Installation Manual - Lehner Lifttechnik

Installation Manual - Lehner Lifttechnik
Installation Manual
MEGA
Ω
stairlift
A – 4724 Neukirchen/W, Salling 8
Email: office.lehner@gmx.at
Tel: 07278/3514-15, Fax: 07278/3514-12
Mobil: 0664/1612980
OMEGA Installation Manual
Edition Jan. 2010
CONTENTS
OBSERVE THE FOLLOWING POINTS BEFORE INSTALLATION!.................................................................. 2
GENERAL PROCEDURE OF INSTALLTION THE OMEGA: ............................................................................. 3
STEP 1. - INSTALLING THE RAILWAY.............................................................................................................. 4
Wall Mounted Unit: .............................................................................................................................................................4
Pillar Mounted Unit:............................................................................................................................................................5
STEP 2. - INSTALLING THE DRIVE BOX........................................................................................................... 7
Small drive box.....................................................................................................................................................................7
Large drive box (only for long installations) .....................................................................................................................8
STEP 3. INSTALLING THE ROPE SYSTEM....................................................................................................... 9
STEP 4. INSTALLATION OF THE PLATFORM ONTO THE RAIL/ROPE SYSTEM ....................................... 12
STEP 5. TIGHTENING OF THE ROPE .............................................................................................................. 13
STEP 6. CONNECTING THE PLATFORM SWITCHBOARD WITH THE CURRENT COLLECTOR AND THE
ROPE .................................................................................................................................................................. 14
STEP 7. MOUNTING THE MECHANICAL SWITCHES .................................................................................... 15
Mounting of the limit switches in the landing stations....................................................................................................16
Mounting the control cams................................................................................................................................................16
Mounting the ultimate limit switch...................................................................................................................................17
STEP 8. INSTALLING THE ELECTRIC CONTROL BOX AND ELECTRICAL CONNECTIONS .................... 18
STEP 9. TURNING ON THE POWER ................................................................................................................ 23
STEP 10. ADJUSTMENTS................................................................................................................................. 24
Adjustment of the limit switches in the landing stations and the control cams............................................................24
Adjustment of the platform inclination............................................................................................................................25
Adjustment of the loading ramps .....................................................................................................................................27
LAST CHECKS BEFORE USING THE STAIRLIFT .......................................................................................... 28
Omega platform lift
page 1 of 28
OMEGA Installation Manual
Edition Jan. 2010
Observe the following points before installation!
This installation manual is written for all installation teams authorised by Lehner-Lifttechnik.
Installation teams must have a general knowledge in
•
•
working on electric controls.
reading and understanding circuit diagrams and wiring schematics.
In order to save time and energy, it is wise to be properly prepared before installing the
OMEGA-platform lift. The following points will assist in completing the installation efficiently
and on schedule.
•
Have a complete electrical and mechanical tool kit on hand.
•
Have different flexible electrical cables for the electrical connections on hand.
These flexible cables should have the following characteristics:
2x1mm²
4x1mm²
7x0,75mm²
7x1,5mm²
The length on the cables depends on the length of the rail and the position of the
electrical control box.
•
Check the packages for shipping damage and missing parts before bringing the lift
to the site.
•
Open the installation package (which is in the box of the OMEGA lift). Review the
enclosed Installation notes, if supplied. In some cases, additional components must
be brought to the site.
•
Ensure that the main power will be supplied on time.
•
Assemble a team of two technicians to mount the plant.
•
Read the sections for any optional equipment that is supplied with the lift before
beginning the installation.
•
Refer to the tube layout drawing and familiarise yourself with the tube configuration.
Omega platform lift
page 2 of 28
OMEGA Installation Manual
Edition Jan. 2010
General procedure of installtion the Omega:
1. step: Installing / fixing the rail system on pillars or directly to the wall
2. step: Installing / fixing the motor at the end of the rail
3. step: Installing the rope
4. step: Installing the platform onto the rail / rope system
5. step: Tensioning the rope - please make sure that the motor / traction
system is completely installed and tightened
6. step: Connecting the current collector and rope to the platform
switchboard
7. step: Installing the mechanical landing limit switches and external
controls
8. step: Installing the electrical control box and the electrical connections to
the traction system, the landing switches and the external controls.
