TERRY HARMONY 2 Series Installation Instructions Manual Download Page 1

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HARMONY Series 2

HOMELIFT

by Terry Group Ltd

Document Number:

XH00200

Issue:

Date:

23/01/12

This installation manual is to be left on site behind a cover panel.

The test certificate, once filled in, must be returned to office.

Installation Instructions

ORIGINAL INSTRUCTIONS

Summary of Contents for HARMONY 2 Series

Page 1: ...Group Ltd Document Number XH00200 Issue D Date 23 01 12 This installation manual is to be left on site behind a cover panel The test certificate once filled in must be returned to office Installation...

Page 2: ...on 28 Trailing Cable Installation at the Powerpack end 28 Trailing Cable Installation at the Control Tube end 29 Ram Installation Preparation bleed nipple cap removal 29 Ram Installation 30 Sling Inst...

Page 3: ...ayout Diagram 73 Function of fuses on Sling PCB 74 Function of LED s on Sling PCB 74 CE1654 PCB Layout Detail Drawing 75 Circuit Diagram Section 77 Wiring Diagram 1 Harmony v2 W C Lift Wiring to P Pac...

Page 4: ...e Work together but make sure that only one person gives clear unhurried instructions x Use protection for hands and feet and protective clothing where necessary x Plywood board should be used to cove...

Page 5: ...H DOWNWARDS 4 SECURED POSITION REMEMBER TO REMOVE THE SCOTCH BEFORE OPERATING THE LIFT NORMALLY 2 HOOK THE SAFETY SCOTCH INTO THE HOLE Important Before any work is carried out underneath the lift the...

Page 6: ...Harmony Series 2 Homelift XH00200 Issue D Page 6 of 106...

Page 7: ...Document to be signed and returned with test certificates ACCESS TO AUTHORISED PERSONNEL ONLY I confirm that I have been informed of the nature of work being undertaken and that due to danger of inju...

Page 8: ...Harmony Series 2 Homelift XH00200 Issue D Page 8 of 106...

Page 9: ...Document to be signed and returned with test certificates ACCESS TO AUTHORISED PERSONNEL ONLY I confirm that I have been informed of the nature of work being undertaken and that due to danger of inju...

Page 10: ...Harmony Series 2 Homelift XH00200 Issue D Page 10 of 106...

Page 11: ...ise Charger circuit The battery is charged by an internal constant voltage battery charger integral to the CE966 board located within the power pack housing Up anti weld circuit The function of this c...

Page 12: ...he lift o Do the joists run parallel to the sides of the lift o If not is the lift base plate directly above a joist o Confirm that the floor where the guide base plate is to be fixed is not springy x...

Page 13: ...STANDARD CAR 1290mm 5 0 910mm LONGER CAR 1490mm 5 0 910mm WIDER CAR 1290mm 5 0 1045mm LONGER WIDER CAR 1490mm 5 0 1045mm A A B B SECTION B B SECTION A A 50 On the back face the aperture must be 50mm...

Page 14: ...h space for the tacfire board Refer to aperture liner INSTALLATION DIAGRAMS FIGS 2 3 and 4 STAGE 1of 2 Installation procedure FIG 2 3 1 The lower frame must be pushed up into the lower aperture openin...

Page 15: ...upper liner is packed up level if necessary Note Do not force either frame into place as this may cause running clearance problems as the carriage travels through the aperture STAGE 2of 2 Installatio...

Page 16: ...e 1 FIG 2 Joist SIDE ELEVATION SECTION DETAIL 6mm Tacfire to be sandwiched between back joist and back angle Retainer Plates Joist Lower Frame Back Angle END ELEVATION SECTION DETAIL Holes A Push fram...

Page 17: ...200 Issue D Page 17 of 106 Aperture Trim Installation Stage 2 Temporarily locate these holes while obtaining lower hole position Joining filler plate LH14022 SIDE ELEVATION FIG 4 Detail A END ELEVATIO...

Page 18: ...Harmony Series 2 Homelift XH00200 Issue D Page 18 of 106 FIG 5 Harmony Lift Loading Diagram...

Page 19: ...of the power pack casing It should be noted that it is sometimes easier to drill the hole in the wall before positioning the lift guides The hole should be lined with 1 1 4 waste pipe The power pack...

