Vancare C450 User Manual Download

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Technical

Manual

Troubleshooting
Repairs
Replacements

C450/ C625

by

9$1&$5(

VANCARE, INC.

1515 1ST STREET, AURORA, NE 68818

|

T

(

800

) 69

4

-

4525

F

(

402

) 69

4

-

3994

info@

vancare

.com | www.

vancare

.com

Manufactured for:

C-450/C-625 Technical Manual

031417

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Summary of Contents for C450

Page 1: ...oubleshooting Repairs Replacements C450 C625 by 9 1 5 VANCARE INC 1515 1ST STREET AURORA NE 68818 T 800 694 4525 F 402 694 3994 info vancare com www vancare com Manufactured for C 450 C 625 Technical Manual 031417 Page 1 ...

Page 2: ...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 Troll...

Page 3: ...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 Microswit...

Page 4: ... 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 th...

Page 5: ...ned 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 shap...

Page 6: ...ble for Power lift or Adaptor Board Cable for Manual Power Turntable lift Adaptor Board Cable for Power XY lift or Power Turntable lift Display Battery Cable Power Switch Cable Limit Switch LED Air Switch Charger Adaptor Board 613882 Rev C C 450 C 625 Technical Manual 031417 Page 6 ...

Page 7: ... 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 confirmatio...

Page 8: ...ift 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 ch...

Page 9: ... 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 n...

Page 10: ... 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...

Page 11: ...C 450 C 625 Technical Manual 031417 Page 11 ...

Page 12: ...Disconnect Batteries Remove side cover bottom screws Remove side cover top screws Remove side covers C 450 C 625 Technical Manual 031417 Page 12 ...

Page 13: ... 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...

Page 14: ...eplaced 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...

Page 15: ...l 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 tig...

Page 16: ... 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 th...

Page 17: ...efore 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 PC...

Page 18: ...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 C 450 C 625 Technical Manual 031417 Page 18 ...

Page 19: ... 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 ge...

Page 20: ... 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 Cha...

Page 21: ...lock on trolley to detach the old copper strips 4 Attach the new stainless steel strips Ensure that the ring terminals on the wire harness are centered under the screw holes The polarity of the RED and BLACK wires is critical 5 If the Wire Harness requires replacement cut cable tie and remove 6 Disconnect the charger harness from the PCB and replace with new harness 7 Reconnect the cable tie and e...

Page 22: ...nstant charger system 2 Ensure that the RED battery lead has been disconnected 3 Remove the charger block screw and nut that holds the constant charger to the trolley base 4 Cut the cable tie that holds the constant charger wire to the trolley base 5 Unplug the constant charger cable to the circuit board 6 Remove the constant charger unit and replace with a new unit 7 Reconnect the charger block s...

Page 23: ...E1 6 Using a Robertson 1 screwdriver unfasten and remove the lift sidewall frame next to location of the recently removed battery 7 On the opposite sidewall frame remove only the 2 screws adjacent to the side closest to the strap opening panel with the Robertson screwdriver 8 Using an M3 Allen Key remove the M4 socket head cap screw on the lift s bottom panel with the strap opening holding it to t...

Page 24: ...site battery sidewall frame fasteners Remove fastener on bottom panel on PCB side Remove fastener on bottom panel on gearbox side Slide off panel with strap opening Test Switches Cut cable ties to free switch harnesses Remove replace switches C 450 C 625 Technical Manual 031417 Page 24 ...

Page 25: ...there are no problems with the lift and the Emergency Shut Off with pull cord is either not shutting off the power to the lift and or restoring power to the lift once pressed in follow the below procedure to replace the switch 1 Remove the lift cover per section B1 Getting Access to the C 450 C 625 2 Access the Emergency shutoff switch on the lift s bottom panel with the strap opening by following...

Page 26: ...f 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 ...

Page 27: ...e handles of the snap ring removal tool together to open up the snap ring out of the trolley wheel shaft groove to remove it 4 Carefully slide the trolley wheel free from the shaft while taking care not to lose the washer 5 Place the new trolley wheel onto the shaft past the snap ring groove 6 Place a new snap ring centred against the shaft and slightly pry it apart gently with the snap ring tool ...

Page 28: ...require service follow steps 1 4 of section M1 NOTING only to remove the shaft only as much as to disengage it from the one wall of the lift motor and ensure BOTH batteries with their brackets are removed 6 Follow steps 6 8 in section E5 7 Carefully slide out the traversing motor mounting plate along with the attached gear box bottom panel until the traversing motor gear are accessible 8 The trave...

