Otolift ‘ONE’ Functionality & troubleshooting Date 220811
Table of content Page-number 1. Chairlift in general 4 1.1 Basics 1.2 Description of types and numbers 4 4 1.3 Locations on chairlift 5 1.4 Definition left/right 5 2. System Functionality 6 3. Main Board and levelboard 7 3.1 Connections at the main board 3.1.1 Controls 3.1.2 Safety inputs 3.1.3 Sensitive edges safety inputs 3.1.4 Other inputs 3.1.5 Outputs 8 8 7 8 9 10 3.2 Connections at the Level board 3.2.1 Inputs 3.2.2 Outputs 11 11 11 4. Sensor control board and sensors 12 4.
8. Powered footrest and powered swivel seat 21 8.1 Powered Footrest. 8.1.1 Connections 8.1.2 Info LED 21 21 21 8.2 Powered swivel seat 8.2.1 Connections 8.2.2 LED’s 8.2.3 Switches at the PCB 8.2.4 Need to know 8.2.5 Program the positions of the seat 22 22 23 23 23 24 9. Testing safety devices 9.1 Testing safety switches 9.2 Testing tiltsensor 9.3 Testing Overspeed Govenor 9.3.1 Working description Overspeed Governor (OSG) 10. Charging Batteries and power modes 10.1 10.2 10.3 10.4 10.5 10.6 10.
1. Chairlift in general 1.1 Basics - 2 Closed loop controls for controlling the 2 synchronous motors and DC brake. - On board charging-circuit for charging the batteries (= 2x12V/7Ah) - The lift is equipped with a buzzer on the PCB and a LED in the armrest for failure report to the user. - The PCB’s have a display for failure report to the technician or installer. - Error log for backwards failure handling. 1.2. description of types and numbers.
1.3 Locations on chairlift Control left/right Incl switch armrest with LED Control footrest up/down (seat rotation) PCB powered footrest or PCB powered swivel seat and motor rotating seat. Back (underside) Endswitch and charge contact Safety-device Drive-unit Chair sensor and Tilt sensor inside Safety-gear (OSG)/ Rotation monitor unit. (RMU) Safety device footrest / motor footrest inside. Locations on chairlift 1.
2. System Functionality The Chair frame will be kept horizontal with the information out of 2 sensors. One gyro is build on the Sensor control board. This sensor (also called ‘lift sensor’ or ‘drive sensor’) measures the rotation of the drive unit. The measured rotation is basically used as data to run the level motor. The second sensor (called the ‘Chair sensor’) has the function to check and compensate the angle of the chair frame.
3. Main board and Level board The Main and Level board are both motor-controllers. The main board (biggest board) controls the main motor. With the service-box you can teach in the speed profile and length of the rail in this PCB. The main board reads back its actual position, through the position of its rotor. This main board is also the PCB where all safety-switches are interconnected, and also the PCB where the control signals come in.
3.1 Connection at the main board 3.1.1 Controls If one of these controls is activated, and all safety contacts are not operated, the chairlift will start to move in the controlled direction. Control input connected to connector-name Control armrest right (NO) X2a-1, 3 Arm1 Control armrest left (NO) X2a-2, 3 Arm1 2-channel receiver (Remote right) (NO) X8-3,4 Remote 2-channel receiver (Remote up) (NO) X8-5,6 Remote 3.1.
Sensitive edges safety inputs left side If one of these safety devices are controlled, the lift can not move in the left direction. It is still possible for the lift to move in the right direction. Control input connected to connector-name Endswitch left (NC) X3a-3,4 Endswitch Safety drive unit left (NC) X4-3,4 Drive Safety footrest left (NC) X5-3,4 Foot Safety chairframe left (NOTE) (NC) X6-3,4 Frame (NOTE) (NOTE) Not used in the Otolift ‘ONE’.
3.1.5 Outputs Motor output 3x 11V for controlling the 0,35 kW synchronous motor Brake 22~29V output for controlling the holdbrake. Battery Supply output Connection for batt. Supply to X1 level board via 8 pole header X17. Supply output +/-24Vdc 1 4A current limited 22~29V output. Only used in 2 tube applications.
