Table of Contents
Related Manuals for Vancare C450
Summary of Contents for Vancare C450
- Page 1 C450/ C625 Technical Manual Troubleshooting Repairs Replacements Manufactured for: VANCARE, INC. 1515 1ST STREET, AURORA, NE 68818 | T (800) 694-4525 F (402) 694-3994 info@vancare.com | www.vancare.com C-450/C-625 Technical Manual 031417 Page 1...
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Page 2: Table Of Contents
Table of Contents C-450/C-625 Lift Symptoms and Problems Finding the Problem – Before Getting Inside Pneumatic Systems Electrical Systems Mechanical Systems Basic Instruction Sheets B1 - Getting Access to the C-450/C-625 Pneumatic Instruction Sheets P1 - Replace Airline Tubing P2 - Replace Grommet P3 - Faulty PCB (Main + Aux) Air Switches Electrical Instruction Sheets E1 - Test and/or Replace Batteries... -
Page 3: Symptoms And Problems
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: ... -
Page 4: Pneumatic Systems
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. -
Page 5: Electrical Systems
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”... - Page 6 Electrical Systems Front side of PCB #613880 Rev C Traverse Motor Cable (for Power lift) or Adaptor Board Cable Adaptor Board Cable (for Manual Power (f or Power XY lift or Power Turntable lift) Charger Cable Turntable lift) Power Switch Cable Air Switch Battery Cable Display...
- Page 7 Electrical Systems 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.
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Page 8: Mechanical Systems
Mechanical Systems 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. - Page 9 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. The lift traverses poorly at specific points in the track system Identify the points of blockage: •...
- Page 10 Mechanical Systems 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.
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Page 11: B1 - Getting Access To The C-450/C-625
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...
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Page 13: Pneumatic Instruction Sheets
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. Separate the Airline tubing from the grommet on the lift unit. 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. -
Page 14: P2 - Replace Grommet
P2 - Replace Grommet IMPORTANT NOTE: There are NO serviceable parts inside the pneumatic Hand Control. 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. -
Page 15: P3 - Faulty Pcb (Main + Aux) Air Switches
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. -
Page 16: Electrical Instruction Sheets
ELECTRICAL INSTRUCTON 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 turns RED and an audible alarm sounds, the batteries may not have sufficient power to operate the lift under load. -
Page 17: E2 - Replace Combined Pcb & Adaptor Board (Printed Circuit Board)
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. - Page 18 Manual Power Turntable lift Power XY or Power Turntable lift 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- switch and Green on Gantry+...
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Page 19: E3 - Replace Charger Adaptor Board
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. -
Page 20: E4 - Repair/Replace C-450/C-625 Charger And End Stop
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 The C-450/C-625 charger end stop consists of the end stop components and the charging spring clips. -
Page 21: E5 - Repair C-450/C-625 Charger Contact Strips And Wire Harnesses (Led)
E5 - Repair C-450/C-625 Charger Contact Strips and Wire Harness (LED) IMPORTANT NOTE: Use extreme caution when performing internal servicing on the lift. Ensure that the battery has been disconnected before starting. The original copper charger contact strips can become corroded in very humid and acidic environments such as pools and spas. -
Page 22: E6 - Repair C-450/C-625 Constant Charger System
E6 - Repair C-450/C-625 Constant Charger System IMPORTANT NOTE: Use extreme caution when performing internal servicing on the lift. Ensure that the battery has been disconnected before starting. The bearings and contact strips can become dirty, oily, and corrode in very humid and acidic environments. -
Page 23: E7 - Adjust/Replace Up/Down Micro Switch Assembly
E7 - Adjust/Replace UP/DOWN Micro Switch 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. - Page 24 Remove display panel Remove battery bracket Remove “battery sidewall” frame Remove opposite “battery Remove fastener on bottom Remove fastener on bottom sidewall” frame fasteners panel on PCB side panel on gearbox side Slide off panel with strap Test Switches Cut cable ties to free switch opening harnesses Remove &...