Page 29: ...OWN to determine how many rectangle characters are shown B a t e r y 0 5 t Note As the lift is initially switched on the level of battery charge displayed may be incorrect However as soon as the lift is actually operated the charge level will update to the correct level In Number of Lifts Mode the lift will 3 Display the word Lifts with the number of lifts completed in the top row of the display e...

Page 30: ... to the first programming option If the user continues to hold the Up and Down buttons for longer than the display flashes Entering Programming Mode the unit will exit the programming mode To exit programming mode If no buttons are pressed for ten 10 seconds the unit exits the programming mode automatically The lift should then 11 Beep three 3 times the beep should be as loud as the existing emerg...

Page 31: ...ee 3 seconds The lift should then 15 Beep one 1 time 16 Go back into Programming Mode and allow the user to cycle through the other settings using the Up and Down buttons o If the user does not press any buttons for ten 10 seconds while in Change Setting Mode the lift should revert back to Programming Mode Programming Options The programming mode will offer the following choices 1 Display Mode see...

Page 32: ...ii 180 seconds iv 240 seconds 2 RTC Drop Time i 3 seconds ii 6 seconds v 9 seconds factory setting iii 12 seconds iv 15 seconds v 18 seconds vi 21 seconds vii 24 seconds 3 RTC Speed i 2 ii 4 factory setting iii 6 iv 8 Measuring Lifts The lift should add one to the lift counter if it has been raised under load i e greater than 50 lbs raised a minimum of 10 sec C 450 C 625 Technical Manual 031417 Pa...

Page 33: ... user manual and reset the lift counter See the following section titled Resetting The Lift Counter LCD Display Programming Functionality Reset the PM lifts counter 2 options to reset A 1 The lift must be in power off state 2 While pressing both Up Down buttons on hand control turn ON lift Mode Tech Prog will show on LCD display with beep 3 Follow the instruction UP RST PM Lift on LCD and press UP...

Page 34: ...in 6 this is the RESET pin 3 Power up the lift system 4 The shunt on the RESET pin must now be removed Note This will not reset the counter recording the total number of lifts performed by the unit Note that the area marked in the following main PCB photo is the program pins area C 450 C 625 Technical Manual 031417 Page 34 ...

Page 35: ...ficient servicing The following is a list of tools required for basic repairs and servicing a Philips Screwdriver medium b Phillips Screwdriver small c Robertson Screwdriver medium d M2 5 Allen key e M3 Allen Key f Pliers g Cutting Pliers h Circlip Pliers i Ratchet Wrench with 5 16 Socket Extension C 450 C 625 Technical Manual 031417 Page 35 ...

Page 36: ...C 450 C 625 Technical Manual 031417 Page 36 ...

Page 37: ...Service Parts List C 450 C 625 Circuit Boards 610519 Soneil charger 24V 1 5 amps C 450 C 625 Technical Manual 031417 Page 37 ...

Page 38: ...C 450 C 625 Technical Manual 031417 Page 38 ...

Page 39: ...C 450 C 625 Technical Manual 031417 Page 39 ...

Page 40: ...l C 450 C 62 Technical C 450 C 625 Technical Manual 031417 Page 40 ...

Page 41: ...C 450 C 625 Technical Manual 031417 Page 41 ...

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Page 46: ...17 C 450 C 625 Technical Manual 031417 Page 46 ...

Page 47: ...C 450 C 625 Technical Manual 031417 Page 47 ...

Page 48: ... the lift makes no unusual sounds when the carry bar is moved UP DOWN or the lift is moved LEFT RIGHT Ensure that there are end stops installed at each end of the track Ensure the lift moves freely along the entire length of the track Certify and record of lift inspection for inspector records Preventative Maintenance 1x yearly Ceiling Lift Track products Complete all steps outlined above under Vi...

Page 49: ...t Switches Description Hold UP until the carry bar is at the top Motor should stop automatically YES NO N A YES NO Let the strap out all the way to the ground Motor should stop before strap winds backwards YES NO N A YES NO While using either UP or Down angle the strap more than 15 degrees Motor should stop automatically YES NO N A YES NO Slack Tape Switch Hold DOWN and lift up on the carry bar Mo...

Page 50: ...eet Client Name Client Address Order Number Number of Pages Including Cover Sheet Date Client Signature The above signed acknowledges the receipt of the completed Certified Inspection Information attached herein C 450 C 625 Technical Manual 031417 Page 50 ...

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