3.2 Connection at the Level board 3.2.1 Inputs Battery Supply input Connection for Supply at X1 via 8 pole header X17 main board. Encoder The encoder is attached at the back of the rotor at the level motor. With this encoder we check the direction and speed of this motor. Connection at X7 Can Bus Communication between Main, Level and sensor control board. Connection to the Sensor Control Board with the flat cable through X4. Connection towards the Main board X16 through header at X2.
4. Sensor control board and sensors The Sensor Control Board is the board which is more or less ‘responsible’ for keeping the chair frame level. Information to keep the chair frame horizontal is gathered out of 2 sensors. The first sensor is the Drive Rotation Sensor. The Drive Rotation Sensor is mounted at the Sensor Control Board, which is mounted at the side the drive unit. This sensor is a gyro and gives information about the rotation of the drive unit.
4.1 Connection at the Sensor control board 4.1.1 Inputs Battery Supply input Fused supply for Sensor Control Board and its sensors. Connection at X1 flat cable. Tilt sensor The safety-line result of Tilt sensor. Connected at X5. Result can only be measured when complete dual safety-line is closed. Chair sensor Input signal of the chair sensor. Connected at X4. Programming Connector X3 and the 3 (2) headers at the board are only used for uploading software into the the Board.
5 Need to know settings. To be able to really run the lift some settings need to set, or checked. 5.1 Dipswitches at the Main board and their functionality. Dipswitch 1= on => The rotation monitor unit is monitored on its functionality. If the rotation monitor (RMU) does not give an alternating signal, during 30 cm of moving the lift, the lift stops. The lift will drive further by re-controlling it.
5.2 Standard dipswitch settings. Dipswitch ON settings as described below must be respected. Type 1000 and 2000 (no power swivel seat) Dipswitch 1, 7 and 8 should be always set in the ON position. Type 3000 and 4000 (equipped with the powered swivel seat) Dipswitch 1,2, 7 and 8 should be always set in the ON position 5.3. Standard interconnections on the Main board Some connectors are not used in the Otolift ‘ONE’ application. In this case we use jumpers to make the interconnection.
5.4 Calibrating sensors In every new system or after replacement of the Chair Sensor or Sensor Control Board, you need to perform a Calibration. It is important that the chair frame is level when this calibration is done. When the system / sensor control board is new (blank), the sensor control board will show E45 to show you that it did not had any calibration procedure yet. Calibration procedure. 1. Turn the switch in the armrest off. (display Main Board will show ‘0’.
5.6 Dynamic of the system. It is possible to change the dynamic of the leveling system. Depending of shape of rail, settings of the lift or sense perception of the user, it is possible that you want to lower the dynamics of the system. Lowering the dynamics, means that the lift will slow down more in bends in the vertical plane, and that the system will respond less nervous. The settings of the dynamic needs to be done at the Sensor Control Board.
6. Programming the chairlift 6.1 Need to know before programming The chairlift must always be programmed, when moving to the right. (seen from user position) Thus a lift which is mounted on the left side of the stairs, must be programmed from the endpoint at the top till the endpoint of the bottom, and a lift which is mounted on the right side of the stairs, must be programmed from endpoint of the bottom till the endpoint at the top.
6.2 Programming the chairlift Only start programming the lift, when the lift is operating OK (without bypass-connector.) The sensors need to be calibrated first and the Tilt sensor should be adjusted first. (see 5.4 / 5.5) Both displays should show a ‘1’ in the display. Start programming procedure when ‘potentiometer’ speed is set. Programming procedure: 1 2 3 4 5 6 7 8 9 10 11 12 Switch on Service.
7. Remotes and receiver. The chairlift has a separated receiver (PCB) build in for remote-control. Before using the remote you have to teach them in. The battery-voltages has to be connected, when you want to teach them in. 7.1 Teaching the 2-channel remotes into a 2-channel receiver 1. 2. 3. 4. 5. Open the cover of the receiver-box. Operate the switch on the receiver once. (LED lights up). Operate within 30 seconds the up or down switch of the remote which should be programmed in. The LED will go off.
