FlexStep V2 INSTALLATION & SERVICE MANUAL FLEXSTEP V2 UK VERSION 1.9

Transcription

1 Installation & Service Manual FlexStep V2 INSTALLATION & SERVICE MANUAL FLEXSTEP V2 UK VERSION Liftup A/S Hagensvej 21 DK-9530 Støvring Denmark T: M:

2 Contents 1 Unpackning & Moving the FlexStep V Definition Unpacking and moving the product Attachment to building Mounting of Wall Profiles without a vertical safety barrier Fixing the wall profiles on the wall Mounting of Wall Profiles with a vertical safety barrier Fixing the wall profiles on the wall Dismantling timing belt system Fitting the Vertical Safety Barrier Assembling timing belt and motor to vertical safety barrier Timing belt tension Connecting the vertical safety barrier and testing it Mounting of FlexStep V2 to Wall Profiles Control Unit Bottom rail Control Boards Control Board Jumpers JP Control Board LED signals Control Board Microswitches ON/OFF Switch Mains outlet Call stations Standard call station wired Key Operated Call Stations (2 ways) Wireless Call Stations (wall mounted) How to pair transmitter and receiver Wireless call station and receiver Handheld Remote control and receiver ON/OFF Key switch (Optional) Setting of Lifting Height and Stair Position Definition Settings of the 2 stops using the Liftup Service Tool Setting virtual top stop by Service Mode Service mode How to set the System into Service Mode Features in Service Mode NOT CALIBRATED Features in Service Mode CALIBRATED

3 7 Safety Features Infrared Sensors (IR) Wiring of Safety Switches to the Infrared Sensor Boards Wiring of push buttons and emergency Stop Safety Pressure Plates Audible Alarms Automatic Ramp/Roll-off Protection Automatic Door (optional) Connecting to Control Unit Unlocking Door in case of Emergency Disassemble the FlexStep V Place the FlexStep V2 on a plane surface Disconnecting the wires Removing the wires Circlips for steps Screws for handrails Assemble the steps Mounting the girders Connecting the wires Check list Actuator replacement Dismounting Actuator Replacing spindle unit Mounting Actuator Enclosures Liftup Control Software Electrical Diagram # Pull Force

4 1 Unpackning & Moving the FlexStep V2 1.1 Definition In order to simplify the reading of this manual, or any conversation with us, it is important to set some basic definitions in place. The FlexStep V2 is a lifting platform capable of transferring a wheelchair or disabled people between 2 levels (max 1250 mm). After transfer the product will in most cases automatically return into staircase position. The product can be with 3, 4, 5 or 6 steps (3+1, 4+1), as an option it can be equipped with a Vertical Safety Barrier. F E D G Right Hand Side of the lift A: Primary Master Actuator B: Primary Slave Actuator C: Primary Control Unit (jumpers are on this side) C A Left Hand Side of the lift E: Secondary Master Actuator F: Secondary Slave Actuator D: Secondary Control Unit H B G: RH Side and LH Side wall profiles H: RH Side and LH Side Girders After opening the wood or carton pallet, you need to remove all packaging around the FlexStep. 4

5 1.2 Unpacking and moving the product The FlexStep V2 is equipped with batteries so even if the power supply is not connected to the lift, the lift can move (not the case if it s prepared for disassembly). To start moving the FlexStep V2 you need to make some changes on the Safety Circuit of the product as it is by default delivered with all safety functions active. Remove the 3 screws on the top of the Primary Control Unit (Right Hand Side of the product). Remove the cover and slide the cover upwards to remove it. Once done, you see the Primary Control Unit. In order to move the product, place a jumper on: - Upper Gate SW - Under Pan SW If you now release the emergency button, you should have all green LED s on (see photo). 5

6 Type Type Use the up button on the platform to move the product upwards. Use e.g. a fork lift to remove the FlexStep V2 from the wooden pallet. During transport of the product, remember to activate the emergency button. Once at site, it is helpful to move the FlexStep on a rolling table. NOTE: Remember to always push the emergency button after moving the lift as it may try to return to staircase immediately. 6

7 2 Attachment to building ATTENTION! Remember to push the emergency stop button, before you start working underneath the lifting platform. 2.1 Mounting of Wall Profiles without a vertical safety barrier. If your FlexStep V2 is fitted with a vertical safety barrier go to chapter 2.2. The FlexStep V2 lifting platform/staircase is delivered almost fully assembled. Only the two wall profiles need to be attached to the adjoining wall to ensure a stable performance Fixing the wall profiles on the wall 1. Start by removing the plastic cover on the top of the left hand side wall profile. Remove the protection profiles. 2. Start by checking the upper landing floor. If the floor is not even, start fitting the wall profile where the floor is lower (could be the right hand side). 820 Make sure the distance between the top of the wall profile and the upper level is precisely 820 mm Make sure that you also have 20 mm free space under the wall profile (use a piece of wood or plastic shims). If you cannot have 20 mm at the bottom, you need to shorten the wall profile at the bottom. 20 mm wood 7