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Page 25: E8 - Repair/Replace Emergency Shut-Off With Pull Cord
E8 – Repair/Replace Emergency Shut-Off with Pull Cord IMPORTANT NOTE: Use extreme caution when performing internal servicing on the lift. Ensure that the battery has been disconnected before starting. The Emergency Shut-Off/Down with Pull Cord is a safety function that either cuts all power coming from the battery to the rest of the lift or allows the lift lower. -
Page 26: Mechanical Instruction Sheets
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. Using the DOWN button on the hand control release the entire strap (until the lower limit switch engages and stops the strap). -
Page 27: M2 - Replace Trolley Wheels
M2 - Replace Trolley Wheels IMPORTANT NOTE: Ensure that the lift is fully supported at all times. Take great care in protecting the PCB. There is a tendency to turn the lift over, thus damaging or breaking the aluminum standoffs that support the PCB. The same procedure is used to replace any manual or charger trolley wheel assembly. -
Page 28: M3 - Replace Traversing Drive Motor, Traversing Gear And Traverse Idle Gear
M3 - Replace Traversing Drive Motor, Traversing Gear and Traverse Idle Gear IMPORTANT NOTE: Ensure that the lift is fully supported at all times. Take great care in protecting the PCB. There is a tendency to turn the lift over, thus damaging or breaking the aluminum standoffs that support the PCB. -
Page 29: Lcd Display & Programming Functionality
LCD Display & Programming Functionality • Default Display Modes: − The user can set either of the following as the ‘Default’ display mode: 1.– Battery Level (the factory setting for the Default Display Mode); or, 2.– Number of Lifts. − In Battery Level Mode the lift will: Display the word, “Battery”, with the percentage charged (in 10% increments) in the top row of the display (e.g., “Battery Level 60%”). - Page 30 LCD Display & Programming Functionality − In any ‘Default display mode’, if the unit is in the charger the lift will go into Charging Display Mode regardless what the user has selected as ‘Default Display Mode’. Charging Display Mode should over-ride Low Battery Mode. −...
- Page 31 LCD Display & Programming Functionality • Change Setting Mode : − To change one of the programmable settings, the user should press the ‘Up’ and ‘Down’ buttons simultaneously when a particular setting is being displayed. The display will then display the setting name and the setting itself. The setting will then display as reverse-highlighted (as in the following example) D i s p l a x y B A T...
- Page 32 LCD Display & Programming Functionality If the lift has the return-to-charge (“RTC”) feature, the following programming choices will also be available: 1.– RTC Max. Time 60 seconds (ii) 120 seconds (factory setting) (iii) 180 seconds (iv) 240 seconds 2.– RTC Drop Time 3 seconds (ii) 6 seconds...
- Page 33 Preventative Maintenance The lift should recommend preventative maintenance if it hasn’t had any preventative maintenance for: 1,000 lifts (four or five lifts a day 180 days); or, Five (5) total hours or operation To recommend preventative maintenance, the Lift will: ...
- Page 34 LCD Display & Programming Functionality • Resting Lift Counter 1. Ensure the power is off before beginning. 2. Place a shunt on pin #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’...
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Page 35: Tool List
Tool List The lifts have been designed to minimize the tools required for servicing the lifts. Common and swappable components provides for efficient servicing. The following is a list of tools required for basic repairs and servicing: a) Philips Screwdriver – medium f) Pliers b) Phillips Screwdriver - small g) Cutting Pliers... - Page 36 C-450/C-625 Technical Manual 031417 Page 36...
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Page 37: Service Parts List
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...
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- Page 48 General Inspection and Preventative Maintenance for Ceiling Lift & Track products Below is a non-inclusive list of services Vancare will provide during their visit(s): Visual Inspection 1x yearly (Ceiling Lift & Track products): - The lift lifting tape shows no signs of fraying or breaking along its entire length.
- Page 49 NO LED Light: when on, dark when off, and amber when charging. YES NO N/A YES NO Casing Check for cracks or wear in case Use hand control to end program mode. Log # of lifts in upper right YES NO N/A YES NO PM Reset corner on this sheet. Reset the PM Counter. Vancare, Inc.: Customer: C-450/C-625 Technical Manual 031417 Page 49...
- Page 50 Final Checklist and Inspection Commissioning Cover Sheet 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...