9. step. Turn on the unit and check the functions.
10. step: When the unit is running the mechanical switches on the landings,
the mounting brackets and the loading ramps have to be adjusted.
Omega platform lift
page 3 of 28
OMEGA Installation Manual
Edition Jan. 2010
Step 1. - Installing the Railway
•
Note: See the following diagrams for some typical mounting arrangements. The
bows between the tubes of the railway can be mounted on pillars or on the wall.
Mounting onto the wall.
Mounting on pillars.
Pillar screwed on the wall
of the staircase.
Mounting on pillars.
Pillars mounted
in the well hole.
Mounting on pillars.
Pillar mounted onto the steps.
Mounting on pillars.
Pillar screwed onto the side of the
stairs.
Wall Mounted Unit:
Omega platform lift
page 4 of 28
OMEGA Installation Manual
Edition Jan. 2010
Place the first tube section onto the wall, in reference to the measures of the first step
shown in the layout drawing. Affix the first section to the wall provisionally and be sure the
bows behind the railway are in plumb line. Take the second tube section and connect it with
the first one. Look at the plumb of the bows, at the measures shown in the layout plan and
fix the rail section provisionally. Continue in this manner until reaching the last section. Then
check all measures between the staircase and the railway. Fix the wall mounted units with
dowels, adhesive anchors, wood screws, etc., depending on the material of the wall.
Pillar Mounted Unit:
Fix the first pillar as shown in the layout plan on
the bottom or on the side of the stairs. It will
now be possible to place the first tube section
and secure it onto the first pillar with a screw
clamp. Adjust the rail into its right position, then
drill a thread M10 into the pillar (the pillar
requires a minimum of 4mm wall thickness).
You can go on with the next rail section and the
next pillars as described above.
Note: The support pillars have the serial letters
stamped on the base. You can find the
corresponding serial letters in the layout
drawing.
Depending on the order, the pillars and
distances can be delivered from LehnerLifttechnik or you can produce them yourself by
referring to our layout drawing. If the lift is supplied with mounting brackets, install them with
the
corresponding
tube
section.
•
Note: It is necessary to distinguish
between brackets (to bridge the
distance to the wall or pillar) and
distances (for unevenness of walls
or mounting tolerances). Brackets
can be ordered from LehnerLifttechnik, but for distances you
must use washers or shims with 50
mm in outside diameter.
•
Drill the mounting holes, starting at
the bottom with Pillar A and working
up the system. In concrete, use a
10 mm diameter masonry bit.
Otherwise use a dowel and drill a
12 mm hole!. When mounting in
wood, use a standard 6 mm wood
drill.
Omega platform lift
page 5 of 28
OMEGA Installation Manual
•
Edition Jan. 2010
Pass the lag bolt (screw materials like lag bolts, nuts, washers, etc., are not included
in Lehner-Lifttechnik delivery-specification) through a washer, and screw it into the
end of a plug anchor. The anchor can then be tapped into position using a small
hammer. Avoid spilling dust into the hole. Do not use plug anchors when mounting
into wood.
Note: Lag bolts used for mounting into concrete are longer than those used for wood.
•
Drill and fasten each hole in turn; this will prevent the tower from shifting.
•
Check each splice for damage and lightly grease
both ends before joining the tube sections.
Fasten the splices with the splice bolts and nuts
provided.
•
Check the clearance dimensions. Ensure that the
actual measurements correspond with the
clearance dimensions on the layout drawing. If
they do not meet the required clearances, have
the lift serial number on hand and call LehnerLifttechnik.
•
Remember: Vertical clearances are measured from the centreline of the tube (this is
also the lower point of the bows on the railway) to the stair nose or to the floor.
•
Installation Tip: The clearance dimension at the lower landing is often 42 mm from
the centreline to the bottom. You can therefore use a shim to support the tube at the
lower landing.
•
Install the rest of the pillars if you are installing a pillar mounted lift. Remember to
check the pillar numbers with those shown on the tube layout drawing.
•
Clean any debris from the inside of the tubes.