8 3. Make sure that the wall profile is vertical (front view and side view) (use shims between the wall and the profile if necessary). 4. Once the position and the dimensions are correct. Fit the first wall profile to the wall through the mounting holes. Use relevant screws and plugs for the actual wall type. 8

9 5. Mount cover plate to left hand side wall profile, using two M4 screws top and bottom. 6. Mount cover plate to right hand side wall profile, using two M4 screws top and bottom. Use e.g. shims at the bottom to support the wall profile as it is heavy. (approx 2 cm). Fix the second wall profile to the wall through the mounting holes. Use relevant screws and plugs for the actual wall type. 9

10 7. Remove the cover plate and approach the bottom rail. 8. Push bottom rail 20 mm up into LH and RH wall profile. Fasten bottom rail to wall profiles using a M5 screw in each side. 9. Wall profiles are now ready for mounting the FlexStep V2. (Go to chapter 2.3) 10

11 2.2 Mounting of Wall Profiles with a vertical safety barrier The Vertical Safety Barrier can be delivered as an add-on solution, which can be fitted to an existing FlexStep V2, To do this you need to change the wall profiles, as they are different Fixing the wall profiles on the wall 1. Start by removing the plastic cover on the top of the left hand side wall profile. Remove the 2 brush rails, and the aluminium cover rail. 2. Start by checking the upper landing floor. If the floor is not even, start fitting the wall profile where the floor is lower (could be the right hand side) mm Make sure that the distance between the top of the wall profile and the upper level is precisely 1100 mm. Make sure that you also have 20 mm free space under the wall profile (use a piece of wood or plastic shims). If you cannot have 20 mm at the bottom, you need to shorten the wall profile at the bottom. 20 mm wood 11

12 3. Make sure that the wall profile is vertical (front view and side view) (use shims between the wall and the profile if necessary). 4. Once the position and the dimensions are correct, fit the first wall profile to the wall through the mounting holes. Use relevant screws and plugs for the actual wall type. 12

13 5. Mount cover plate to left hand side wall profile, using two M4 screws top and bottom. 6. Mount cover plate to right hand side wall profile, using two M4 screws top and bottom. Use e.g. shims at the bottom to support the wall profile as it is heavy. (approx 2 cm). Fix the second wall profile to the wall through the mounting holes. Use relevant screws and plugs for the actual wall type. 13

14 7. Remove the cover plate. 8. Push bottom rail 20 mm up into LH and RH wall profile. Fasten bottom rail to wall profiles using a M5 screw in each side. 9. Wall profiles are now ready for mounting the vertical safety barrier. 14

15 2.2.2 Dismantling timing belt system The left hand side wall profile is delivered with motor, timing belt etc. already mounted. The motor and timing belt must be dismounted before mounting the plates that forms the Vertical Safety Barrier. 1. Remove the top cover from the wall profiles in both left and right hand side to access the top mounting bracket for the timing belt. 2. Loosen the belt tension screw in the top cover. 3. Loosen two screws and dismount motor. 15

16 4 Pull the timing belt up from the left hand wall profile leaving cm hanging outside the wall profile. Fasten the timing belt to the wall profile with masking tape or similar. 5. Mount a bar clamp on the wall profile temporarily, to secure vertical safety barrier from sliding down towards the floor. Remove it when barrier plates are placed into the wall profiles, motor is mounted and connected to timing belt. 16

17 2.2.3 Fitting the Vertical Safety Barrier The three plates that form the vertical safety barrier, are held together by a pin in each side, for easy mounting on the wall profiles. The pins are factory mounted. 1. LH side pin/cable binder 2. RH side pin/cable binder 17

18 3. Carefully slide the plates for the vertical safety barrier down in the wall profiles. 4. Remove pins/cable binder in both sides of plates for vertical safety barrier 5. Carefully slide the plates for the vertical safety barrier down towards the bar clamp. 18

19 2.2.4 Assembling timing belt and motor to vertical safety barrier Remove the masking tape holding the timing belt against the wall profile. 1. Carefully slide down timing belt, grey wire and top mounting bracket. 2. Top mounting bracket placed correct in left wall profile. 3. Make sure the cog on the motor is in grip with timing belt. Remount the motor to the wall profile. 19

20 4. 5. Remount top cover on the wall profiles in left hand side 20

21 2.2.5 Timing belt tension Tension on the timing belt should be "firm". The timing belt must be tight enough to ensure sufficient grip on the cog but not too tight to overload the drive motor. Adjust distance between top cover and top mounting bracket to be app. 20 mm. 1. Tighten the timing belt with the screw in the top cover of the left hand wall profile. 2. Adjust distance to 20 mm. ATTENTION If the tension of the belt is too tight, the vertical safety barrier will not work properly and the motor and belt will have significantly reduced lifetime. 21

