walls
sometimes collapse in the bending process. Replace an improperly bent curve or try to
correct it using a track bending tool.
•Is the blockage in a turntable? Check the vertical and/or horizontal alignment of
turntable and track. Brackets should be used to “force” permanent proper alignment.
•Clean inside of track with alcohol
5. The lift does not power traverse well anywhere along the track
Open up the lift and check the alignment of the traversing system. There should be little
noise in the gears and minimal sway in the motor bracket when the motor is running.
Ensuring that the motor is tightly fastened and the gears are mounted securely, aligned
with each other can eliminate “Laboured noise and excessive sway”.
6. The lift motor seems to be running, but does not work in UP or DOWN direction.
The motor output shaft or worm wheel of the motor may have worn out. The acceleration
activated the overspeed governor, which is designed to prevent further use until the lift has
been repaired. (The overspeed governor is a universal, failsafe mechanical brake, which is
triggered by centrifugal force and functions independently of the lift’s pneumatic electro-
mechanical system.) The motor will need to be replaced.
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Mechanical Systems
7. The charger system does not work
The C-450/C-625 lift charger system has five components: a charger, charger end stop,
charger plates, wiring harness and circuit board.
Check that power is coming into the charger: the indicator light on the charger should
be green when the lift is not parked in the charging station.
Check that the charging strips of the charging station (bent in a wave pattern with the
middle section tensed and clear) make contact with the stainless steel contacts on the
trolley block.
Check the plugs along the wiring harness. The black wire from the charger should
correspond to the black wire from the harness.
Check the board by plugging the white plug into a replacement board.
8. The on/off buttons (and/or emergency lowering buttons) on the hand control and the
lift do not work
Simultaneous failure of the pneumatic and electrical systems, strongly indicate a circuit
board failure. Confirm this by hooking a replacement board. In the case of emergency
lowering, if the replacement board does not resolve the problem, the fault is in the
“slack tape” lower limit switch. (See point #1 ‘If the lift goes down to the end of the strap
and then goes up again with up and down functions reversed.’)
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Disconnect Batteries Remove side cover bottom screws
Remove side cover top screws Remove side covers
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PNEUMATIC INSTRUCTION SHEETS
P1 - Replace Airline Tubing
IMPORTANT NOTE: If an air leak is suspected, it is important to check the entire pneumatic
system for air leaks.
1. Separate the Airline tubing from the grommet on the lift unit.
2. Take note of the force required to separate these items. The connection should be very tight.
If the connection appears somewhat loose, an air leak may develop and cause a problem.
3. Air leaks occur at the grommet connections because the hand control and airline tubing are
frequently used to pull the lift along the track. This results in the frequent disconnection of the
airline and grommet.
4. Remember to reassemble the airline to the grommet by aligning the ribs. If not connected
correctly, operating buttons on the hand control will not function properly.
Separate airline Rejoin airline
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P2 - Replace Grommet
IMPORTANT NOTE: There are NO serviceable parts inside the pneumatic Hand Control.
1. If an air leak is suspected but there is no detected failure from test P1, there may be an air
leak at the lift grommet because the airline pins do not fit tightly. This lift grommet may be
replaced using the following steps.
2. Follow steps 1 - 11in section B1.
3. Remove the battery on the side of the lift nearest to the grommet. See section E1.
4. Before starting, take note of the positions of the individual airline tubes inside the lift unit.
These should be marked in a way that they can be replaced in the exact same places.
Check the wire diagrams if not sure.
5. Lift away the blue oval plate to access the damaged grommet & clasp & flatten the rubber
using pliers to reduce the diameter enough to fit through the mounting hole. Then gently rock
the grommet back and forth while PUSHING the grommet through the lift control panel.
6. Disconnect the airline tubing from PCB to the grommet & discard the damaged grommet.
7. Replace the new grommet by gently PULLING the grommet through the lift control panel.
8. Reattach the internal air tubes and replace covers to reattach hand control airline.
9. Retest the entire pneumatic system to ensure that all hand control buttons function.
Compress grommet Gently push through Remove air tubes Reattach airline
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P3 –Faulty Combined PCB Air Switches
IMPORTANT NOTE: There are no serviceable parts on the Combined PCB. These air switches
are not serviceable and the whole board must be replaced if they fail. As this is part of the
pneumatic system, it is important that all connections are airtight.Please note that all lifts will
come with new combined (Main + Aux.)PCB’s, C-450/C-625 Manual has only 2 air switches on
PCB, C-450/C-625 Power has 4 air switches on PCB and C-450/C-625 Power X-Y or Power
Turntable has 6 air switches on PCB.
1. If there are no leaks in the hand control, airline tubing and grommets, there could be a leak
in air tubes to the pressure switch or failure of air switch. Check by performing the air leak
test with the hand control buttons.
2. If there is an air leak, tighten all air tubes and recheck.
Gantry+
Front side of new combined PCB (Main + Aux.) with air switches
Up Down Travers- Travers+Gantry-
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ELECTRICAL INSTRUCTON SHEETS
E1 - Test and/or Replace Batteries
Disconnect batteries Replace batteries
IMPORTANT NOTE: Sealed Lead Acid batteries must be handled with extreme care. Any
leakage or warpage of the battery cover indicates battery failure. Replace immediately.
1. If the indicator light (LED) on the control panel turns RED and an audible alarm sounds,
the batteries may not have sufficient power to operate the lift under load. Lift should be
returned to charger.