Page 20: ...m holes offset diagonally to each other through the trapdoor aperture liner fins as shown and into each of the guides It is recommended that these holes be drilled a minimum of 30mm from rear of guide...

Page 21: ...to upper guide installation 1 With care drop the bottom lateral roller into the RH lower guide 2 Clamp the RHS top axle and the top lateral roller to the guide in a suitable position that will be abo...

Page 22: ...x There will always be a guide join above and below the aperture x Join below aperture needs to be braced back to wall Intermediate Guide Installation Long Sling ONLY Long Sling Lower Guide Brace Kit...

Page 23: ...ed x If floor to floor is 3020mm STD Sling or 3650mm Long Sling cut excess length off TOP of lower tray 1 Fit middle control tube tray LHG2023 Ledge Detail MIDDLE TRAY Ledge locates on aperture Use re...

Page 24: ...ng Sling and middle control tube LHG2025 Note This is just to check everything fits these covers will need to be removed again when installing the trailing cables Lower Tube Lower Control Tube Tray Sl...

Page 25: ...e ceiling to the top of the guides 2 Fix upper and lower guides using fish plate cross bar Upper Guide Keep a 10mm gap between guides and ceiling Cover Aperture Trapdoor RH Profile Trim with Plunger U...

Page 26: ...ossible Standard Kit LH9164 Wider Kit LH9191 Use two M6 x 20 csk screws washers and nyloc nuts to fix each side of the cross bar to the guides Use wall brackets fasteners in kit to fix to the wall Min...

Page 27: ...FIG 7 1 Hole 12mm x 60mm 1 Hole 5 8 x 16mm Recess for bolt head Lock 2 nuts together 1 Hole 12mm x 60mm 1 5 1 3 6 4 3 4 Nutsert within cross bar No DESCRIPTION PART No 1 Part of Coach Screw Plug Kit C...

Page 28: ...r TUBE slots into tray Upper TRAY use pilot holes in side of tray to drill 3mm holes in tube Fix with 1 8 x rivets CF472 as it will never need to be removed For full wiring details see Wiring Diagram...

Page 29: ...e cables leading to powerpack out over rear of spreader plate at bottom of lower control tube tray Cable tie to spreader plate where necessary x Taking care to avoid cables refit control tubes 1 Attac...

Page 30: ...he banjo block is at a slight angle approx 25 so that the cables attached to the pressure switch will be contained inside the catch tank cover 5 Slot the ram clamp end plates into the ram clamp bracke...

Page 31: ...in guide Carefully fit collar inside head of ram and using hot wire kit raise ram to locate fastening ram bolt Fit bolt through ram and plates Secure with nyloc nut BE VERY CAREFUL 3 Feed the ends of...

Page 32: ...ower bleed port on the side of the ram The end of the bleed pipe should be held over a can to catch any fluid bleeding from the cylinder 4 Run the powerpack using the special control hand set supplied...

Page 33: ...ensure it sits flush down into the liner during set up 1 Remove roller arrangement from front of trapdoor leg 2 Feed trapdoor leg through cut out in trapdoor panel dropping the four holes in trapdoor...

Page 34: ...Red Rod Red Rod Installing the Control Mechanism Linking Rod Control mechanism linking rod is painted red Two different lengths standard long sling 1 Navigate rod past middle roller and insert bottom...

Page 35: ...the studs need to be fixed to the floor in an upright position as illustrated in figure B It is CRITICAL that each screw is tightened with the shakeproof washer hard up against the mating clinch nut...

Page 36: ...les slots with the floor as shown and slot the two parts together Nuts should be pre assembled with enough gaps to be able to slide the car sides on Once assembled pull the hockey stick shaped plunger...

Page 37: ...tations will conflict with the inner panels that are later assembled into the carriage 2 Secure carriage axle to brackets at base of sling and use shims provided to set carriage in correct position le...

Page 38: ...no interference with the free movement of the door cables 1 Fix the door to the side hinges and fit the door safe edge cables through the side as shown IMPORTANT NOTE Premature failure will occur if...

Page 39: ...achieve the 5mm free play in the highest corner of the floor that the lift will land on 2 The tilting floor can now be adjusted to drop the front of the car to a position that is suitable for wheelcha...