22 2.2.6 Connecting the vertical safety barrier and testing it Connect the cable for connection box (103273) to the connecting board. Operate the lift to test the movement of the vertical safety barrier. 1. Mount the cable for connection box (103273) as shown below. 2. Connect the 2 cables on connector board. 22

23 3. Remove the jumper placed on Upper Gate SW. Type Type Release the emergency button from the FlexStep and push the UP button. The Vertical Safety Barrier should now go up. 23

24 2.3 Mounting of FlexStep V2 to Wall Profiles 1. Place the FlexStep V cm from the wall profiles and connect the E chain with the 2 x M5 screws. 2. Attach the cover plate. 3. Attach the top profile (only when no Vertical Safety Barrier). 24

25 4. Approach the lift close to the wall profiles. 5. Place the 2 connecting brackets on the left and right hand side wall profiles. Glide the connecting brackets all the way down. 25

26 6. Fix the connecting brackets with 4 M5 screws (2 on the left hand side and 2 on the right hand side). LH Top RH Top LH Bottom RH Bottom 7. Finish the installation by fixing on both sides: E B C A Side protection A or the brushes if a vertical Safety Barrier is installed Front protection B to hide the fixing holes Top cover C Side protection D for the Control Unit Top cover E the girder protection (if you had removed then) D 26

27 3 Control Unit The control unit consists of the power supply unit (103080), the PCB for connection box (102726), both factory mounted on the bottom rail and two control boards ( or ) mounted inside the two control boxes, placed on each side of the FlexStep V Bottom rail PCB for connection box Power supply unit Connect to mains Power supply / PSU From safety barrier switch (optional) From safety barrier motor (optional) Key Stairs Down Up RF status From wired call station (optional) From primary control board 3.3 V AC ON Description LED Colour Action if LED is ON Key Orange Key locked (I.e. FlexStep V2 not usable) Stairs Yellow Button activated Down Yellow Button activated Up Yellow Button activated RF Status Orange Remote control activated 3.3 V Green DC supply for remote control OK AC ON Orange Power supply connected (mains) 27

28 3.2 Control Boards The FlexStep V2 control boards ( or ) are mounted inside the two control units, placed on each side of the FlexStep V2. Remove covers for control box to access control boards. Primary control board (always on right hand side of the Flexstep V2) Secondary control board SECONDARY Control unit LH side PRIMARY Control unit RH side Battery Power connector Actuators cables LH side Actuators cables RH side PCB for Connection box cables Battery CR 1220 IR safety TX boards Primary Control board IR safety RX boards Operating panel Secondary Control board 28

29 3.3 Control Board Jumpers JP1 IMPORTANT! Remove all jumpers to reactivate all safety functions. (Except Ignore GO ) Jumpers and LED is only valid on PRIMARY control board right hand side. PRIMARY Control board (102352)RH side mounted Jumpers PRIMARY Control board ( or ) Type Type Description Under Pan SW. IR Platform Lower Gate SW. IR Stairs Upper Gate SW. Ignore GO Action if jumper is ON. (ONLY on PRIMARY Control Board) Ignore safety switches Ignore IR error upper step Ignore ramp switch Ignore IR error stairs and girder squeeze protection Ignore safety barrier switch Allows auto return and soft stop 29

30 3.4 Control Board LED signals Control board type H-BRO SUP Yellow H-BRO3 SUP Yellow OC. H-BRO3 Red +12V Yellow AC ON Yellow BATT. FLOAD Yellow EMS. OK Green H-BRO ON Green Under Pan SW. Green Lower Gate SW. Green Upper Gate SW. Green IR Stairs Green IR Platform Green HB. Yellow +3V3 Yellow 30

31 Control board type H-BRO SUP Yellow H-BRO3 SUP Yellow OC. H-BRO3 Red +12V Yellow AC ON Yellow BATT. FLOAD Yellow EMS. OK Green H-BRO ON Green Under Pan SW. Green Lower Gate SW. Green Upper Gate SW. Green IR Stairs Green IR Platform Green +3V3 Yellow HB. Yellow 31

