OTOLIFT MODUL-AIR, Installation Manual

Page 1: ...Otolift Modul Air Installation manual 19 01 2017 ...

Page 2: ...Otolift Stairlifts Postbus 64 2860 AB Bergambacht The Netherlands Tel 31 0 182 352544 E mail info otolift com Internet www otolift com ...

Page 3: ... Assembling seat 41 43 21 Wiring manual swivel 44 45 22 Wiring powered swivel 46 47 23 Power up chair lift 48 50 24 Rail finish assembly 51 53 25 Connect transformer 54 26 Teach in Rail profile 55 56 27 Teach in Extra charge contact 57 28 Powered swivel Teach in drive position 58 59 29 Powered swivel Teach in endpoint 60 30 Powered swivel Teach in Intermidiate stop 61 62 31 Remote control Mounting...

Page 4: ...ied screws and plugs 4 All torque settings needs to be verified with a torque wrench 5 Use of installation tools 403060616 and 200060042 is required for placing drive unit at rail see chapter start 6 Verification tests before use document needs to be verified and signed Save a copy for your own and company account 7 All screws and nuts may only be used one time In case of second life always replac...

Page 5: ...amming chairlift Installation drawing is required before start Torque wrench is required for verifying torque settings according to verification before use document The use of special workbench 908000000 is recommended Installation tools tube 403060616 and cross 200060042 are required for placing drive unit at rail 1 Requirements ...

Page 6: ...upports for more detail Picture shows Rail section OK 252 06 Drawing shows a leg support at position 1 Always mount a Coupler leg support 200060051 Picture shows a Coupler leg support set 200060051 mounted at postion 1 NOTE This parts must always be assembled at position 1 rail coupling Drawing shows the position of the leg support at position 2 Installation drawing explained 1 2 3 4 ...

Page 7: ...cture shows a Leg support set 200060052 mounted at pos x NOTE It is forbidden to place 200060052 at position 1 Drawing shows a BOP support at position 1 Always mount a Coupler BOP support Picture shows Coupler BOP support set 200060055 incl BOP mounted at position 1 Drawing shows no legsupport at rail coupling Mount a coupler plate 2 Installation drawing explained ...

Page 8: ...ight 200060060 Picture shows BOP support set 200060056 incl BOP mounted at pos x NOTE It is forbidden to place 200060056 at position 1 Drawing shows an extra charge contact in an external bend rail section Mounted charge contact 200060061 for external bend Drawing shows an extra charge contact in a straight rail section 2 Installation drawing explained ...

Page 9: ...ing shows an BP250 BP250SP1 verified with measuring tape Length 250mm BP250 verified with measuring tape Length 250mm Drawing shows an LF200 LF200 verified with measuring tape Length 200mm Drawing shows an BP250SP1 2 Installation drawing explained ...

Page 10: ... a standard rail connector Picture shows a mounted rail connector offset Picture shows a mounted rail connector Drawing shows a dropstart as rail start Picture shows a mounted dropstart Drawing shows a rail connector offset 2 Installation drawing explained ...

Page 11: ...al finsh start Picture shows a mounted incline start Drawing shows incline of rail and total length of rail supports Picture shows the correct verified incline of 42 degrees See chapter leg assembling for detail about length Drawing shows an horizontal finish as rail finish or rail start 2 Installation drawing explained ...

Page 12: ...200000040 Mount coupling start assembling in direction of rail start Note position of cable at toothed rack side Place Nuts Note orientation of nuts Assemble set screw with hexagon 5mm tool Do not tighten the set screw Assembly ready for mounting 3 Rail coupling Connect railpart ...

Page 13: ...Otolift Stairlifts Installation manual 13 Assemble set screw with hexagon 5mm tool Tighten both set screws Use a level to make sure that parts are in line 3 Rail coupling ...

Page 14: ...is indicated always mount coupler leg support set 200060051 Postion 3 mount leg support set 200060052 at this location when drawing indicates 3 Postion 4 mount leg support set 200060052 at this location when drawing indicates 4 In case of position 3 4 or higher mount a leg support start counting at position 1 4 Location of leg supports ...

Page 15: ...OTE this parts must always be assembled at position 1 rail coupling Mount coupler Coupler in position Note that fitting has some friction 5 Coupler leg support Place nuts tighten with Hexagon 5mm and socket wrench 10mm Coupler leg support assembled Coupler leg support assembled ...

Page 16: ...support Leg support set 200060052 NOTE It is forbidden to assemble this part at position 1 rail coupling Mount Leg support Leg support in position Place nuts tighten with Hexagon 5mm and socket wrench 10mm Leg support assembled Leg support assembled ...