8. Powered footrest and powered swivel seat. As written earlier in this document the Otolift ‘ONE’ can also be equipped with a powered footrest and a powered swivel seat. 8.1 Powered Footrest. The PCB of the powered footrest gets its supply from the Mainboard (connector X11). The footrest can be operated via the rocker switch in the opposite armrest. The PCB is only a regulator between the supply and motor. The motor direction is given directly (switched) via the operating switches under the rocker.
8.2 Powered swivel seat The PCB of the powered swivel seat is also supplied via the Mainboard (connector X11). In case of powered swivel seat the footrest motor is also controlled via this PCB. S2 S1 Info LED’s Jumper The swivel seat can be operated via the rocker switch in the armrest, or will be controlled when you control the lift up or down. The drive, park and end stop positions of the swivel seat can be programmed via the 2 buttons . Basically there are 2 modes.
8.2.2 LED’s LED yellow (programming) Off => No programming in progress. Blink => Programming in progress. ON => Programming confirmed. (Becomes active after 4sec “programming in progress”) LED red (error) Off => No error. Blink => Overcurrent / encoderfault swivel seat motor ON => PCB error. LED orange (CPU) Off => Sleepmode / no supply. Blink => OK and running. ON => CPU / PCB error. 8.2.
8.2.5 Program the positions of the seat. Before able to program the positions of the seat the profile of the rail should programmed in first. Also dipswitch 2 at the main board should be set first into ON position. Zero position (park position) This position is triggered via the calibration switch which almost at the top of the chairframe. The switch point of this switch (where it goes from ON to OFF) is the zero position. (Switch goes ON to OFF, only when seat rotates in CCW direction.
9. Testing safety devices Before you give the lift free for use, you need to be sure that all safety-features are working properly. The best way is to verify the functionality when the lift is open. (without front and frame covers.) 9.1 Testing Safety switches. Control arm left/right Incl switch armrest with LED Back (underside) Endswitch Tilt sensor Safety-device Drive-unit Safety device footrest.
9.2 Testing of the tilt sensor To be sure that in worst case situations, for instance the event that the lift is unable to keep the seat horizontal, the lift will stop, you always need to verify the functionality of the Tilt sensor and the safety related circuits. This testing should be done after the adjustment of the tilt sensor. The idea is that you rotate the base plate to +7 and -7 deg and test the sensor. To keep the adjustment of this sensor saved, we have mounted this sensor on an extra base plate.
9.3 Test functionalty gripper and safety gear switch You need to remove the plastic cover first, before you can test this functionality. (If you are not familiar with the functionality, we advise you to read chapter 9.3.1. first) Testing procedure 1. Turn the gripper out of the ‘Reset OK position’. This turning (rotating) should go smooth with a minimum of force. 2. Check if the display ‘shows’ E08, and check if the lift cannot run by controlling the lift. The ‘technician needed alarm’ will sound. 3.
10. Charging Batteries and power modes If the chairlift is on, and the batteries are being charged, the LED on the armrest is on continuously. When the chair is on and the batteries are NOT being charged the LED will blink with a frequency of 1 Hz. 10.1 Charging-points The voltage for charging the batteries is interconnected through the charging contacts. A detail drawing of the connections of the charging-points is attached. (drawing 300-charge) 10.
10.4 Battery-fuse For protection of all electronics a main-fuse is put in series with the batteries. The fuse-holder is placed as an interconnection between the batteries The blade fuse should have a value of 25A. 10.5 Sleepmode When the lift has not been charged for 2,5 hours it will go into a sleepmode. In sleepmode, the current-consumption is approximately 10 mA. If the lift is in the sleepmode, you can simply wake it up by controlling the armrest control left or right.
11 Need to know before Trouble shooting To be able to do some error handling some items need to be known first. 11.
11.2 Fuse safety-line A 375 mA SMD fuse is used as a safety-fuse for all the switches in the Main safetyline. The fuse melts when a wire or contact from the safety-line has a short-circuit to (chassis) ground. When the fuse is broken the display shows E08, the 3 LED’s at the left bottom are off, and the LED near the display should be on. NOTE; that a short-circuit from x10-3 or x11-1 to ground during movement can give the same info as a defect fuse.
