Vancare P-600 User manual

Manufactured for:
P-600 Technical Manual

Table of Contents
P-600 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 P-600 10
Pneumatic Instruction Sheets
P1 - Replace Airline Tubing 12
P2 - Replace Grommet 13
P3 - Faulty Main PCB Air Switches 14
Electrical Instruction Sheets
E1 - Test and/or Replace Batteries 15
E2 - Replace Main PCB (Printed Circuit Board) 16
E3 - Adjust/Replace UP/DOWN Micro Switch Assembly 17
E4 – Replacing LCD, Charger Port or Emergency Shut Off Switch 19
Mechanical Instruction Sheets
M1 - Replace Lifting Strap – Frayed, Stress Streaks, Length 20
Tool List 22
Wiring Diagrams
Main PCB (Printed Circuit Board) Schematic Diagram 23
Service Parts List 24
P-600 Technical Manual
REV: 101316
Page 2

SYMPTOMS AND PROBLEMS
Finding the Problem – Before Getting Inside
Please note that the majority of technical problems that can occur with the P-600 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
•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
•Grommet Connectors
•Connector Pins
•Air Tubes
•Air Receiver Mechanism
2. Electrical System
•Charger and Charger Connections
•Main PCB – 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
•Lifting Hooks
•Lifting Strap
•Tape Switch Assembly
•Motors and Gears
P-600 Technical Manual
REV: 101316
Page 3

Pneumatic Systems
The pneumatically operated functions up and down functions . 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
•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.
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.
•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 printed on the
PCB), then pinch the open end of the air tube between two fingers, then release the
function button. The dome of the button should stay slightly compressed 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.
P-600 Technical Manual
REV: 101316
Page 4

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.
2. The P-600 main board
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 on the right most side of the board. 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 white plug on the far PCB side, connects the charger to the PCB. The 16 pin connector,
second from the left connects the LCD display to the PCB. The 4-pin white plug, next to the air
switches, 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).
P-600 Technical Manual
REV: 101316
Page 5

Electrical Systems
Front side of the PCB
Back side of the PCB
Up
Down
Limit
Switch Battery
Charger
Membrane
LCD
Display
Motor
P-600 Technical Manual
REV: 101316
Page 6

Electrical Systems
3. If the batteries and circuit board appear in order, no air leak is found and no fault is
found with the wiring
•Proceed to check that the lift motor is 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 motor
•The most likely cause of failure is a blown fuse on the circuit board. To confirm, check
the fuse on the board and verify that it is operable. If a fuse is blown replace it with
another fuse 25 amp fuse and test the lift. Under no circumstances should a fuse with a
fuse rating other than the specified amperage 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 your local Vancare distributor.
•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.)
2. If the Up/Down buttons on the hand control and/or lift; or the lift emergency lowering
do not work
•Check the Emergency Shut-Off Switch. If it has been activated during an emergency,
call customer service. If it has been activated accidentally turn the switch to the “ON”
position. This will allow you to operate the lift again. If the lift still fails to operate
examine the Emergency Shut-Off switch to make sure it is not obstructed and activates
and deactivates the lift. If the problem persists, replace the Emergency Shut-Off switch.
P-600 Technical Manual
REV: 101316
Page 7

Mechanical Systems
2. 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 up or down
•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 P3.
Frequent detachment and re-attachment of the airline or rough usage causes wear and
tear in the air holes of the grommets.
2. 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.
CAUTION: The hand control and airlines must never be used to pull the lift along the track
P-600 Technical Manual
REV: 101316
Page 8

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.
2. 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.
Mechanical Systems
1. The charger system does not work
The P-600 lift charger system has three components: a charger, 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 the connections from the charger to the neutrik port on the lift
•Check the board by plugging the white plug into a replacement board.
2. The Up/Down 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.’)
P-600 Technical Manual
REV: 101316
Page 9

P-600 Technical Manual
REV: 101316
Page 10

Separate the second cover
Disconnect the charger harness Disconnect the LED harness
Disconnect the membrane harness Disconnect the airlines
Disassembled covers
P-600 Technical Manual
REV: 101316
Page 11

P-600 Technical Manual
REV: 101316
Page 12

P-600 Technical Manual
REV: 101316
Page 13

Use Loctite 401 to secure the new grommet to the cover.
P3 – Faulty Main PCB Air Switches
IMPORTANT NOTE: There are no serviceable parts on the Main 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.
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.
Air Switches
P-600 Technical Manual
REV: 101316
Page 14