•
With the tubes in position, check all splice connections for alignment. Note that the
proper fit of the splices is critical to ensure smooth lift operation. When fixing the lift in
place, smooth out any misalignment using shims behind the mounting struts.
•
On longer lifts some discrepancies may occur. Try to average them out while making
a final check for landing clearances, splice alignment and fit.
•
With the system in place, check that all struts and support pillars are plumb. Use a
water level for this work!
Note that when a lift is supplied with distances that must be located in core-drilled
holes, it will be necessary to mark the holes and remove the tubes for core drilling at
this stage. The lift can then be relocated for installation.
•
Omega platform lift
page 6 of 28
OMEGA Installation Manual
Edition Jan. 2010
Step 2. - Installing the drive box
When the tube system is anchored in place and you are satisfied that everything is as it
should be, mount the drive box.
It is possible to have either a small or a large drive box, depending on the size of the gear.
Small drive box
•
Dismantle the cover as shown on the pictures below.
•
Fix the drive on the end of the railway. Do not close the box yet, the rope and the
electric must be installed first.
Omega platform lift
page 7 of 28
OMEGA Installation Manual
Edition Jan. 2010
Large drive box (only for long installations)
•
Adjust the drive box to the appropriate height in reference to the railway and fasten
the box on the support construction.
•
Move the drive box with the support construction into the correct position and mark
the holes on the bottom for fixing the support.
•
Move the drive box out of the way, drill the mounting holes, and tap the anchor plugs
in place. Now anchor the drive box in place.
•
Mount the gear motor into the drive box.
1.
2.
3.
4.
5.
6.
7.
8.
gear motor
lever for unbreak
hand wheel
upper tube of railway
lower tube of railway
tube for electric installation
(in option only!)
device for tensioning the
rope
slack rope switch
Omega platform lift
page 8 of 28
OMEGA Installation Manual
Edition Jan. 2010
Step 3. Installing the rope system
1.
2.
tension rope
support rope
1
2
•
Lay the complete support rope on the
bottom. Open the rope clamp on the end
and compress the plastic support parts (in
order to avoid any clearance between the
support parts) before fastening the rope
clamp again.
•
Remove the arrestor section (at
the bottom of the system).
•
Then feed in the support (lower)
rope, starting with the splice end
and work your way down from
the drive (top) to the bottom of
the system. Lubricate every
third to fifth plastic part lightly
with special grease! Do not
overgrease!
•
At the bottom, use some clean paper to protect the rope against dust!
Omega platform lift
page 9 of 28
OMEGA Installation Manual
•
Now feed the tension (upper) rope
into the upper tube.
Lubricate each ball lightly as it
goes into the tube.
•
Feed the lower rope through the
arrestor section.
•
Complete the ends of both ropes
with the rope levers shown in the
illustration below.
Edition Jan. 2010
Please note that the end of the lower rope should not got through the hole in the plastic cap,
but look like in the picture shown above or the illustractoin below.
•
Draw back the tension rope while inserting the rope lever into the slot on the lower
side of the upper tube. Install the sliding contact into the tube below the upper rope
lever and pull the support rope up into the upper tube. The sliding contact will then be
positioned between rope levers, as shown in the diagram on this page.
•
Now check the distance between the rope levers. This must be a distance of 90mm.
The rope may be too long. In this case pull the support rope out from the upper tube,
then dismantle the end of the support rope and remove one (or more) plastic support
part. Begin the installation of the support rope once more.
Omega platform lift
page 10 of 28
OMEGA Installation Manual
Omega platform lift
Edition Jan. 2010
page 11 of 28
OMEGA Installation Manual
Edition Jan. 2010
Step 4. Installation of the platform onto the rail/rope system
When the tube system is securely in place, begin
mounting the carriage. Complete the following steps:
•
Bring the carriage to the bottom of the tube
system and unwrap it.
•
Remove the shoulder bolts for the conical
rollers and the rope liners.
•
Carefully lift the carriage into position, guiding
the upper carriage rollers onto the upper tube.
Ensure that the rope levers fit between the bosses of the upper carriage. Be careful
not
to
scratch
the
paint
on
the
tubes.
Note: The carriage weighs about 90 kg, so two
people should install it to ensure safety and avoid
damage.