Page 17: ...er plate set 200060050 NOTE This part must always be assembled at rail coupling Mount coupler Coupler in position Note that fitting has some friction Place nuts tighten with Hexagon 5mm and socket wrench 10mm Coupler plate assembled 7 Coupler plate ...

Page 18: ...coupling Coupler BOP support mounted First position outer bolds m6x20 and start tighten inner m6x16 with hexagon 5 Note that fitting has some friction Mount coupler BOP support tighten with Hexagon 5mm and socket wrench 10mm Mount nuts and tighten with hexagon 5 and socket wrench 10mm Coupler BOP support assembled 8 Coupler BOP support ...

Page 19: ...l 19 BOP support set 200060056 NOTE It is forbidden to assemble this part at position 1 rail coupling BOP support mounted Mount BOP support Mount BOP and tighten with Hexagon 5mm Tighten with Hexagon 5mm BOP support assembled 9 BOP support ...

Page 20: ...end Mount charge point 10 Extra charge point straight Hold the extra charge point at recommended position Holes of chargepoint should be in line with holes rack Mark middle of charge point Chargepoint straight set 200060060 Drill a 8 5mm hole in the tube Hole as close as possible to the railstrip Tighten charge point ...

Page 21: ...tion Mark middle of charge point and holes for drilling into railstrip Drill a 8 5mm hole in the tube Hole as close as possible to the railstrip Remove sharp edges Drill a 4mm hole in the railstrip Tap the holes with thread M5 Guide cable through hole and guide cable to direction of closest railstart end Mount and tighten charge point with hexagon 3 ...

Page 22: ...ation manual 22 Dropstart service set 406060600 406060601 200060057 Buffer not assembled Buffer assembled Mount dropstart do not tighten set screw Mount rail coupling NOTE position of cable Mount m6 screws and nuts 12 Dropstart ...

Page 23: ...allation manual 23 12 Dropstart Tighten with Hexagon 5mm and wrench 10mm Mount 2nd set screw Dropstart assembled Continue with assembling charge contact Tighten both set screws Use a level to make sure that parts are in line ...

Page 24: ...ncline start set 406060602 406060603 403060606 200060058 Mount rail coupling Note position of cable at toothed rack side Buffer not assembled Mount incline start do not tighten set screw Buffer assembled Mount m6 screws and nuts 13 Incline start ...

Page 25: ...loorplate Tighten both set screws Use a level to make sure that parts are in line Tighten screw and nuts with socket wrench 13mm and hexagon 6 Tighten with Hexagon 5mm and socket wrench 10mm Incline start assembled Continue with assembling charge contact 13 Incline start ...

Page 26: ...able 2cablesincase of extrachargpoint Untighten bolds with hexagon 2 5mm Separate movement of plate should be possible Cables correctly positioned Mount chargepoint with hexagon 3mm Chargepoint assembly Cut cables according picture 14 Charge contact ...

Page 27: ...nstallation manual 27 Strip wires and connect red to red black to black Untighten screw Use plier to mount cable shoes Mount coverplate and tighten screw Connect wires to contact block Coverplate mounted 14 Charge contact ...

Page 28: ...Otolift Stairlifts Installation manual 28 Adjust chargepoint pin against thoothed rack Chargepoint correctly adjusted 14 Charge contact ...

Page 29: ...ifts Installation manual 29 Rail support Length is 250 mm Rail support assembled Rail support kit 210000025 Inner rail support Length is 200 mm Leg filler parts 210000081 Rail support parts 15 Rail support assembling ...

Page 30: ...hen set screw with hexagon 4 mm tool First mount legfiller then push in rail connector Mount inner rail support Tighten set screws when length is acording to drawing Length in this picture is 260mm Numbertherailsupport Inthispicturethisisrail supportnumber4 Push in rail connector 15 Rail support assembling ...

Page 31: ...couplerBOPsupportaccordingto drawing Thispictureshowsacouplerlegsupport Every tube will be coupled with a rail coupling Placetheleg support orBOP according to drawing Thispicture showsaleg supportatposition 4 Assemble the bottom as far big as possible Note that each meter rail has a weight of 10 Kg Guide the rail cable through each Rail coupling Note that the cable must always run at the toothed r...

Page 32: ...led and length are according to drawing Tighten all leg support screws with torque wrench set to 15 Nm Place railpart at the staircase and mount legs according to drawing at first assembled railpart Use hexagon 5mm Railpart placed at staircase Tighten coupler plate screws with torque wrench set to 15 Nm 16 Rail assembling ...