32 Description LED Colour Action Primary / Secondary H-BRO SUP. Yellow Supply for actuator ready P + S H-BRO3 SUP. Yellow Supply for ramp (Secondary) / safety barrier (P)+(S) ready (Primary) OC. H-BRO3 Red Over current ramp (Secondary) / safety barrier (P)+(S) (Primary) AC ON Yellow AC mains on (Supply) P + S BATT. FLOAT Yellow Battery charged = Maintenance voltage 26,22 V P + S EMS. OK Green Emergency switch released OK P H-BRO ON Green Go for actuator supply P + S +12V Yellow 12 V DC supply OK (Supply or batteries P + S connected) Under Pan SW. Green Safety switches Under pan OK or bypassed by P jumper IR Platform Green IR upper step OK or bypassed by jumper P Lower Gate Green Ramp switch OK or bypassed by jumper P SW. IR Stairs Green IR stairs and girder squeeze protection OK or P bypassed by jumper Upper Gate Green Safety barrier switch OK or bypassed by P SW. jumper Ignore GO NA Allows auto return and soft stop P +3V3 Yellow Supply OK P + S HB. Yellow CPU OK when flashing P + S 3.5 Control Board Microswitches Microswitches for resetting and forcing the board into boot mode are located at the bottom of the boards. Reset F-Boot Push to reset the system. The processor will restart and reload the current firmware. To force the board into boot mode. Only for firmware update. Push both F-BOOT and RESET, and release RESET before F-BOOT => The system is now in boot mode. (The HB LED will stop flashing). See

33 3.6 ON/OFF Switch The FlexStep V2 is mounted with an ON/OFF switch for mains supply. The ON/OFF switch is placed on the bottom of the right hand side control box. Access the switch from below. Use to turn the power off e.g. when pairing remote controls. ON/OFF Switch 3.7 Mains outlet It is possible to mount a mains outlet* behind the foreclosure. Please see illustrations below for possible placement of mains outlet. Hole size: (W x H) = 100x120 mm. (not factory standard) * Please note: Mains outlet is not Liftup A/S supply. 33

34 4 Call stations The FlexStep V2 can be delivered with different types of call stations to be mounted on upper level and lower level (recommended). Find different solutions on How to connect a standard Liftup call station is described below. 4.1 Standard call station wired 2 ways connections: Lower Call station (X3): Green / Common White / Down Yellow / Staircase Upper Call station (X2): Green / Common White / Up Yellow / Staircase 34

35 3 ways connections: Call station (Upper level): Green / Common (X2) White / Down (X3) Yellow / Staircase (X3) Brown / Up (X2) Call station (Lower level): Green / Common (X3) White / Down (X3) Yellow / Staircase (X2) Brown / Up (X2) 35

36 4.2 Key Operated Call Stations (2 ways) Upper Call station (X2): Green / Common White / Up Yellow / Staircase Lower Call station (X3): Green / Common White / Down Yellow / Staircase 36

37 4.3 Wireless Call Stations (wall mounted) 2 ways: Lower Call station Upper Call station 37

38 4.4 How to pair transmitter and receiver Wireless call station and receiver The transmitter and receiver must always be paired in order to work. The receiver will not react to a transmitter which is not paired with it. A receiver can be paired with up to 20 transmitters. A transmitter can be paired with several receivers if required. When a receiver is powered on (please see section 3.6) the RF-Status in the connection box will flash for 2 minutes. Or until it is paired with a transmitter. 1. Ensure that there is power to the system. Press the emergency stop and switch off the on/off switch on the side of the lift (please see item 10.6). 2. Wall-mounted remote-controlled call station: Set micro switch S4 #2 to ON and press on the contact or short-circuit ( ) or ( ) using a metal object. The control LED on the call station will start to flash slowly. The call station is now in installation mode for 2 minutes. Return S4 #2 to its starting position (off). 3. Within these 2 minutes, release the red emergency stop on the lift by turning it clockwise. 4. The control LED on the call station is paired with the lift when it stops flashing. 5. Test the system so as to ensure the pairing has been performed correctly. If not, repeat 1-5 above. If you need to pair several call stations to the receiver, repeat items 2-6 above. 6. Switch on the on/off switch on the side of the lift. How to reset the transmitter and receiver To reset a call station so it is no longer paired with a particular lift, do as follows: Set microswitch S4 #1 to ON and press on the contact or connect ( ) or ( ) using a metal object. The control LED on the call station will flash rapidly. The pairing with the receiver has now been erased. Return microswitch S4 #1 to off. 38