•
Screw the carriage on the rope levers of the
tension and support rope.
•
Install the conical rollers on the lower tube. Put
some grease on the area of the shoulder bolt on
which the conical rollers will rotate.
•
This diagram on the right side shows the carriage
arrangement on the lower tube.
Omega platform lift
conical
rollers
page 12 of 28
OMEGA Installation Manual
Edition Jan. 2010
Step 5. Tightening of the rope
When the carriage is mounted, the rope must be tensioned.
•
Feed the support rope into the rope clamping system on the upper carriage of the
platform.
Note: Close the cover of
the drive box before
tightening the rope! The
cover of the drive box is the
bearing for the drive
wheel!!!
screw fixed
•
Use the special tool for
rope tightening. Put it on
screw loose
the rope and secure the
rope with a rope clamp
(see illustration). Now you
can turn the thread out of
the main body – the rope will be tightened. If it is too loose, it may short against the
tube.
•
When you have the right tension, clamp the rope in the clamping system and secure
the rope with two rope clamps.
Note:
•
Do not cut the rest of the support rope!!!
Take the plastic tube, put it over the rest of the support rope, turn it to a circle (see
illustration) and fix it with cable binding screws.
Omega platform lift
page 13 of 28
OMEGA Installation Manual
Edition Jan. 2010
Step 6. Connecting the platform switchboard with the current
collector and the rope
The platform communicated via the rail and rope with the main electrical control box and
vice versa. The functions (folding and unfolding of platform and the command from the
platform control) are communicated via low voltage current alterations.
•
Open the upper front side of the carriage by using a
hexagon socket wrench.
Note: Remove the four-pole plug from the socket and put
the special plug for mounting only (delivered from LehnerLifttechnik with the first plant) into the socket. Now you
have bridged key switch and emergency stop.
•
Open the lower front side of the carriage by using a
hexagon socket wrench.
Note:
Dismantle the connection between slider and
platform first!
Caution: The barriers are
without support now – they will
fall down – watch your head!
•
When you dismantle the
lower front side part, fix the
connection between platform
and slider again.
•
Connect
the
carriage
switchboard with the rope
and
sliding
connector.
Connect the black wire for
the rope (S) to the to the
rope clamp after tensioning
of the rope. Then connect
the brown wire for the rail
(R) to the sliding contact
between the platform fixings.
Please see picture of left
side.
•
Do not close the carriage yet. It needs to be open in order to test the power functions
after the installation has been completed.
Omega platform lift
page 14 of 28
OMEGA Installation Manual
Edition Jan. 2010
Step 7. Mounting the mechanical switches
Explanation of the position of the levers for unblocking of the barrier arms and the bypass
switch:
Levers for unblocking of the
barrier arms.
Bypass switch and control
lever
Omega platform lift
page 15 of 28
OMEGA Installation Manual
Edition Jan. 2010
Mounting of the limit switches in the landing stations
•
Mount the plate with the limit switch on the C-profile on the lower tube of the railway.
Mounting the control cams
Note: The controls cams are normally pre-mounted.
Mount the control cams on the profiles between the upper and lower tube of the railway in
the area of the platform stop position.
Note: Adjust the control cams according to the description on the layout drawing. Under
some circumstances, it may be necessary to unclamp both barriers in the lower stop
position. Use two control cams in this situation.
Caution: Do not mount two control cams in the upper stop position (or intermediate stop
positions)!
Omega platform lift
page 16 of 28
OMEGA Installation Manual
Edition Jan. 2010
Mounting the ultimate limit switch
•
Adjust the mechanical limit
block so that it is properly
aligned with the sensor on
the cover of the upper
carriage.
Adjust the ultimate limit
switch and the mechanical
limit block together!
Omega platform lift
page 17 of 28
OMEGA Installation Manual
Edition Jan. 2010
Step 8. Installing the electric control box and electrical
connections
Instruct the person who will be supplying the main power to connect the drive box main
leads. Refer to the electric diagram (and the layout drawing).
Note:
Stairlifts require a 230/400V service.
Caution:
Ensure that the fuses F1/F2 in the control cabinet are deactivated.
Note:
Check the drive direction of the motor after connection to the electric
field!