Page 33: ...ecide to 1 Assemble second big railpart in the workbench and connect railcable with use of terminals In this manual we choose to continue to assemble at the staircase 2 Continue assembling the rail step by step at the staircase Assemble rail part Mount coupler or coupler rail support Continue assembling rail at staircase 16 Rail assembling ...

Page 34: ...en coupler rail support Tighten all leg support screws with torque wrench set to 15 Nm Mount rail support Tighten coupler plate screws with torque wrench set to 15 Nm Tighten rail coupler set screws with torque wrench set to 25 Nm 16 Rail assembling ...

Page 35: ...ng for information about incline of rail Tighten screws Verify incline and when needed adjust Use this installation drawing for information about distance to wall Tighten set screws of rail supports Dimensionisfromfrontsiderailtowallorobstacle 17 Mount rail to staircase ...

Page 36: ...Otolift Stairlifts Installation manual 36 Mount rail support to staircase verify the level of the rail support Assemble BP covers Covers assembled 17 Mount rail to staircase ...

Page 37: ...ve unit at rail Place installation tube Push until toothed wheel of drive unit is against toothed rack Prepare drive unit for mounting on rail Use8mm socketwrenchtodrivetheliftattherail NOTE verify the position of toothed wheel while driving USEOFPOWEREDTOOLSISFORBIDDEN 18 Mount drive unit ...

Page 38: ...anual 38 Drive unit ready for assembly frontframe Remove cover spring Remove both M8 screws Use hexagon 6 Remove cover spring Remove both M8 Nuts Use socket wrench 13 Remove screw left side cover Use hexagon 3 19 Assembling frontframe ...

Page 39: ...lation manual 39 Take off left side cover Verify if studs are horizontal Remove screw right side cover Use hexagon 3 Remove cover level motor Take off right side cover Use 8mm wrench for adjusting level 19 Assembling frontframe ...

Page 40: ...ion manual 40 Adjust level of studs to horizontal Mount both M8 nuts including rings and tighten Place frontframe Tighten both M8 screws including rings Mount both M8 screws including rings do not tighten 19 Assembling frontframe ...

Page 41: ...y cover Use hexagon 3 Screw set for mounting seat In case of manual seatan extrascrewprovidedformountingspacer Remove battery cover Use hexagon 3 Manual swivel See spacer Seat ready for assembling on frontframe Manual swivel Place spacer 20 Assembling seat ...

Page 42: ...ual and powered swivel Mount the 4 m6 bolds including ring Use hexagon 5 Powered swivel Push in plastic part Manual swivel mount the 5 th screw for tightening spacer Place seat in case of powered swivel watch the position of toothed wheel Guide red labeled sensor cable according to picture ...

Page 43: ...icture outside isolation not in tube Guide blue labeled cable into tube Start with ring terminal Guide white labeled cable into tube Next guide connector X1 C2a and C1a into tube Note that cables may not cross each other 20 Assembling seat Manual swivel Continue at page 44 Powered swivel Continue at page 46 ...

Page 44: ...plastic ring Guide C2b C1b and ring terminals through plastic ring Mount panel connectors C2b and C1b Place plastic ring Place tie wrap according to picture Arround cables which come out tube Do not tighten Tighten Tie wrap Tie wrap must hold the last cm of the outher sheath ...

Page 45: ...ls Use screws which are in screwset mounting seat ConnectX8aandX8b controlfootplateup down X7 should not be connected Connect X1 supply and X3 motor Mount tie wrap according to picture NOTE Do not mount tie wrap to front frame NOTE that cables must be in line no crossings 21 Wiring manual swivel Continue at page 48 ...

Page 46: ...att and Batt to the front Place tie wrap according to picture Arround cables which come out tube Do not tighten Guide cables through plastic ring and place ring Mount panel connectors C2b and C1b Tighten Tie wrap Tie wrap must hold the last cm of the outher sheath 22 Wiring powered swivel ...

Page 47: ...ect Connect X1 supply X2 swivel seat X5 X4 motor swivel and X3 motor footplate Mount ring terminals Use screw which are in screwset mounting seat Connect X7 footplate down X6 seat down and X8a control footplate up down Mount tie wrap according to picture Note that cables must be in line no crossings 22 Wiring powered swivel ...