Page 40: ...ng Special Leg 2395mm Trapdoor Pick Up Kit Details Three different leg lengths dependent on sling type short for low ceiling standard and long Two different RH Trapdoor Profiles one for use with std a...

Page 41: ...the lift to travel down past the Underpan After this time the safe edge is brought back into the circuit thus breaking the DOWN signal TO ADJUST THE CARRIAGE UPWARDS For adjusting the carriage upward...

Page 42: ...ect the wires as per lettered ends 3 With Car at Lowest Level and Door Closed check that the following applies Door Lock is Closed Emergency Circuit is OK x Green LED s Upper Yellow LED should be ON U...

Page 43: ...654 board If pulled this cord will remove TB17 connector from the circuit thus breaking the creep circuit to the CE1654 board preventing the lift from travelling The cord can be removed following full...

Page 44: ...oor enable and u pan o ride should be adjusted so that its roller level is horizontal positioned at the centre of the cut out in the control tube as shown As the car descends this switch should close...

Page 45: ...nished floor covering is fitted on the trap door panel b The trap door panel has been picked up by the car lift the panel approx 200mm above the aperture Loosen the M5 Allen screws to adjust the contr...

Page 46: ...of the CCE1654 board and ensures that a down call cannot be initiated when the lift is travelling upwards The Blue potentiometer on the CE1654 PCB located at position VR5 controls the creep and dump...

Page 47: ...or DOWN safe edge switch Yellow Wires T door UP safe edge switch Brown Wires Only adjust these switches once the carpet flooring has been added to the trapdoor Adjustment can be achieved as illustrate...

Page 48: ...usted so that the roller is horizontal and positioned just off the cam as shown Please note position of Switch To the LHS of the sling there are two cut outs with two switches pre fitted to the top cu...

Page 49: ...Panel Installation Procedure within this manual for guidelines on how to fit the top safe edge cover There are two switch assemblies at the top of the sling The LHS switch assembly is shown here Deta...

Page 50: ...just as the door beak is entering the latch then increase the override potentiometer to increase the length of time the controller overrides the close limit switch This is to ensure the door is firmly...

Page 51: ...witch made The automatic door closure unit is not fitted to a lift with a manual door however the door proving switch is still utilised The door proving switch needs to be installed so that when the d...

Page 52: ...Harmony Series 2 Homelift XH00200 Issue D Page 52 of 106...

Page 53: ...nd clamp just below lower liner Place lower lateral roller Switch assembly and mid sling roller at bottom of guide see manual for order of fit Be careful not to damage switch assembly when installing...

Page 54: ...fit the under pan and profile trim Adjust the ram plates Lower the lift manually and tilt the floor if necessary May need to adjust Ram plates again Set the Underpan switch assemblies x 4 Fit the sli...

Page 55: ...lign guides if necessary to align the door Fit the cover over the trapdoor leg on the top of the trapdoor Fit the intercavity guard cat flap With the lift at the top pull the red rod down with pliers...

Page 56: ...Harmony Series 2 Homelift XH00200 Issue D Page 56 of 106...

Page 57: ...load kg Location of hydraulic drive unit Rated speed m s Description of lift Lift with partially enclosed car and no enclosure Number and type of jack Telescopic ram Type of drive system Direct acting...

Page 58: ...t which the relief valve operated Bar e Confirm that the integrity of the pipe work is acceptable Yes No f Confirm that the relief valve is secured against unauthorised interference Yes No g Confirm t...

Page 59: ...ng down V j Check all fuse ratings Yes No Mechanical Tests a Confirm that the on site load test has been successful Yes No b Confirm that the car clears all obstructions when driven at rated speed Yes...

Page 60: ...that the lift Stops Rides away from obstruction Correct LED goes out and No sticking edges F1 LH Car Top x 3 F2 RH Car Top x 3 F3 Door Top x 3 F4 Sling Top x 2 F5 Door Bottom x 2 F6 Underpan x 4 F7 Tr...

Page 61: ...ts and that the foregoing is a correct report of the result Signatures s Qualifications Address es Date If employed by a company or association give their name and address CERTIFICATE OF ACCEPTANCE BY...