ELECTRICAL INSTRUCTION SHEETS
E1 - Test and/or 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 indicates “Low Batt!” 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 an Allen Key (M4) to remove two screws M4 x 12mm to remove the battery holding
bracket.
6. Ensure that an equivalent battery set is used to replace the original batteries (see
specifications).
7. Install the batteries and reinstall the battery holding brackets. 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.
P-600 Technical Manual
REV: 101316
Page 15

E2 - Replace Main PCB (Printed Circuit Board)
IMPORTANT NOTE: Use extreme caution when servicing the lift. The PCB 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 PCB.
2. Before installation of new PCB, test the new PCB 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 (M3 x 8mm hex socket cap screw) using a 3mm allen key.
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.
P-600 Technical Manual
REV: 101316
Page 16

Remove the circuit board using a Install a new PCB onto the stand offs.
3mm allen key.
E3 - Adjust/Replace UP/DOWN Microswitch Assembly
IMPORTANT NOTE: Use extreme caution when performing internal servicing on the lift. Ensure
that the battery has been disconnected before starting.
The UP/DOWN micro switch assembly controls numerous safety functions and maintains an
absolute control over the polarity logic of the entire system. The primary functions are to control
the UP limit, Down limit, monitor “slack tape” condition and prevent the motor from winding the lift
tape in the wrong direction.
1. Have the strap extended out about 1’ & remove the lift covers as per section B1, Getting
Access to the P-600.
2. Remove the PCB as per section E2.
3. Use a 4mm Allen Key to remove the two M4X10 screws on the front and back of the
gearbox.
4. Using an Allen Key (M4) to remove two screws M4 x 12mm to remove the one battery
holding bracket
5. Remove this battery as per section E1.
6. Remove the motor and gearbox by unscrewing 3 M6 x 50 motor mounting screws.
7. Remove the motor and gearbox.
8. Remove the hook brace using an allen key to remove the 2 M6x12 screws.
9. Remove one hook bracket assembly by using an allen key to remove 4 M6 x 12 screws.
10. Separate the hook bracket assembly.
P-600 Technical Manual
REV: 101316
Page 17

11. Slide off the top extrusion to gain access to the limit switches.
12. Use a Phillips screwdriver to remove both microswitches and replace the whole microswitch
wire harness.
13. Reassemble lift and test.
Remove the screws from the front and back of the gearbox
Remove the motor/gearbox assembly
Remove the hook bracket assembly
P-600 Technical Manual
REV: 101316
Page 18

Remove Hook Bracket Assembly
Separate Hook Bracket Assembly
Slide Off Top Cover Replace the microswitches
E4 – Replacing the LCD, Charger port, Emergency Shut Off Switch.
1. Use a Phillips screw driver to remove the LED or the charger port from the required lift cover.
2. Replace the afftected LCD or Charger port with a new component as required.
3. To remove the emergency shut off switch, press on the sides of the shut off switch and push it
through the opening in the side cover.
P-600 Technical Manual
REV: 101316
Page 19

LCD replacement Charger replacement Shut Off Switch Replacement
MECHANICAL INSTRUCTION SHEETS
M1 - Replace Lifting Strap – Frayed, Stress Streaks, Length
IMPORTANT NOTE: Use extreme caution when performing internal servicing on the lift. Ensure
that the battery has been disconnected before starting.
1. Using the DOWN button on the hand control release the entire strap (until the lower limit
switch engages and stops the strap).
2. Remove the lift cover per section B1, Getting Access to the P-600.Also, remove the battery
& its brackets (nearest to the strap pin) as per section E1, and remove the PCBs as per
section E2.
3. Remove the C-Clip from the motor side of the main drive axle.
4. Using the large vice grips, grab hold of the free end of the shaft. Leave the C-clip attached to
prevent accidental damage to the shaft. If damaged, the shaft will not fit back into gearbox.
Gently rotate and pull at the same time to release shaft. Pressure may be applied to the
gearbox to assist in the shaft removal.
5. Pull out and replace the old strap. It is very important that the end of the strap that is inserted
into the shaft is oriented with the overlapped side facing towards the motor side of the lift &
away from the gearbox side. Use two fingers to guide the strap.
6. Use a pencil or ballpoint pen to centre the strap through the gearbox.
7. Reinsert the shaft into the gearbox. DO NOT USE FORCE. If the strap has been centered
properly, the shaft should move easily into position.
8. Replace the C-clip on the drive axle using needle nose pliers.
P-600 Technical Manual
REV: 101316
Page 20