Page 48: ...8 Nm Use 8mm wrench for adjusting seat to horizontal Verify torque settings of m8 screw 20Nm and nuts 15Nm Place cover back to levelmotor Verify if seat is level horizontal Place batteries connect black to black at left battery red to red at right battery 23 Power up chair lift ...

Page 49: ...tionthat calibrationissuccesfull Place fuse holder like picture and connect NOTE Chair will power up after connecting fuse Operate chairlift away from endpoint with seat in up position Wait 10 seconds after connecting fuse NOTE Do not control lift Do not touch chairlift Verify if LED at tiltsensor is active during movement at a straight railpart 23 Power up chair lift ...

Page 50: ...ghten bolds after adjustment Verify if chairlift stops when endswitch left is activated Connect servicebox NOTE verify if service and teach are not active switch down Set service on and control right Set service on and control left Verify if chairlift stops when endswitch right is activated 23 Power up chair lift ...

Page 51: ...olift Stairlifts Installation manual 51 Rail finish assembly 406060602 406060603 200060006 200060059 Mount m10 set screw Mount rail finish Tighten set screws Mount m6x20 Place nuts 24 Rail finish assembly ...

Page 52: ...ual 52 Tighten with Hexagon 5mm and wrench 10mm Connect cable to charge point Guide rail cable and cut Mount charge point with hexagon 3mm Use plier to mount cable shoes Adjust chargepoint pin against toothed rack 24 Rail finish assembly ...

Page 53: ...t Stairlifts Installation manual 53 Mount cover plate Tighten with Hexagon 6 mm and wrench 13mm Assemble floor plate Hexagon 4mm Mount floor plate to floor Place plate and mount screws 24 Rail finish assembly ...

Page 54: ...n manual 54 Decide where to connect transformer disassemble coverplate Mount coverplate Connect transformer to charge point Brown to red and Blue to black Use tie wrap to prevent pull cable loose after instal 25 Connect transformer ...

Page 55: ...rvice active and left pressed in against left endstop Display will show 11 Drive slowly service left right to verify if travel is OK Release left and switch off service Set speed 1 and 2 when lower speed is required at certain railparts Set the required start speed for teach in speed 1 2 or max ...

Page 56: ...until stopped at right endstop Release right and switch off teach in Switch between 1 2 and max speed when required max 35 times posible Do not change set speed during teach in Lift stopped at endpoint right PCB shows 11 and gives 5 beeps to confirm that teach in is stored 26 Teach in Rail profile ...

Page 57: ... indication for number of programmed extra charge points Switch on service and teach one beep will be heard Set dipswitch 4 to ON when the lift must stop at extra chargepoint when controlled by remote Switch off service and teach Set dipswitch 5 to ON when the lift must stop at extra chargepoint when controlled by armrest 27 Teach in Extra charge contact ...

Page 58: ...lease set screw at upper ring so that ring can rotate freely Use hexagon 2 5 NOTE DO NOT release bottom ring Verify if the upper ring is not activating the switch rol in hole Push button S1 or S2 at PCB to rotate seat in preffered position NOTE Keep hexagon key in the setscrew Tighten setscrew 28 Powered swivel Teach in drive position ...

Page 59: ... Powered swivel Teach in drive position Put down the seat Program the drive position by pushing S1 and S2 both for 3 seconds Release both switches when yellow LED is active The seat will rotate shortly to determine precise swivel switch position ...

Page 60: ...heyellow LEDwilllight up whencontrolled and on endpoint Release both switch when yellow LED is active Rotate the seat to the preffered position by using switches at swivel PCB Repeat upper steps also at other endpoint Only when necessary Push both switches at PCB yellow light will blink 29 Powered swivel Teach in endpoint ...

Page 61: ... jumper JP2 Rotate the seat to the preferred position by using S1 and S2 switches at swivel PCB Place jumper at 6 pole header according to picture Chairlift in preferred intermidiate stop position Push both switches at PCB yellow light will blink 30 Powered swivel TeachinIntermidiatestop ...

Page 62: ...allation manual 62 Release both switch when yellow LED is active Place jumper back at JP2 Verification of positioncanbe donebij controling footplateup downwhenlift isnoton an endpoint 30 Poweredswivel TeachinIntermidiatestop ...

Page 63: ...ation manual 63 Use drilling template for location of screws Place remote and mount bottom screw Tighten all screws Mount the 2 top screws Place battery Head of screw 4mm from surface Place bottom knob 31 Remote control Mounting ...