Page 62: ...Harmony Series 2 Homelift XH00200 Issue D Page 62 of 106...

Page 63: ...rectly manufactured wired If Yes please detail below Y N 5 Was the paint quality acceptable If No please detail below Y N 6 Was the specification of the lift as ordered If not please detail below Y N...

Page 64: ...Harmony Series 2 Homelift XH00200 Issue D Page 64 of 106...

Page 65: ...appropriate tests and been issued with a certificate of competence by the Company or one of its authorised agents 1 After installation the installation test certificate must be completed see Test Cer...

Page 66: ...Harmony Series 2 Homelift XH00200 Issue D Page 66 of 106...

Page 67: ...tall Date Set on Install sticker to be affixed on installation Safe edge override switch Underpan Door beak Door actuator close limit switch Bottom stop height ram plate adjustment Trapdoor safe edge...

Page 68: ...Harmony Series 2 Homelift XH00200 Issue D Page 68 of 106...

Page 69: ...No Control locations and operation Safety features Emergency lowering procedures Cleaning procedures Power supply location Contents of Lift operation booklet Contact details I confirm that the engine...

Page 70: ...Harmony Series 2 Homelift XH00200 Issue D Page 70 of 106...

Page 71: ...Note On a Harmony Lift the Emergency Door key must be used to unlock the door even when parked at level 1 Power the door by pressing the top safe edge on the latch side and holding it down fully when...

Page 72: ...emergency circuit will blow when up or down signal is given and the safety circuit board is detecting a fault Function of LED s on Main controller PCB LED 1 RED ON Mains supply OK LED 2 RED ON Onboar...

Page 73: ...t Diagram Numbered circles shown above illustrate LED positions LED and fuse functions are shown on next page TB11 TB13 TB12 TB15 TB16 TB10 TB9 TB8 TB7 TB17 TB6 TB5 TB4 TB3 TB2 TB1 TB14 2 4 1 5 6 3 13...

Page 74: ...the CE966 board to the lifts batteries F5 5A Remote control and Creep Control Power circuit for receivers and Creep control mechanism F6 2A Creep Control Voltage Regulator Protects Creep Controller V...

Page 75: ...Harmony Series 2 Homelift XH00200 Issue D Page 75 of 106 CE1654 PCB Layout Detail Drawing...

Page 76: ...Harmony Series 2 Homelift XH00200 Issue D Page 76 of 106...

Page 77: ...ssue D Page 77 of 106 Circuit Diagram Section x Wiring Diagram 1 Harmony v2 W C Lift Wiring to P Pack Circuit Board CE966 XH00155 d x Wiring Diagram 2 Wiring Cables from W C Door x Wiring Diagram 3 Ha...

Page 78: ...Harmony Series 2 Homelift XH00200 Issue D Page 78 of 106...

Page 79: ...Harmony Series 2 Homelift XH00200 Issue D Page 79 of 106 Wiring Diagram 1 Harmony v2 W C Lift Wiring to P Pack Circ Board CE966 XH00155d...

Page 80: ...Harmony Series 2 Homelift XH00200 Issue D Page 80 of 106...

Page 81: ...Cables From W C Door To Upper Door S Edge To Lower Door S Edge SAFETY NOTE It is vital that up down safety circuits are not crossed over Test door safe edge after doing any work in this area Only use...

Page 82: ...Harmony Series 2 Homelift XH00200 Issue D Page 82 of 106...

Page 83: ...Harmony Series 2 Homelift XH00200 Issue D Page 83 of 106 Wiring Diagram 3 Harmony W C Control PCB 7 core colour...

Page 84: ...Harmony Series 2 Homelift XH00200 Issue D Page 84 of 106...

Page 85: ...Batteries 13 6V ii 5A Fuses on Battery Negative 3 CE966 CB2 Resettable Fuse 4 TB4 CE966 STOP LINK 5 TB3 CE966 Pressure Switch Fitted on Ram 7 TB12 CE1654 EMERGENCY Trailing Cable Orange 8 CE1654 TB9 F...

