Installation and Service - Flexstep Compact - UK - Ver4.00

FLEXSTEP COMPACT INSTALLATION & SERVICE
Date 09-09-2008
Installation & Service

FlexStep Compact
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UK v4.00
http://www.salvaescalerasyascensores.es/
http://www.creacionesvilber.com/
Date 09-09-2008
Content
ATTACHMENT TO BUILDING .................................................................................................................... 3 1.1 ASSEMBLY OF VERTICAL RAIL BRACKETS ........................................................................................................ 3 1.2 CABLE WIRING................................................................................................................................................. 5
CONTROL UNIT .............................................................................................................................................. 7 2.1 POSITION OF THE CONTROL UNIT .................................................................................................................... 7 2.2 ............................................................................................................................................................................. 8 2.3 LINEAR ACTUATOR CABLES ............................................................................................................................ 8
SETTING OF VIRTUAL TOP STOP ............................................................................................................. 9 3.1 DEFINITION...................................................................................................................................................... 9 3.2 SETTINGS BY COMPACT PROGRAMMING SOFTWARE ....................................................................................... 9 3.3 SETTING VIRTUAL TOP STOP BY THE SERVICE MODE. ................................................................................. 10
SERVICE MODE ............................................................................................................................................ 10 4.1 HOW TO SET THE SYSTEM INTO SERVICE MODE. ............................................................................................. 10 4.2 FEATURES IN SERVICE MODE. ........................................................................................................................ 11
SAFETY FEATURES ..................................................................................................................................... 12 5.1 INFRARED SENSORS ....................................................................................................................................... 12 5.2 WIRING OF SAFETY SWITCHES TO THE INFRARED SENSORS ............................................................................ 13 5.3 WIRING OF JOYSTICK AND EMERGENCY STOP ................................................................................................ 14 5.4 SAFETY COVER.............................................................................................................................................. 15 5.5 COMPACT MAIN BOARD. ................................................................................................................................ 15 5.5.1 Mainboard Jumpers ............................................................................................................................ 16
6 7
AUTOMATIC RAMP/ROLL-OFF PROTECTION.................................................................................... 18 SAFETY BARRIER (OPTIONAL EQUIPMENT)...................................................................................... 20 7.1 MOUNTING THE SAFETY BARRIER: ................................................................................................................ 20 7.2 DISMANTLING OF THE TIMING BELT SYSTEM: ................................................................................................ 23 7.3 ASSEMBLING THE TIMING BELT AND SAFETY BARRIER PLATE: ..................................................................... 23
8 9 10
ENCLOSURE .................................................................................................................................................. 24 ENCL. 1 ................................................................................................................................................................... 24 ELECTRICAL DIAGRAM #1 ....................................................................................................................... 25 ELECTRICAL DIAGRAM #2 ....................................................................................................................... 26
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UK v4.00
Date 09-09-2008
1 Attachment to building
1.1 Assembly of vertical rail brackets
The FlexStep Compact is delivered almost fully assembled. Only the two vertical rail guides need to be fitted to the adjoining wall to ensure a stable performance a. Move the FlexStep Compact in the approximate position and place the two vertical rail guides over the four vertical rail brackets Vertical rail guides
Vertical rail brackets
b. Move the FlexStep Compact to the correct position facing the adjoining wall. c. Align the two vertical rail guides into vertical position with the top end 560 mm above upper level.
d. Make sure that there is aprox. 10mm space between the floor and the rail guides. The space is for the wires to the actuators.
10mm
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Date 09-09-2008
e. Fix the rail guides in the upper mounting hole with appropriate fixation. *996 mm 560 mm
*Depending on with of the Compact
f.
Place all the cables in the control unit (can be temporarily fitted). See section 2.
g. When all cables have been connected as described; turn on the power supply. h. Elevate the lifting platform to the upper level (see section 3). i. Align the two vertical rail guides exactly into vertical position and mount the rails in the remaining holes with appropriate fixation.
Lower screw fittings
j.
The FlexStep Compact is now mounted and initial test can be activated. operating panels can now be fitted.
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External
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1.2 Cable wiring