39 How to reset the receiver Switch the receiver on. Short-circuit JP1-1on the connection box board. When the control LED begins to flash rapidly, the receiver has been reset. Should the control LED not flash rapidly, this means that no receiver has been paired Handheld Remote control and receiver The transmitter and receiver must always be paired in order to work. The receiver will not react to a transmitter which is not paired with it. A receiver can be paired with up to 20 transmitters. A transmitter can be paired with several receivers if required. When a receiver is powered on (please see section 3.6) the RF-Status in the connection box will flash for 2 minutes. Or until it is paired with a transmitter. 1. Ensure that there is power to the system. Press the emergency stop and switch off the on/off switch on the side of the lift (please see item 10.6). 2. Press the UP ( ) and DOWN ( ) buttons on the remote control at the same time and hold them down for approx. 5 seconds until the control LED on the remote control begins to flash slowly. The remote control is now in installation mode for 2 minutes. 3. Within these 2 minutes, release the red emergency stop on the lift by turning it clockwise. 4. When the control LED on the remote control stops flashing it is paired with the lift. 5. Test the system so as to ensure the pairing has been performed correctly; if not, repeat 1-5 above. If you need to pair several remote controls to the receiver, repeat item 2 above. 6. Switch on the on/off switch on the side of the lift. How to reset the transmitter and receiver To reset a remote control so it is no longer paired, do as follows: Press the UP ( ) and DOWN ( ) buttons at the same time and hold them down for approx. 5 seconds until the control LED on the remote control begins to flash slowly. The remote control is now in installation mode for 2 minutes. Perform the following within the 2 minutes: Press: UP( ), UP( ), DOWN( ), DOWN( ), UP( ), DOWN( ), UP( ), DOWN( ) 39

40 How to reset the receiver Switch the receiver on. Short-circuit JP1-1on the connection box board. When the control LED begins to flash rapidly, the receiver has been reset. Should the control LED not flash rapidly, this means that no receiver has been paired. 4.5 ON/OFF Key switch (Optional) The FlexStep V2 can be delivered with a key switch to switch off the unit (part number ). How to connect a standard Liftup key switch is described below. Standard key switch Wires mounted to contact in key switch box 40

41 Wires from key switch mounted on print for connection box. Placed on bottom rail. 41

42 5 Setting of Lifting Height and Stair Position 5.1 Definition All FlexStep V2 are delivered with 2 programmable height settings. 1 st programmable height setting (Platform Lifting Height) is the position where the platform will stop when it reaches the top landing. 2 nd programmable height setting (Stair Position) (can be the same as the Platform lifthing height) is the position of the top step when the FlexStep V2 is in Staircase position. According to your order confirmation the lift is tested and set to your specified heights but can be modified, if adjustment is needed. Staircase top stop is the same as platform top stop Staircase top stop is lower than platform top stop (= 2 top stops) 5.2 Settings of the 2 stops using the Liftup Service Tool The Liftup Service Tool must be installed on a PC(*) (Laptop) with a USB output. 1. Place the USB cable into the PC and into the USB plug of the Master control board ( or ) on the FlexStep V2 (RH side of the lift). 2. Start the Liftup Service Tool on PC (make sure you know the name of the COM port, see Annexe to see how). You should see the Connected box with green background (see below, USB detected on COM 4) (*) PC must be Windows 7 or newer. Windows XP is usable but requires special drivers. 42

43 In the Stroke area, set the value of actuators: o Platform Lifting height, in mm (see NOTE) o Stair Position, in mm (see NOTE) 4. Push the Write system parameters to device. Now the system is ready to run, please remember to check that all settings are as expected. NOTE: Remember to deduct approx. 70 mm to your settings as the platform is approx. 70 mm thick. IMPORTANT! After programming the system must be calibrated by pushing the lift down button until the platform is positioned at lower landing. 43

44 5.3 Setting virtual top stop by Service Mode When the system is in service mode (see 6.1) it is possible to set the virtual top stops. 1. Set the system into service mode. 2. Push the emergency button, (Push and hold the on-board UP & DOWN buttons, release the emergency button while holding the UP & DOWN buttons for 15 seconds. 3. Move the platform down to the lower level, to make sure that the system is calibrated. 4. Push the lift up button, until the desired level is reached. 5. Push the emergency button, and push the on-board UP-button to set Platform Lifting Height and push the on-board DOWN-button to set the Stair Position. (Sound will confirm, when height is programmed) (As all lifts are with 2 stops, you have to program both, before leaving the Service Mode) 6. Leave service mode, Push the emergency button, (Push and hold the on-board UP & DOWN buttons. Release the emergency button while holding the on-board UP & DOWN buttons for 15 seconds.) 44

45 6 Service mode 6.1 How to set the System into Service Mode. To set the system into service mode, do as following: 1. Push emergency stop button. 2. A) Push and hold two buttons, while B) releasing the emergency stop button. Hold the two buttons for 15 sec. 2A) 2B) 1) Use one of the following combinations: Push and hold 2 buttons, and release the emergency button, and hold the buttons for 15 seconds. In service mode the system needs to have the ramp lock switch and the vertical Safety Barrier Switch. In this mode the auto return function is disabled, so is the top stop and the stair stop. To leave service mode: Push the emergency stop button, Push and hold 2 buttons, and release the emergency button, and hold the buttons for 15 seconds. 6.2 Features in Service Mode NOT CALIBRATED NOTE 1: Be careful not to travel with the platform higher than 1250 mm. This can happen in service mode if not calibrated. Disconnect one of the Actuator on the control Unit. Now the lift is travelling on 3 Actuators (Handy during installation or in case of changing an actuator) NOTE 2: As the FlexStep is not calibrated, the actuators are not synchronized between each other (the platform will therefore not stay parallel to the floor). NOTE 3: Be careful not to brake the E-chain, disconnect it from the RH Side wall profile is necessary 6.3 Features in Service Mode CALIBRATED When the system is in service mode, different kind of features are available, see following: 1. It is possible to set virtual top stops. (see 5.3) 2. All four actuators can be moved by pushing the lift down or lift up. 3. By pushing stairs on the call station only master actuator will move up. 7 Safety Features 45