11.7 Reposition When you move the chairlift off the rail, and put it on again later, there is a big chance that the profile has shifted. In this case you do not have to teach in the profile again. To do a reposition, follow step 1 to 5. 1. Drive the chairlift in the direction of the endpoint, which it does not reach, until it stops automatically (software endpoint). (in case of an E-seat first fold up the seat) 2. Switch off the armrest-switch. (LED is off). 3.
12 Error-handling for technicians 12.1 MAIN PCB Because of its backward capability to a 2-tube lift, the diagnostics is divided into Drive unit related and Chair levelling related. The Main board only shows the drive related errors in detail. When the fault is to the levelling, the Main board will show E97 or E98, which means that you have to check the error at the sensor control board. 12.1.1 Diagnostic displays The display on the MAIN PCB shows the actual error.
If for example the display shows 2, this means that the swivelseat-switch is controlled, or that the wiring to this switch is defect. In combination with the detail drawing of the wiring (attachment 300901_connect) it should be easy to solve the problem, if the problem is related to the wiring. All Exx errors are shown blinking. (for example Error 12 will shown as E, 1, 2, E, 1, 2, E, 1, 2 etc.) Most Exx errors will generate a fast beep (5Hz). Exception for error 13,18 and error 97 and 99.
Example 1 The lift has been active for more then 20 days. (today it is Monday) A user complains that the lift has stopped several times during movement on Wednesday and Friday. When the error-log has been read out the display could show: Note that the first error you read is the most recent one. _ _ _ 2 2 2 _ _ 2 2 2 2_ _ _ _ _ _ _ _ or _ _ 2 2 2 _ _ 2 2 2 2_ _ _ _ _ _ _ _ _Display-error 2 means that the swivel seat-switch was operated during controlling the lift.
12.2 Errors shown by the sensor control board If the fault is related to the levelling, the Main board will show E97 or E98, which means that you have the check the error at the sensor control board. 12.2.1 Diagnostic displays The display at the sensor control board shows the actual error. More detail and updated info of these display errors is attached to this document. The display can show the following errors. ‘‘ 1 System 2 in sleepmode, “no power” on Sensor control PCB.
12.1.2 Error-log The PCB stores the errors in its memory. By using the 2 buttons at this PCB, you can read out the error-log. Facts & functions of error-log - Control lower switch => read the stored errors backwards - Control upper switch => start at latest stored error - Control upper switch for 10 sec. => delete error-log - Errors are only stored when the lift is controlled by armrest left/right or remote up/down. - Maximum of 20 errors can be stored.
13. Error-handling for the user of the chairlift 13.1 Operating the chairlift The chairlift will not start to move directly when operated , it will start to drive after 2 seconds of operating. Before starting to drive a 0,5 second beep will be heard. (start-to-move-signal) When the chairlift is stopped on a endpoint a 0,25 second beep will be heard.
13.3 Logic of the beeper When the LED in the armrest is on or blinking and the chairlift will not move when controlled, the beeper will give a number of beeps 1 second after releasing the control. In this case one of the sensitive edges is controlled The number of beeps gives the location of the controlled sensitive edge. The location of the controlled sensitive edge is at the same side as the controlled direction. • When 2 beeps are heard the safety cap of the drive-unit is controlled.
14.
ERRORS shown by MAIN BOARD Display description problem " " 0 1 2 3 4 5 6 7 A b C d E F g 11 11 H L t P (nothing) = PCB stanbymode Switch armrest is in OFF position Switch armrest is in ON position (main safety-line is OK) Swivelseat-switch is operated (3 options in case of powered rotating seat) Extracontact is not connected (via jumpers) Current x10-3 is higher then 100 mA Lift is controlled on 2 places Lift did not charge for 1 or 8 hours depending of dipswitch 3 Lift came out of sleepmode / batterie
ERRORS shown by SENSOR CONTROL BOARD (SCB) 22-aug-11 Display description problem " " 1 (nothing) = PCB standbymode/ sleepmode All OK, ready to run E25 E26 No response main drive. (via CAN) Fail Safetyline test Main board Check Flatcable / Replace Main Board Replace Main Board E30 E31 E32 E33 * E34 * E35 E36 E37 E38 * No response level board. (via CAN) Fail Safetyline test Level board Fail Selftest Level board. Overload LevelPCB / Levelmotor Long time high load.
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