•
Complete the field wiring in accordance with the electrical drawings supplied in the
installation package. The following pictures show a typical arrangement, but note that
no two systems are the same; you must choose the most effective method of wiring
in your situation.
Omega platform lift
page 18 of 28
OMEGA Installation Manual
Edition Jan. 2010
The electrical control box can be place in any location. Nevertheless the best location is to
place it as close as possible to the upper or the lower end of the rail, because varios cables
lead from the control box to both ends of the rail). If there is an installation pipe on the rail
then the cables can be brought through this pipe from one end to the other. In general the
following electrical connections have to be made on site:
Connection on the lower end of the rail:
• 1 cable with 7 x 0,75 mm² for external hall call at the lower landing station
• 1 cable with 2 x 1 mm² for ultimate down emergency stop switch and safety gear
switch (both switches are connected in series)
• 1 cable with 2 x 1 mm² for lower landing stop switch
Connection on the upper end of the rail:
• 1 cable with 7 x 0,75 mm² for external hall call at the upper landing station
• 1 cable with 7 x 1,5 mm² for the motor connections
• 1 cable with 4 x1 mm² for the ultimate up stop switch and the upper landing stop
switch
• 1 cable with 2 x 1 mm2 for the connection of current collector of the rope (“S”) and
the rail (“R”) (both are located inside the motor box)
General layout of the electrical installations:
Omega platform lift
page 19 of 28
OMEGA Installation Manual
Edition Jan. 2010
Connection scheme for the upper and lower end of the rail:
Connection scheme for an intermediate landing switch:
Omega platform lift
page 20 of 28
OMEGA Installation Manual
Edition Jan. 2010
Connection scheme for hall call stations (external controls):
•
Mount the Call Stations, starting with the Call Station at the lowest landing.
•
When mounting the Call Station, remember to allow enough clearance for the
carriage at the lower landing. The height of each Call Station should be 1 m,
measured from the floor to the centre of the Call Station.
•
Wire the Call Stations according to the electrical drawings.
•
On outdoor lifts, install the hood that is supplied with each Call Station.
•
If the Call Station is supplied with a pedestal, ensure that the pedestal is plumb
before mounting the Call Station.
Omega platform lift
page 21 of 28
OMEGA Installation Manual
Edition Jan. 2010
Connection scheme for the current collector on the traction wheel:
•
Connect the current collector with the “Ra” and “Sa” (“R” and “S” for a manual platform
respectively) connections in the control cabinet as shown in the picture below:
Ra
Sa
Current
collector
Omega platform lift
page 22 of 28
OMEGA Installation Manual
Edition Jan. 2010
Step 9. Turning on the Power
Before turning on the power, check the following items:
•
Ensure that the rope is tensioned properly. If it is too loose, it may short against the
tube.
•
All station boards should be wired and plugged in.
•
All safety and final limit circuits should be wired.
•
The wires to the carriage should be properly connected and the carriage emergency
stop switch should be released.
•
All support pillars (if supplied) should be secure and the strut fasteners should be
snug.
Note: The strut fasteners will be fully tightened once the carriage landing locations
and stair clearances are checked.
Caution:
Do not ride on the lift until all of the fasteners have been fully
tightened!
Now you can switch on the building breaker, the drive box main switch. Look for the two
fuses F1/F2 in the control cabinet to be active.
If you encounter problems, refer to the user handbook or technical documentation.
•
Unfold the platform and run the unit out of the lower landing for a short distance using
the remote control.
Omega platform lift
page 23 of 28
OMEGA Installation Manual
Edition Jan. 2010
Step 10. Adjustments
Adjustment of the limit switches in the landing stations and the control
cams
•
Adjust the position of the plate in reference to the stop position of the platform.
Note: The carriage must touch down slightly on the bottom with the buffers on the lower end
of the backside of the carriage in the lower stop position.
•
In the upper stop position (and also intermediate stop positions) the platform should
be in one line with the landing height.
•
Adjust bolt 1 and bolt 2 now, in reference to the bypass switch
Adjust the control cams according to the scheme below. First always the bypass switch
S
16 has to be activated before the control cams start to unblock the barrier arms. The same
applies for the lower stop. Otherwise the lift will stop when the barrier arms are unblocked,
as thus the switches S14 and/or S15 are pushed and the safety circuit is interrupted!