Cable wiring is very important when installing the FlexStep Compact. All cables must be placed in a position where they will not interfere with the safety system nor will be damaged by the movement of the FlexStep Compact. Please see photo below for areas where careful attention is required.
Make sure all cables and connectors are fixed in their right position. Otherwise, they may activate the safety system unintentionally.
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Date 09-09-2008
Make sure all cables and connectors are securely fastened in their position.
The cable from the slave actuator may be fixed to the Master actuator to prevent it from being damaged or squeezed.
The Flex cable must be allowed to move freely when the FlexStep Compact moves up or down.
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Date 09-09-2008
2 Control Unit
The Control Unit contains the power supply and the control boards for the FlexStep Compact. All cables are led to the Control Unit as described in section 2.2 - 2.4.
fig. 2.0
2.1 Position of the Control Unit

The Control unit is positioned near to the staircase. Preferably in a room behind the staircase (Fig. 2.1) Alternatively, place the Control Unit to either side of the staircase Important! The Control Unit must be placed in a dry space or a watertight enclosure. The Control Unit is not waterproof and cannot withstand moist or outdoor environment
Side view
Top view
Fig. 2.1
2.2
Control Unit
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Date 09-09-2008
2.3 Linear Actuator cables

Important! The four actuator cables is mounted in pairs; The REAR actuators (near the wall) are "Masters" and the FRONT actuators are "Slaves"
Important! Extension Cable for actuators (optional) (100.419) must be used in pairs of two. (Master-Master or Slave-Slave)
Fig. 2.2
Cables for actuators
REAR/MASTER actuator
FRONT/SLAVE actuator
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3 Setting of Virtual Top Stop

3.1 Definition
The Virtual Top Stop is a variable height adjusted through the installation procedure. The Virtual Top Stop is programmed via the Compact Programming Software and the enclosed serial cable, or by setting the system into service mode.
Switch A: Run or Program mode Switch B: 1= master; 2= slave
Fig. 3.1
3.2 Settings by Compact Programming Software

1. The Compact Programming Software must be installed on a PC (Laptop) with a serial COM output. 2. Place the serial cable in the COM port on the PC and in the Dongle port in the Control Box. 3. Turn power on to the Control Unit. 4. Make sure that the switch A is set to program mode. 5. Set the Switch B towards 1 (master). 6. Start the Compact Programming Software 7. Read the actual settings from the Control Box 8. Adjust the Stroke values to the desired settings, See encl. 1 9. Adjust the Stair time out (auto return) 10. Write the settings to the Master Control board. 11. After writing to master control, set the Switch B towards 2 (slave). 12. Write the settings to the Slave Control board 13. Remove the serial communication cable and plug in the Dongle. Alternative set the switch towards run mode (for testing the settings). 14. Now the system is ready to run, please remember to check that all settings are as expected. Important! After programming the system must be calibrated by pushing the Lift down button.
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Date 09-09-2008
3.3 Setting virtual top stop by the Service mode.

When the system is in service mode (see section 4) it is possible to set the virtual top stops. 1. Set the system into service mode. 2. Push the lift up button (not joystick on staircase) or stairs button, until the desired level is reached. 3. Now push the joystick on staircase UP for 1-2 seconds. 4. If the system is delivered with 2 top stops, you push the lift down button until the desired level for lower top stop (as stair) is reached. 5. Now push the joystick on staircase DOWN for 1-2 seconds. 6. Push the emergency stop to leave service mode, and the system is now ready with the new stop settings.
4 Service mode
4.1 How to set the system into service mode.
To set the system into service mode, do as following: 1. Make sure the is power (90-265Volt) connected to the control box. 2. Move the EasyLift down to the lower level, to make sure that the system is calibrated. 3. Push and release emergency stop button.
4. Use one of the following combinations. Push exact at the same time, and hold the buttons for 20 seconds. After 20 sec. the system starts beeping and the ramp goes up, and the system is in service mode.
a) Lift Down on call station + Lift Down on lifting platform (Joystick down) (Hold for 20 sec.)
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Date 09-09-2008
b) Lift Up on call station + Lift Up on lifting platform (Joystick up) (Hold for 20 sec.)
c) Lift Down + Stairs button on call station. (Hold for 20 sec.)
4.2 Features in service mode.

