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INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION
1.7

Liftup A/S

Hagensvej 21| DK-9530 Støvring | Denmark |

T:

+45 96 86 30 20 |

M:

[email protected] | www.liftup.dk | CVR DK-1015 3964

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.

2.

3.

Remount the motor to the
wall profile.

Carefully slide
down timing belt,
grey wire and top
mounting bracket.

Make sure the cog on the motor
is in grip with timing belt.

Top mounting
bracket placed
correct in left wall
profile.

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Summary of Contents for FlexStep V2

Page 1: ...Liftup A S Hagensvej 21 DK 9530 Støvring Denmark T 45 9686 3020 M support liftup dk www liftup dk Installation Service Manual FlexStep V2 INSTALLATION SERVICE MANUAL FLEXSTEP V2 UK VERSION 1 7 ...

Page 2: ... vertical safety barrier and testing it 22 2 3 Mounting of FlexStep V2 to Wall Profiles 24 3 Control Unit 27 3 1 Bottom rail 27 3 2 Control Boards 28 3 3 Control Board Jumpers JP1 29 3 4 Control Board LED signals 30 3 5 Control Board Microswitches 31 3 6 ON OFF Switch 32 3 7 Mains outlet 32 4 Call stations 33 4 1 Standard call station wired 33 4 2 Key Operated Call Stations 2 ways 35 4 3 Wireless ...

Page 3: ...ttons and emergency Stop 48 7 4 Safety Pressure Plates 49 7 5 Audible alarms 50 7 6 Automatic ramp roll off protection 51 8 Disassemble the FlexStep V2 52 8 1 Place the FlexStep V2 on a plane surface 52 8 2 Disconnecting the wires 53 8 3 Removing the wires 55 8 4 Circlips for steps 56 8 5 Screws for handrails 56 9 Assemble the steps 57 9 1 Mounting the girders 57 9 2 Connecting the wires 58 9 3 Ch...

Page 4: ...eople 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 Right Hand Side of the lift A Primary Master Actuator B Primary Slave Actuator C Primary Control Unit jumpers are on this side Left Hand Side of the lift E Second...

Page 5: ...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 mo...

Page 6: ...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 ...

Page 7: ...he adjoining wall to ensure a stable performance 2 1 1 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 Make sure the distance between the top ...

Page 8: ...up dk www liftup dk CVR DK 1015 3964 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 ...

Page 9: ... 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 ...

Page 10: ...86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 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 0 ...

Page 11: ...ixing 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 Make sure that the distance between the top of the wall profile and the ...

Page 12: ...p dk www liftup dk CVR DK 1015 3964 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 ...

Page 13: ... 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 7 Remove the cover plate ...

Page 14: ...530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 14 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 ...

Page 15: ... 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 2 3 Loosen two screws and dismount motor 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 Loosen the belt tension screw...

Page 16: ...ming belt to the wall profile with masking tape or similar Pull the timing belt up from the left hand wall profile leaving 20 25 cm hanging outside the wall profile 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 ...

Page 17: ...0 20 M support liftup dk www liftup dk CVR DK 1015 3964 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 2 RH side pin cable binder LH side pin cable binder ...

Page 18: ...6 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 18 3 4 5 Carefully slide the plates for the vertical safety barrier down in the wall profiles Remove pins cable binder in both sides of plates for vertical safety barrier Carefully slide the plates for the vertical safety barrier down towards the bar clamp ...

Page 19: ...4 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 2 3 Remount the motor to the wall profile Carefully slide down timing belt grey wire and top mounting bracket Make sure the cog on the motor is in grip with timing belt Top mounting bracket placed correct in left wall profile ...

Page 20: ...ICE MANUAL FLEXSTEP V2 UK VERSION 1 7 Liftup A S Hagensvej 21 DK 9530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 20 4 5 Remount top cover on the wall profiles in left hand side ...

Page 21: ... 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 2 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 Tighten the timing belt with the screw in the top c...

Page 22: ...up dk www liftup dk CVR DK 1015 3964 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 ...

Page 23: ...agensvej 21 DK 9530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 23 3 Remove the jumper placed on Upper Gate SW 4 Release the emergency button from the FlexStep and push the UP button The Vertical Safety Barrier should now go up ...

Page 24: ...T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 24 2 3 Mounting of FlexStep V2 to Wall Profiles 1 Place the FlexStep V2 30 40 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 ...

Page 25: ...ej 21 DK 9530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 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 ...

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

Page 27: ...each side of the FlexStep V2 3 1 Bottom rail 4 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 Power supply PSU Key From safety barrier switc...

Page 28: ...ced on each side of the FlexStep V2 PRIMARY Control unit 102352 RH side SECONDARY Control unit 102352 LH side IR safety RX boards Actuators cables LH side PCB for Connection box cables Operating panel Primary Control board Actuators cables RH side Battery Power connector Secondary Control board IR safety TX boards Battery CR 1220 Remove covers for control box to access control boards Primary contr...

Page 29: ...eactivate all safety functions Except Ignore GO Jumpers and LED is only valid on PRIMARY control board right hand side Description Action if jumper is ON ONLY on PRIMARY Control Board Under Pan SW Ignore safety switches IR Platform Ignore IR error upper step Lower Gate SW Ignore ramp switch IR Stairs Ignore IR error stairs and girder squeeze protection Upper Gate SW Ignore safety barrier switch Ig...

Page 30: ...rt liftup dk www liftup dk CVR DK 1015 3964 30 3 4 Control Board LED signals Control board 102352 HB Yellow H BRO SUP Yellow H BRO3 SUP Yellow OC H BRO3 Red AC ON Yellow BATT FLOAD Yellow EMS OK Green H BRO ON Green 3V3 Yellow IR Platform Green IR Stairs Green Upper Gate SW Green Lower Gate SW Green Under Pan SW Green 12V Yellow ...