Run the carriage down to the lower landing again and stop it in the desired loading position.
Note: Allow the carriage to bottom out on the lower landing.
Run the carriage out of the landings and back again. If the lift does not stop in the correct
position, adjust it as necessary.
Omega platform lift
page 24 of 28
OMEGA Installation Manual
Edition Jan. 2010
Adjustment of the platform inclination
•
For the following chapter, first look over the Technical Documentation to know the
definitions of the components.
•
To adjust the platform correctly it is necessary
that all electric installations (limit switch,
emergency limit switch, overspeed governor,
landing controls, electrical connection of the
carriage, etc.) are finished. The front side of
the carriage should be opened!
•
Adjust the platform into horizontal position
first. It is necessary to dismantle the
connection between the platform and the
slider in the carriage again. Use a water level!
•
Counter the adjusting screw with the counter nut
after successful adjustment.
Note: Check the horizontal line of the platform
only in loaded condition!
Caution: Check if both adjusting screws are
supporting the platform!
•
Adjust the slider for platform.
Left and right side, the
slider must a slight
distance to the bearing
support.
Bearing for lifting the
platform
•
Mount the connection between platform and carriage again. The platform slider must
have around 1mm distance to the bearing support on both sides (see illustration).
This can be adjusted by changing the length of the connection between the platform
and the carriage. This is important so that mechanical force of the platform in an
unfolded position is not directly carried forward to the mechanical parts inside the
platform, but rather held by the adjusting screws.
Omega platform lift
page 25 of 28
OMEGA Installation Manual
Edition Jan. 2010
Note: Every time you modify the horizontal adjustment of the platform, it is
necessary to adjust also the slider again!
Move
the
limit
switch
S11p,
until it makes contact with the platform slider.
•
Check the horizontal position of the barriers.
They are pre-adjusted from LehnerLifttechnik already, but it could be necessary
to finish them on site.
•
It is possible to adjust both barriers
separately. Open the screw shown in the
illustration, adjust the barrier and lock the
adjustment with the screw again.
•
Adjust limit switch S11m, so the barriers
are in horizontal position when the
automatic platform is opened.
•
Adjust limit switch S11o, so the platform is
pressed towards the carriage by the
automatic drive when the platform is
closed.
Omega platform lift
Screw for
adjusting
page 26 of 28
OMEGA Installation Manual
Edition Jan. 2010
Adjustment of the loading ramps
•
Be sure the control ramps on the railway and all limit switches are adjusted before
looking for the ramps.
•
Adjust the ramps to achieve a 45 °
angle between the platform and ramp
when the barrier is in horizontal
position. When the barrier is open,
the ramp has to fit to the bottom of
the landing area.
•
During closed and drive position of
the platform, the ramps are used as
safety pads also. To get a secure
switch function it is necessary to
move the fixing of the ramps as far
outside as possible.
Note: Look for a safety switch function, but do not adjust too “secure”! This would
require some service after a few weeks.
bearing for
the bord
•
Move the joint for the ramp as far as
possible into direction of the arrow.
Check if there is enough space to
open and to close the ramp.
Check the loading ramps for proper operation.
Note: Remember to check the travel clearances of the carriage. Do not let the unit
run past the upper limit position.
•
Before you close the carriage, ensure that all screws fixing the limit switches are
secured.
Omega platform lift
page 27 of 28
OMEGA Installation Manual
Edition Jan. 2010
Last checks before using the stairlift
•
With all limit blocks and interlock cams in place, unfold the platform and run the
carriage up to the top of the system and back while checking the travel clearances of
the carriage. If you encounter any problems, have the lift’s serial number on hand and
call Lehner-Lifttechnik.
Caution:
Do not ride on the unit until the fasteners are tightened.
•
When you are satisfied that the lift clearances are correct, tighten all strut fasteners.
•
When the landing is uneven and the loading ramp does not rest properly on the floor,
adjust the ramps on the platform once more.
•
To adjust the ramps, see chapter “Adjusting the platform”.
Omega platform lift
page 28 of 28
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