In service mode, the system ignores all safety features (infrared and pressure plates). The system runs with all connected actuators, without synchronizing the actual heights. When the system is in service mode, there are different kinds of features witch is only possible in service mode, see following: 1. Possible to set virtual top stops. (see section 3.3) 2. Moves all actuators without looking for infrared and pressure safety.* 3. Move all 4 actuators by pushing the lift down or Liftup up the call stations, or only two (the masters) by pushing stairs button.* 4. Move 1-2-3 or 4 actuator by unplugging the ones you dont want to move.* *Handy in installation or in case of changing an actuator. Important! Use only the buttons on the lifting platform (joystick) if you want to program a new virtual stop point.
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Date 09-09-2008
5 Safety Features
5.1 Infrared sensors
Infrared sensors are mounted in the frame outside the edge of each step. This is to minimise the risk of getting squeezed between the steps. Mounting the Safety TX/RX Boards on the frame: Terminals for safety switch Short circuit by soldering, when no switch is mounted see 4.2
Must be connected on the last TX board IR safety TX board. (100.358) IR safety RX board. (100.359)
The Safety IR boards are attached to the frame with self adhesive cushions. TX boards with the LED through the hole and RX boards with the receiver opposite the hole:
Terminals for ramp switch
IR OK (yl) Ramp Lock (gr) Power On (gr)
Terminals for safety switch, left side frame IR safety termination board. (100.360)
NB. Red wire to the marked side.
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5.2 Wiring of safety switches to the infrared sensors

The pictures bellow shows how the wires from the safety switches are connected to the IRboards. Last RX board & termination board Ramp switch. Safety switch lower step
Safety switch left side frame
When no safety switch is connected to board, the terminal must be short circuit (see 4.1)
When a safety switch is connected to board, the terminal must NOT be short circuit (see 4.1)
Safety switch right side frame
Black and red wire from the ramp
Must be short circuit on the last TX board
Last TX board
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5.3 Wiring of joystick and emergency stop
Emergency Stop (GND)
Platform Down (Joystick) GND (Joystick)
Platform Up (Joystick)
Emergency Stop
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5.4 Safety Cover

Below all steps and below the two frames there is a cover plate connected to micro switches. This minimises the risk of getting squeezed below the steps. The safety covers are all connected and if activated during downwards motion, the staircase/lift will stop and move approx 5 cm upwards. Mounting screws
Safety Covers
fig. 4.2 The safety covers are mounted with the two mounting screws (Fig. 4.2)
5.5 Compact main board.

The Compact main board (100.361) is attached to the frame with 4 screws and distance washers: Main board Ramp Motor Ramp Motor + Emergency Stop (GND) Emergency Stop GND (Joystick) Platform Down (Joystick) Platform Up (Joystick) To IR safety TX board
To IR Power safety RX board

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Safety on (Flashing)
IR detection
IR protection Squeeze alarm (Only OK if IR is OK)
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Date 09-09-2008
5.5.1
Mainboard Jumpers
NOTE: For PCB version 100.361_C

JP8_1 JP8_2 JP8_3 JP4 JP5 Ignore all errors. Ignore IR error. Ignore safety switches. Ignore stand by mode. Ignore ramp lock switch.
Important! Remove all jumpers to reactivate all safety functions.
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5.5.2 Mainboard Jumpers
NOTE: For PCB version 100.361_B

JP1 Ignore all errors. JP4 Ignore stand by mode. JP5 Ignore ramp lock switch. JP6 Ignore IR error. JP7 Ignore safety cover switches.
Important! Remove all jumpers to reactivate all safety functions.
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6 Automatic ramp/roll-off protection.