Page 86: ...ge Yellows 12 CE1654 TB6 Down S Edge Yellows 13 CE1654 TB6 Final Down Blacks 14 CE1654 TB5 Final Down Blacks 15 CE1654 TB12 Down Hold Trailing Cable Yellow 13A Door Bottom Safe Edge 15A CE966 TB5 Trai...

Page 87: ...Brown 19 TB5 Up Safe Edge Brown 20 TB6 Up Safe Edge Brown 21 CE1654 TB12 Up Hold Trailing Cable Brown 19A Door Top Safe Edge 17C TB4 Underpan Up Separation O ride Brown 22 CE966 TB5 Up Hold Trailing...

Page 88: ...ss the Y button 3 times until the yellow LED is ON Whilst the yellow LED is ON press a button on the FOB and the receiver is now programmed To check that the receiver is correctly programmed press but...

Page 89: ...eiling x Deduct a certain amount from the measurement to allow for the small amount of tube that will be within the cap at each end and the cut the tube to the required length x Slot each end of the t...

Page 90: ...two M6 x 20 hex head setscrews washers and spring washers 4 Each tube has two nutserts ready for seat to be fixed at standard height Nutserts can be added on site to the various holes available if he...

Page 91: ...91 of 106 Old Style Seat Design With this design the seat must be fitted to the car side frames BEFORE the inner side panels are fitted 1 Fit bracket to car sides with two M6 x 16 csk screws 2 Fix sea...

Page 92: ...horter The seat will then be set at an angle On the old style seat the bracket height can be adjusted but this becomes a special modification Lap Belt Regardless of design a lap belt kit can be fitted...

Page 93: ...a connector block Blue to White Single Blue to Black At the sling end connect the phone extension box to the sling board connector TB2 Plug the phone in to test and then mount the phone as shown below...

Page 94: ...o underside of centre brace support tube Lower Back Panel Fixed in two places at top to sling middle cross bar Fixed with Velcro on LHS Roller Switch Cover Pre fitted to Lower Back Panel Has Velcro on...

Page 95: ...n top of sling and position carefully in between car sides as shown Fix to top of sling and gusset cover as illustrated 4 Fix LH RH Corner Gusset covers LH shown here Slot cover over centre brace corn...

Page 96: ...he back in Secure at the back using the white screws supplied On the Motor side make sure the door actuator arm protrudes through the slot as shown 8 Fit Emergency Control Cover Hook cover to the Uppe...

Page 97: ...top safe edge plungers which must be pointing forwards and allow to hang freely over Sling Upper Panel Side Safe Edge Cover Attach by slotting over safe edge channels in top of side frames The inner...

Page 98: ...ic Compatibility EMC BS5900 1999 Powered Domestic Lifts Person authorised to compile Technical File Greg Gnyp Terry Group Ltd Longridge Trading Estate Knutsford Cheshire WA16 8PR EC examination carrie...

Page 99: ...d up seat fixings screws 15 Check all aperture liner fixings screws 16 Check carriage fixings are tight 4 across top of centre brace 2 x nuts on axle 17 Check ram fixing bolts x 2 18 Check ram cover f...

Page 100: ...rride 9mm pad h Trapdoor down safe edge override 20mm bar i Door cable conditions With the door actuator side panel removed disconnect the door connecting rod from the detent cassette and power the ac...

Page 101: ...t persons trained in servicing and repair of the product For reliability of the lift the following components should be replaced at the interval indicated Component Interval Trapdoor Pick Up Arm Suspe...

Page 102: ...sides These checks should incorporate the following Lift actually operating and lift can drive away Check there is 20mm follow through after lift stops Check LED Indications functioning correctly Chec...

Page 103: ...Remove sling cover and disconnect the LED connection IN THE POWER PACK UNIT 4 Disconnect the mains lead at TB8 of the top controller board and Megger test using the 250V range at TB8 on the board bet...

Page 104: ...binations and each wire to earth 7 Disconnect wiring to connector TB9 1 red from the control mechanism and Megger test to earth 8 Disconnect the yellow green wires from connector TB4 2 from the trapdo...

Page 105: ...other household waste at the end of their working life Where batteries are marked with the chemical symbols Hg Cd or Pb it indicates that the battery contains mercury cadmium or lead above the referen...

Page 106: ...Harmony Series 2 Homelift XH00200 Issue D Page 106 of 106...

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