2. Using a voltmeter (set for DC volts 100 scale) measure the voltage across the RED and
Black wire terminals on the batteries. The reading should be greater than 27.5 VDC if fully
charged.
3. With the lift on charge, measure VDC. The reading should be between 27 to 30 VDC
indicating that the batteries are being charged. The lift should be left on charge for 30
minutes and retested. If the low battery indication still persists, the batteries should be
replaced.
4. Disconnect all wires from the batteries.
5. Using a M3 Allen Key, unscrew both M4 x 12 socket cap screws that fasten the battery
bracket to the gearbox and remove the batteries.
6. Ensure that an equivalent battery set is used to replace the original batteries (see
specifications).
7. Install the batteries. Ensure that any wire harnesses or airline tubing are loose, free of
obstructions. A blockage of the airlines will cause hand control problems.
8. Connect the SEPARATE BLACK wire across the inside RED and BLACK battery
terminals. Reconnect the (+) and (-) wire harness wires to the matching terminals on the
batteries.
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E2 - Replace Combined PCB (#613880 Main+ Aux.) (Printed Circuit Board)
IMPORTANT NOTE: Use extreme caution when servicing the lift. The combined PCB (Main +
Aux.) should be handled with care. Use of proper E.S.D. protection to prevent damage to the
circuit board is highly recommended. Contact with metal objects (screw drivers, rings, etc.) will
damage the PCB.
1. Before starting, disconnect the RED battery wire and all wire harnesses and all air tubes
(remove off from the steel pins) from the combined PCB.
2. Before installation of new combined PCB, test the boards to ensure that the diagnosed
problem will be solved. Attach all wire harnesses and reconnect the battery wire. Test lift
unit. If lift unit still does not function, the problem is elsewhere. Contact customer service for
further instructions.
3. Remove the mounting screws (2 x #4-40 Phillips Head Screws) for combined PCB (613880).
4. Carefully remount the PCB and tighten screws. Do not over-tighten screws.
5. Attach all wire harnesses and reconnect the battery wire. Test lift unit.
Connect harnesses 1 Connect harnesses 2
Disconnect harness Remove harnesses Unscrew #8 screws
Manual & Power Traverse lifts
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Connect harnesses 3 Connect harnesses 4
Connect air tubes A
Connect air tubes B
NOTE: To Manual-PT Lift
Ensure Clear airline tube is on Up air switch, Blue is on Down air switch, Red on Gantry- air
switch and Green on Gantry+ air switch as shown in figures Connect air tubes A&B. (Red
airline tube replace Black on Gantry- and Green replace Yellow on Gantry+ in figure A)
Manual Power Turntable lift
Power XY or Power Turntable lift
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E3 - Replace Charger Adaptor Board (#613882)
IMPORTANT NOTE: Use extreme caution when servicing the lift. The combined PCB (#613880
Main + Aux.) and Charger Adaptor Board (#613882) should be handled with care. Use of proper
E.S.D. protection to prevent damage to the circuit board is highly recommended. Contact with
metal objects (screw drivers, rings, etc.) will damage the PCB or charger adaptor board.
1. Before starting, disconnect the RED battery wire and all wire harnesses and all air tubes
(remove off from the steel pins) from the combined PCB.
2. Before installation of new charger adaptor board, test the board to ensure that the diagnosed
problem will be solved. Attach all wire harnesses and reconnect the battery wire. Test lift
unit. If lift unit still does not function, the problem is elsewhere. Contact customer service for
further instructions.
3. Remove the mounting screws (2 x #4-40 Phillips Head Screws) for combined PCB (613880).
4. Remove the attached Charger Adaptor Board from gear box plate or traverse motor.
5. Carefully re-stick the charger adaptor board on to the same place of gear box plate or
traverse motor.
6. Carefully remount the PCB and tighten screws. Do not over-tighten screws.
7. Attach all wire harnesses and reconnect the battery wire as shown in E2 section. Test lift
unit.
Adaptor board
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E4- Repair/Replace Charger and End Stop
IMPORTANT NOTE: There are no serviceable parts in the C-450/C-625 charger. Use extreme
caution when performing internal servicing on the lift. Ensure that the charger has been
disconnected from the power supply before starting.
REPAIR Charger End Stop
1. The C-450/C-625 charger end stop consists of the end stop components and the charging
spring clips. If it has been determined that the lift is no longer charging because there is poor
contact with the charge strips, an adjustment can be made.
2. Remove the charger end stop from the track.
3. While holding the end stop gently pull up on the charge strips and bend to desired tension.
4. If too much tension is generated, the lift will not be able to be driven out of the charger end
stop. Adjust the tension so that lift can be driven in and out of the charger end stop.
5. With the manual traverse C-450/C-625, there is a tendency to pull the lift into the charger
end stop at an angle. This can cause one of the charger strips to lose tension. Please
explain to client that the lift should be placed on the charger gently.
REPLACE Charger End Stop
1. Should the charger strips bend and snap, a new charger end stop needs to be installed.
Remove the old end stop and disconnect the charger wires.
2. Reconnect the charger wires to the new end stop. Match the Red wire to the POSITIVE
marker on the charger end stop. The polarity of the RED and BLACK wires is critical.
3. Replace the end stop and tighten bolts. Adjust tension as above.
Disconnect End stop Gently bend strip Correct positioning Connector Polarity
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