The automatic ramp/roll-off protection is driven by an electric motor inside the steel tube on the lower step. The motor also drives the mechanical lock inside the tube. The lock ensures that no one or nothing rolls off the lift during motion. See Fig. 5.1 for assembly details.
A I B
A. Dismantle the ramp, by removing the 5 screws (A). B. Unscrew the four screws (two on each side) holding the long tube, and remove it gently. Beware of the wires connecting to the motor! C. Now the lock assembly can be gently removed from the tube (C & H). If the lock pawl (H) 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!!. D. Enter a long M4 screw into the cam disc. E. Unscrew the screw holding the motor flange and pull gently in the long M4 screw. Be cautious with the cable to the motor! F. Grove for O-ring gasket. The thickness of the O-ring gasket decides the friction when the ramp is moving down. G. Screw locking the cam disk to the motor shaft. H. When mounting the lock assembly, the lock pawl should point towards the micro switch in the step. I. Adjust the micro switch to be activated when the lock pawl is out. (see picture on next side)
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Microswitch
Screws for ajustment of microswitch
Make sure that the lock powl (H) is out (ramp at upper position)
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7 Safety Barrier (Optional equipment)

The Safety Barrier is an Add-on Module which can be mounted on the FlexStep Compact Steplift. The vertical rail guides for the Safety Barrier is mounted in the rail guides similar to the ones on the FlexStep Compact. On the rails for the safety barrier, will the standard rail guides be mounted.
965mm
For the two rail guides, mark and, if required, drill holes for appropriate plugs in the wall (Distance between rail guides is 996mm). Always leave approximate 10mm* free space underneath the rails for wiring. The total length of the rail guides for the Safety barrier is Split level+965mm 10mm*
Split level
7.1 Mounting the Safety Barrier:

Start by mounting the right hand side rail guide (The one without the motor). The Safety Barrier can now be placed in the right hand side rail guide. The wheels on the Safety Barrier plate fits inside the rail guide:
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Place the left hand side rail guide in its approximate position and mount the Safety Barrier plate on top of the black timing belt brackets.
The left hand side rail guide can now be mounted onto the wall. Be careful to keep the timing belt free from the screws, otherwise the timing belt may be damaged.
Position the motor cable in the free space underneath the rail guide.
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On the left hand side rail guide a switch is mounted in a black plastic enclosure. The switch indicates when the Safety Barrier is in its top position. Attention: The FlexStep Compact will not be allowed to move away from the upper level position until the switch has been activated. Ensure that the switch moves freely and that the Safety Barrier Plate will activate the switch when in its top position.
Black plastic enclosure for the switch.
The timing belt tension can be adjusted by the screw mounted in the top bracket on the left hand side rail guide. Tension the timing belt to be "firm". The correct tension of the timing belt is carried out when the Safety Barrier is connected to power. The timing belt must be tight enough to ensure sufficient grip on the cog but not too tight to overload the drive motor. Attention: If the tension of the belt is too tight, the safety barrier will not work properly and the motor and timing belt will have significantly reduced lifetime.
.
Mount the guide rails for the FlexStep Compact on the guide rails for the Safety Barrier.
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7.2 Dismantling of the timing belt system:

1) Loosen the belt tension screw in the top bracket. 2) Remove the motor cover. 3) Loosen the two screws on the motor bracket. 4) Gently remove the top plastic bracket on the rail guides. 5) Safety Barrier Plate, timing belt and drive motor can now be elevated from the left hand side rail guide.
7.3 Assembling the timing belt and Safety Barrier plate:

1) The timing belt system is positioned in the left hand side rail guide. From below: The drive motor, the black timing belt bracket, the Safety Barrier plate and finally the top bracket, which gently is pressed into the rail guide. 2) Tighten the belt by holding the motor bracket downwards, while tightening the two screws on the motor bracket. 3) Tighten the timing belt with the screw in the top bracket on the rail guide.
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Stroke in mm.
8 Enclosure
Encl. 1
fig. 6.1
In the Compact 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. Field definitions. Switch settings: Switches between Easylift and Compact mode. In the Easylift mot, the system always runs with all 4 actuators, and in Compact mode the system allows the FlexStep to turn into staircase (runs only with master actuators) Stroke (mm): Stroke sets the Virtual top stop. The Upper value indicates the stroke height for the maximum travel of the Lifting platform. See sketch 6.1. The Lower value is only used, when the FlexStep Compact is equipped with two-stop software (optional). Indicates the stroke height where the FlexStep Compact stops when moving to staircase. Maximum current level to each actuator. For normal load (250 kg. on platform) the value is set to 11 Amps, must not exceed 12 Amps, as this may cause damage to the actuators. (may vary depending on specifications) Time interval from No-Action to Auto Return is activated. Normal set to 60 seconds. Download the settings on the screen to the control unit. Read the settings from the control unit to the screen. Shows the actual level of the connected actuators.
Current (A).
Stairs timeout.
Write. Read. Motor 1 & 2