Page 31: ...nder Pan SW Green Safety switches Under pan OK or bypassed by jumper P IR Platform Green IR upper step OK or bypassed by jumper P Lower Gate SW Green Ramp switch OK or bypassed by jumper P IR Stairs Green IR stairs and girder squeeze protection OK or bypassed by jumper P Upper Gate SW Green Safety barrier switch OK or bypassed by jumper P Ignore GO NA Allows auto return and soft stop P 3V3 Yellow ...

Page 32: ... 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 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 ou...

Page 33: ...Step V2 can be delivered with different types of call stations to be mounted on upper level and lower level recommended Find different solutions on www liftup dk 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 Staircas...

Page 34: ...530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 34 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 ...

Page 35: ...agensvej 21 DK 9530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 35 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 ...

Page 36: ...LEXSTEP V2 UK VERSION 1 7 Liftup A S Hagensvej 21 DK 9530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 36 4 3 Wireless Call Stations wall mounted 2 ways Lower Call station Upper Call station ...

Page 37: ...ver has now been erased Return microswitch S4 1 to off 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 1 Ensure that there is power to the system Press the emergency stop and switch off the on o...

Page 38: ... 2 minutes Perform the following within the 2 minutes Press UP UP DOWN DOWN UP DOWN UP DOWN 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 1 Ensure that there is power to the system Press the e...

Page 39: ... dk CVR DK 1015 3964 39 4 5 ON OFF Key switch Optional The FlexStep V2 can be delivered with a key switch to switch off the unit part number 103480 How to connect a standard Liftup key switch is described below Standard key switch Wires mounted to contact in key switch box Wires from key switch mounted on print for connection box Placed on bottom rail ...

Page 40: ...case position According to your order confirmation the lift is tested and set to your specified heights but can be modified if adjustment is needed 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 102352 on the FlexStep V2 RH side o...

Page 41: ... 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 i...

Page 42: ...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 ...

Page 43: ... 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 ...

Page 44: ... 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 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 ...

Page 45: ...ng Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 45 Yellow flashing when IR is OK IR safety TX board 103009 IR safety RX board 103008 Yellow when IR is OK Flashing or constant IR termination board 103011 Yellow flashing when IR is OK Power On yellow Ramp Lock green ...

Page 46: ...iftup dk CVR DK 1015 3964 46 IR safety RX board 103008 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 IR safety RX board 103008 IR termination board 103011 RH side girder Safety switch lower step Ramp lock switch IR termination board 103011 ...

Page 47: ...agensvej 21 DK 9530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 47 LH side girder IR safety TX board 103009 IR safety TX board 103009 IR safety TX board 103009 Safety switch for steps Ramp motor power Red wire to the marked side ...

Page 48: ...6 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 48 7 3 Wiring of push buttons and emergency Stop Emergency Stop Button 100339 Speaker 103083 Background light Platform up Platform down Platform up Speaker Background light Emergency Stop Button 100339 Platform down Emergency Stop GND Emergency Stop ...

Page 49: ...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 The safety pressure plates are attached with two screws each Safet...

Page 50: ...ment _ _ Alarm something is on the lift 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...

Page 51: ...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 moto...

Page 52: ...ww liftup dk CVR DK 1015 3964 52 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 ...

Page 53: ...015 3964 53 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 ...

Page 54: ...w liftup dk CVR DK 1015 3964 54 Disconnect Hall sensor actuator wires for the SLAVE actuator H2 from connector X9 1 4 6 Disconnect control panel wires from connector only on the primary side Disconnect Hall sensor actuator wires for the SLAVE actuator H2 from connector X8 1 2 3 4 Repeat on the LH side Control Board 1 2 3 4 5 6 7 1 2 3 4 5 6 7 ...

Page 55: ... dk CVR DK 1015 3964 55 Left hand girder 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 Remove cable binders where necessary RH side girder 1 Actuator 2 Control Panel 3 IR Board 1 IR Board 2 Safety Switch ...

Page 56: ...he 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 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 ea...

Page 57: ...e steps app 5 10 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 IMPORTANT When both girders have been mounted mak...

Page 58: ...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 102352 3 Mount wires to girders with cable binders Pull the wires from the actuators up behind the Control Board and reconnect the ...

Page 59: ... 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 Wires for Actuator connector X9 1 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 1 2 3 4 5 6...

Page 60: ...eg 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 ...

Page 61: ...www liftup dk CVR DK 1015 3964 61 10 Enclosures 10 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 ...

Page 62: ...INSTALLATION SERVICE MANUAL FLEXSTEP V2 UK VERSION 1 7 Liftup A S Hagensvej 21 DK 9530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 62 Electrical Diagram 1 ...

Page 63: ...INSTALLATION SERVICE MANUAL FLEXSTEP V2 UK VERSION 1 7 Liftup A S Hagensvej 21 DK 9530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 63 10 2 Electrical Diagram 2 ...

Page 64: ... 10 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 ...

Page 65: ...INSTALLATION SERVICE MANUAL FLEXSTEP V2 UK VERSION 1 7 Liftup A S Hagensvej 21 DK 9530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 65 Factor of Safety 3 ...

Page 66: ...INSTALLATION SERVICE MANUAL FLEXSTEP V2 UK VERSION 1 7 Liftup A S Hagensvej 21 DK 9530 Støvring Denmark T 45 96 86 30 20 M support liftup dk www liftup dk CVR DK 1015 3964 66 1 ...

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