46 7.1 Infrared Sensors (IR) The FlexStep V2 is mounted with Infrared Sensors, to minimise risk of getting squeezed between the steps and under the girders. The Infrared Sensors are positioned on the girders off the edges of each step and protected by removable covers. ½ Removable cover IR safety boards Attaching the IR safety boards TX (Transmitter) & RX (Receiver) to the girder: The safety IR boards are attached to the girder with plastic clips. TX boards with the LED through the hole and RX boards with the receiver opposite the hole. 46

47 Yellow when IR is OK (Flashing or constant) Yellow flashing when IR is OK IR safety TX board. (103009) IR safety RX board. (103008) Ramp Lock green Power On yellow Yellow flashing when IR is OK IR termination board. (103011) 47

48 7.2 Wiring of Safety Switches to the Infrared Sensor Boards The pictures bellow show how the wires from the safety switches are connected to the IR-boards. RH side girder IR termination board (103011) IR safety RX board. (103008) Safety switch lower step Ramp lock switch. IR termination board (103011) IR safety RX board. (103008) 48

49 LH side girder IR safety TX board. (103009) Ramp motor, power IR safety TX board. (103009) IR safety TX board. (103009) Safety switch for steps Red wire to the marked side. 49

50 7.3 Wiring of push buttons and emergency Stop Speaker Platform up Platform down Emergency Stop Button Background light Platform up Emergency Stop Speaker Emergency Stop (GND) Background light Platform down Emergency Stop Button

51 7.4 Safety Pressure Plates Below all steps and below the two girders, pressure plates are connected to safety micro switches. This minimises the risk of getting squeezed below the steps. The pressure plate micro switches are connected and work in a normally closed circuit and if activated during downwards motion, the staircase/lifting platform will stop and move approx. 5 cm upwards. Screws Safety Pressure Plate The safety pressure plates are attached with two screws each. 51

52 7.5 Audible Alarms If speak is installed on the lift this will be activated in the event of an alarm. Otherwise an alarm tone will sound. Speak Activity/warning Opening The vertical safety barrier is opening. Closing The vertical safety barrier is closing. Overload alarm The platform is overloaded. _ _ Battery fault the lift cannot be used The battery has a fault. Inadequate power supply (please see section 5 Technical Specifications). _ _ Alarm something is under the lift Alarm something is on the lift Remove the object under the lift which is preventing downward movement. Change from platform to staircase is not possible because someone/something is on the platform. _ _ _ _ Ding Ding Ding Arriving at top/bottom level. Ding Ding Ding The lift has become a staircase. Warning automatic operation A warning that the lift has to become a staircase. BEEP-BEEP-BEEP The lift is in the process of becoming a staircase. Emergency stop pressed The red emergency stop button has been pressed in. This must be released in order that the lift can function again. The lift is locked The lift is locked with a key switch. Battery warning Low battery level. Power supply is interrupted connect or press emergency stop Connect to a power supply or activate emergency stop in order to power off the lift. Inspection due Call your service technician: High tone followed a deeper tone Low tone followed by higher tone Identical tones (3 off) 52

53 7.6 Automatic Ramp/Roll-off Protection Ramp part numbers Lifting platform Ramp types Pipe for ramp Width steps >120mm steps >140mm steps >175mm Indoor Outdoor 700 mm mm mm mm The automatic ramp/roll-off protection is driven by an electric motor inside the steel tube. The motor also drives the mechanical lock inside the tube. The lock ensures that no one or nothing rolls off the lifting platform during motion. Maintenance/Repair/Replacement: 1. Unscrew the two screws holding the mounting bracket (A) for the ramp tube, and remove gently. Beware of the wires connecting to the motor! 2. Gently pull out the lock assembly from the tube (B & F). If the lock pawl (F) is out, push it in with a finger. If the lock assembly is tight, use a screw to retract it from the tube. The lock pawl is spring loaded - be careful! 3. Gently pull out the cam disc and spring from the tube (C). 4. Unscrew the screw holding the motor flange (D). 5. Pull out the motor assembly. Be careful with the cable for the motor! 6. When attaching the lock assembly, the lock pawl (F) should point towards the micro switch (G). 7. Micro switch for ramp lock. 53