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9 Electrical Diagram #1
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10 Electrical Diagram #2
Pin 2
Pin 2
Pin 3
Pin1
Pin1
Pin 3
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Installation and Service - Flexstep Compact - UK - Ver4.00

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Installation and Service - Flexstep Compact - UK - Ver4.00

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FLEXSTEP COMPACT INSTALLATION & SERVICE

Installation & Service

FLEXSTEP COMPACT INSTALLATION & SERVICE

FLEXSTEP COMPACT INSTALLATION & SERVICE

Vertical rail brackets

FLEXSTEP COMPACT INSTALLATION & SERVICE

*Depending on with of the Compact

Lower screw fittings

FLEXSTEP COMPACT INSTALLATION & SERVICE

1.2 Cable wiring

FLEXSTEP COMPACT INSTALLATION & SERVICE

FLEXSTEP COMPACT INSTALLATION & SERVICE

2.1 Position of the Control Unit

FLEXSTEP COMPACT INSTALLATION & SERVICE

2.3 Linear Actuator cables

Cables for actuators

FLEXSTEP COMPACT INSTALLATION & SERVICE

3 Setting of Virtual Top Stop

Switch A: Run or Program mode Switch B: 1= master; 2= slave

3.2 Settings by Compact Programming Software

FLEXSTEP COMPACT INSTALLATION & SERVICE

3.3 Setting virtual top stop by the Service mode.

FLEXSTEP COMPACT INSTALLATION & SERVICE

c) Lift Down + Stairs button on call station. (Hold for 20 sec.)

4.2 Features in service mode.

FLEXSTEP COMPACT INSTALLATION & SERVICE

Terminals for ramp switch

IR OK (yl) Ramp Lock (gr) Power On (gr)

NB. Red wire to the marked side.

FLEXSTEP COMPACT INSTALLATION & SERVICE

5.2 Wiring of safety switches to the infrared sensors

Safety switch left side frame

Safety switch right side frame

Black and red wire from the ramp

Must be short circuit on the last TX board

FLEXSTEP COMPACT INSTALLATION & SERVICE

5.3 Wiring of joystick and emergency stop

Emergency Stop (GND)

Platform Down (Joystick) GND (Joystick)

FLEXSTEP COMPACT INSTALLATION & SERVICE

5.4 Safety Cover

5.5 Compact main board.

To IR Power safety RX board

IR protection Squeeze alarm (Only OK if IR is OK)

FLEXSTEP COMPACT INSTALLATION & SERVICE

NOTE: For PCB version 100.361_C

Important! Remove all jumpers to reactivate all safety functions.

FLEXSTEP COMPACT INSTALLATION & SERVICE

5.5.2 Mainboard Jumpers

NOTE: For PCB version 100.361_B

Important! Remove all jumpers to reactivate all safety functions.

FLEXSTEP COMPACT INSTALLATION & SERVICE

6 Automatic ramp/roll-off protection.

FLEXSTEP COMPACT INSTALLATION & SERVICE

Screws for ajustment of microswitch

FLEXSTEP COMPACT INSTALLATION & SERVICE

7 Safety Barrier (Optional equipment)

7.1 Mounting the Safety Barrier:

FLEXSTEP COMPACT INSTALLATION & SERVICE

FLEXSTEP COMPACT INSTALLATION & SERVICE

Black plastic enclosure for the switch.

FLEXSTEP COMPACT INSTALLATION & SERVICE