Page 64: ...te is set for a left handed stairlift Pushupanddownbuttonofremotefor5seconds untilledreceivergoesoff Ledremotecontrolwill blinkasindicationthatteachinwassuccesful Dipswitch 9 at mainboard is ON remote is set for a right handed stairlift Repeat upper steps for each remote max of 10 remotes possible 32 Remote control Teach in ...

Page 65: ...he set 200000261 is required for key fob Repeat upper steps for each key fob max of 30 key fobs possible Push switch at receiver PCB Led will light up Push lock and unlock button for 1 second until led receiver goes off 33 Remote control Key fob ...

Page 66: ...required for pin code Keep button 1 and 3 pressed in for 5 seconds Until ed remote will start blinking Cut the triangle shaped ribs Enter the 4 digit code within 15 seconds Repeat upper steps at all remotes Mount buttons and paste sticker 34 Remote control Pincode ...

Page 67: ...hen controlled by armrest Dipswitch 5 ON Powered swivel dipswitch 2 ON Lift is left handed set remote control for left handed Dipswitch 9 is OFF Lift is right handed set remote control for right handed Dipswitch 9 is ON Chair stop at programmed charge contact when controlled by remote Dipswitch 4 ON 35 Setting dipswitches ...

Page 68: ...0 when chairlift is stopped by armrest switch Poweredswivel verifyifchairliftisstoppedwhen notindrivepositionorwhennotinfoldupposition Display shows 2 when chairlift is stopped by swivel seat switch seat down or footplate position switch Manual swivel verify if the seat locks properly Verify if switch is pressed in when in swivelled position 36 Testing safety switches ...

Page 69: ...ed by switch safety drive unit left Display shows A when chairlift is stopped by switch safety drive unit right Verify the functionality and direction of safety edge footplate right Display shows C when chairlift is stopped by switch safety footplate right Verify the functionality and direction of safety edge drive unit left 36 Testing safety switches ...

Page 70: ...ge footplate left Rotate gripper Display shows d when chairlift is stopped by switch safety footplate left Display should show E08 and Led should be off Verify that lift can not drive when gripper rotated Rotate gripper back to middle neutral position Remove cover OSG 36 Testing safety switches ...

Page 71: ...ee reference Top and bottom screws removed Control the lift 2 times for 15 seconds Lift may not move Display mainboard will show E98 Sensor control board will show E60 Rotate the mountingplate counter clockwise to 7 degree reference Rotate the mountingplate clockwise to 7 degree reference 37 Testing tilt sensor ...

Page 72: ...ing OK after resetting 10 seconds Tilt sensor should light continuesly when running over straight railpart chair moves Control the lift 2 times for 15 seconds Lift may not move Display mainboard will show E98 Sensor control board will show E60 Set mountingplate to 0 degrees Neutral Tighten al screws 37 Testing tilt sensor ...

Page 73: ...rlifts Installation manual 73 Mount backrest Slide back of seat into holes Backrest mounted Tighten front screws at seatplate Tighten back screws at seatplate Pre mount screws in back of seatplate 38 Mounting seat ...

Page 74: ...allation manual 74 Replace OSG cover Slide cover into key hole Mount white nuts Mount battery cover Press battery cover into back slots Front cover remove white nuts 39 Mounting covers Mount and tighten screws Use hexagon 3mm ...

Page 75: ...tallation manual 75 39 Mounting covers Mount left side cover Tighten screw Use hexagon 3mm Cover spring mounted Mount and tighten screws Use hexagon 3mm Mount cover spring Mount right side cover Tighten screw Use hexagon 3mm ...

Page 76: ...ings page 2 Use verification tests before use document for verifying all torque settings page 3 Fill in page 1 of verification tests before use document sign this document and send copy to your manager Use verification tests before use document for verifying all torque settings page 4 40 Verification and completing ...

Page 77: ...hat round edges of wedges point to each other Use small screwdriver for further de assembling cover plate Push out the 6mm pins Disassemble side cover Push out axle Open cover plate by pushing pin against inside cover plate by using a plier Annex A Assembling straight to curved armrest ...

Page 78: ... bearing Carefully disassemble wedges from pins Mount 4mm pins horizontal Carefully mount wedges Notethatroundedgesof wedges pointtoeachother Note that pins may not stick out of the wedges Remove pins Otolift Stairlifts Installation manual Annex A Assembling straight to curved armrest ...

Page 79: ...Put cable behind spacer and mount side cover Mount 6mm pins and axle Wedges mounted for curved armrest Mountcoverplateandpushtreeclipfirmlyintoaxle Otolift Stairlifts Installation manual Annex A Assembling straight to curved armrest ...

Page 80: ...Otolift Stairlifts ...