54 7.7 Automatic Door (optional) An automatic door can be delivered as an add-on solution. It can be fitted on the upper level to an existing FlexStep V2. The door can be delivered as left hand- or right hand side mounted. 1. The bracket for door actuator is attached to the wall profile and upper landing floor 2. The door contact is attached to the wall profile and upper landing floor opposite the bracket for door actuator. 54

55 3. The door can now be fixed 4. The height of the door can be adjusted to fit the electronic switch on the other side of the door by means of the two bolts holding the top bracket. 55

56 5. Connect the door to the actuator by using the supplied metal clip fitting. The door can be adjusted in the closing direction by loosening the nut. Then turn the head of the actuator to the desired position and tighten the nut. It is of utmost importance that the door is adjusted carefully so that it will activate the two electronic contact pins correctly. 56

57 7.7.1 Connecting to Control Unit Remove the cover plate and approach the bottom rail. Connect cables from door actuator and door contact to connecting board on bottom rail. Door actuator Door contact Cable from door contact brown/yellow Cable from door actuator black/brown 57

58 7.7.2 Unlocking Door in case of Emergency In case of emergency/malfunction: Relish the folding spring bolt. Pull the spring out from the shaft of the clevis, using a suitable tool, screwdriver, ruler, bottle-opener, etc. From outside, you can approach the lower side. Spring is relased. When the spring is relished pull out the bolt. 58

59 8 Disassemble the FlexStep V2 8.1 Place the FlexStep V2 on a plane surface Use a table, or place the Flexsep V2 on the floor. It is important that the steps and girders are in the same level, to ensure that the wires won t be cut when the steps are loosened from the girders (see more at 8.3). Table or plane surface 59

60 8.2 Disconnecting the wires Disconnect the following wires from the master control board, RH side mounted. Disconnect wires from actuators Disconnect wires from actuators Disconnect wire from control panel Disconnect wire from IR sensors Disconnect the following wires from connectors: Disconnect the power cable for the SLAVE actuator (1,2,3) from connector 60

61 Disconnect Hall sensor actuator wires for the SLAVE actuator (H2) from connector X9 (1, 4 & 6) Control board type : Control board type : Disconnect control panel wires from connector (only on the primary side) Disconnect Hall sensor actuator wires for the SLAVE actuator (H1) from connector X8 (1,2,3,4) Control board type : Control board type : Repeat on the LH side Control Board

62 8.3 Removing the wires Remove the step inserts on the lower step, upper step and step with control panel, for easy access to the wires. Pull the disconnected wires through the bushings on the steps. RH side girder 1. Actuator 2. Control Panel 3. IR Board Left hand girder 1. IR Board 2. Safety Switch Remove cable binders where necessary 62

63 8.4 Circlips for steps Remove the circlips and washers from the two girders on all steps. Carefully remove the girders from the steps, while taking care of the wires. Please note it is important to hold the steps in fixed position to avoid the wires to be cut when the girders are removed. Circlips 8.5 Screws for handrails Remove all the M5 screws at the handrails and remove the handrails. When the screws are removed, be careful to keep the steps and girder in fixed position to avoid the wires to be cut. Now you can easily move the FlexStep V2 parts to the desired installation site. M5 screws 63

64 9 Assemble the steps 9.1 Mounting the girders Place the steps in the correct position ( ) and place the two girders near by the steps (app cm from the steps). Make sure that the right hand side girder is at the right hand side, (PCB s are always on the outer side). First assemble the handrails. Push the girder towards the steps and on to the shafts. Place the plastic spacers on the shafts. Mount the circlips on the shafts. Now put all the wires through the holes of the bushings. M5 screws IMPORTANT! Circlip Plastic washer When both girders have been mounted, make sure that all the wires are able to move freely in the holes (Not squeezed). 64

65 9.2 Connecting the wires Left hand side 1 Pull flat wire and blue wires out through upper step shaft and connect to IR Safety TX board (103009). 2 Pull black wire from secondary slave actuator in through upper step shaft for connection to control board ( or ). 3 Mount wires to girders with cable binders. Right hand side 1 Pull flat wire out through upper step shaft and connect to IR Safety RX board (103008). 2 Pull black wire from primary slave actuator and grey wire from control panel in through upper step shaft for connection to control board ( or ). 3 Mount wires to girders with cable binders Pull the wires from the actuators up behind the Control Board and reconnect the wires to the connectors as illustrated below: Wires for Actuator (Connector X4 ) Black (slave = H2) 2. Brown (slave = H2) 3. Red (slave = H2) 4. Black (master = H1) 5. Brown (master = H1) 6. Red (master = H1) Mount connectors from actuator wires to control board ( or ) 65

66 Wires for Actuator (connector X9) Control board type Green H2 (Slave) 2. Green H1 (Master) 3. Red H1 (Master) 4. Brown H2 (Slave) 5. Brown H1 (Master) 6. Blue H2 (Slave) 7. Blue H1 (Master) Mount connectors from actuator wires to control board (102352). Wires for Actuator (connector X8) Control board type Yellow H2 (Slave) 2. Orange H2 (Slave) 3. Black H2 (Slave) 4. Red H2 (Slave) 5. Yellow H1 (Master) 6. Orange H1 (Master) 7. Black H1 (Master) Mount connectors from actuator wires to control board (102352). 66

67 Wires for Actuator (connector X9) Control board type Black U 2. Brown +5V 3. Red Vss 4. Orange V 5. Yellow W 6. Green StG 7. Blue Stop Sw Mount connectors from actuator wires to control board (103482). Wires for Actuator (connector X8) Control board type Black U 2. Brown +5V 3. Red Vss 4. Orange V 5. Yellow W 6. Green StG 7. Blue Stop Sw Mount connectors from actuator wires to control board (103482). 67

68 Pull the wire from the Control Panel up in front of the Control Board ( or ) and reconnect the wires to the connector as illustrated below. Wires for Control Panel Red Light Pink/Grey Aux 2 3. Red/Blue (NB) Aux 1 4. Black Light neg 5. Purple Alarm button 6. Yellow Down button 7. Grey Up button 8. White EMS + 9. Blue VSS 10. Pink EMS 11. Green speaker 12. Brown speaker Mount connector from control panel wires to control board (102352) 9.3 Check list When everything is done, please make sure that everything is working correctly using the check list below: Make sure no wires are squeezed. All switches on pressure plates. (2 on each step) All girder safety plates activates IR Stairs. All IR PCB must be checked individually. Green LED s are ON. Check the emergency stop. Maneuvering the FlexStep V2 with the up and down buttons. 68

69 10 Actuator replacement 10.1 Dismounting Actuator 1. Push lift down button until the platform is positioned at lower landing. 2. Set the system into service mode (please see section 6.1). When the system is in service mode, it is possible to run actuators separately. 3. Dismount E-wire from RH wall profile. (please see section 6.2). 4. Disconnect the cable for the actuator you need to replace on the control unit. Now the lift is travelling on 3 actuators (please see section 6.2). 69

70 5. Travel the platform to app. 900 mm lifting height on 3 actuators. 900 mm 6. Unscrew one of the screws holding the actuator under the step. 7. Hang the helping hook on the shaft between the girder and the step. 70

71 8. Carefully unscrew the second screw holding the actuator under the step. Support under the actuator with the second hand. Be careful it is heavy! 9. Lower the actuator and let it hang on the hook in one of the holes on the mounting angel. 10. Support the actuator between the balustrade with the hand to keep it from tilting. Disconnect the two connectors from the top of the actuator using e.g. a screw driver. 11. Support the actuator under the bottom by hand and remove the helping hook. Carefully remove the actuator, by pulling it down between girder and step. Be careful it is heavy! 71

72 10.2 Replacing spindle unit 1. Release the top of the spindle unit from the outer actuator tube. Pull the rest of the assembled spindle unit out from the outer actuator tube. Use a screw driver or similar to bend the sheet metal locks. 2. Release the top of the spindle unit from the middle actuator tube. Use a screw driver or similar to bend the sheet metal locks. 3. Unscrew the three screws holding the spindle unit to the inner actuator tube. 72

73 4. Pull the spindle unit out from the inner actuator tube. 5. Actuator disassembled 6. Mount the new spindle unit and assemble the actuator tubes. Please be careful not to damage gliders when pushing actuator tubes together. 73

74 10.3 Mounting Actuator 1. Before mounting the actuator on the step, be sure to turn it with the widest gap on the top pointing away from the girder. Wide gap Narrow gap 2. Glide the actuator up between the girder and the step. 74

75 3. Hang the actuator on the hook in one of the holes on the mounting angel. 4. Connect the cable to the actuator and carefully slide the actuator up between the balustrade. Be careful not to squeeze the cables. Press the actuator up against the step, remove the hook and mount the screws. 5. Remount E-wire to RH wall profile and connect the cable from the actuator to the control unit. 75

76 11 Enclosures 11.1 Liftup Control Software In the FlexStep V2 Programming Software the virtual Top Stop can be adjusted. The screen shows the settings for the two actuators connected to one control board. Adjust the actuators in pairs, i.e. two Masters or Two Slaves. All values must be identical for all actuators. 76

77 Electrical Diagram #1 77

78 11.2 Electrical Diagram #2 78

79 11.3 Pull Force Recommended strength of screw attachment when installing wall profiles Screws attached to the building must withstand a Pull Force not less than 0.5 kn each. (See next page forexamples of screw attachments) Minimum three screws must be used for each Wall Profile. Note: If the strength of screw, attachment is validated by test, minimum withdrawal strength is 1.5 kn. 79

80 Factor of Safety > 3 80

81 81