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Melody 2 hydraulic MK2 Installation Manual - Issue f

Contents

Safe Working

Weights of Main Parts / Assemblies

Health & Safety Compliance

Fitting safety scotch

Power Pack Isolate Switch

Powerpack / Circuit Box and Cable Runs

Installing Melody 2 Hydraulic Lift

Wiring

Diagnostic Flow Charts

Wiring Diagrams

To conduct an insulation resistance test on the safety circuit

Installation Test Certifi cate for Melody 2 Hyd Lift.

Trade Customer Feedback Questionnaire

Declaration of Conformity

Melody 2 Hyd. lift service points

Melody 2 Hyd. Lift Master Defi nition of Basic Safety Items

Melody 2 hyd 900 x 1400 Platform Details

Melody 2 hyd 1100 x 1400 Platform Details

Lift Disassembly/Safe Disposal of Hazardous Materials

Bulletins

Melody 2 Plinth - No Pins (XB00160B)

Summary of Contents for Melody 2 hydraulic MK2

Page 1: ...Installation Manual Melody 2 MKII Platform Lift Ref ED20400f Date 03 04 2012 Original instructions...

Page 2: ...Wiring Diagrams 34 To conduct an insulation resistance test on the safety circuit 41 Installation Test Certificate for Melody 2 Hyd Lift 43 Trade Customer Feedback Questionnaire 47 Declaration of Con...

Page 3: ...y heavy by yourself Seek assistance Work together but make sure that only one person gives clear unhurried instructions Use protection for hands and feet and additional protective clothing where neces...

Page 4: ...safety scotch can be found within the powerpack and after use must be put back there so it remains with the lift 1 Raise the lift above the safety scotch hole in the LH Gate Post 2 Remove the blankin...

Page 5: ...olate switch has been provided This switch isolates the 12V power to the lifts carriage and disables the use of the call stations re levelling system and gates when turned off The switch contains a re...

Page 6: ...Mechanism Switches are adjusted Terminate the following cables into the control box and pump as follows See wiring diagram in Melody 2Hyd Installation Manual PG25 1 1 x 7 core or 4 core from the upper...

Page 7: ...g the type of lift ordered Upper level plinth 1500mm x 1500mm x 200mm deep Lower landing base level Ducts power supply on a dedicated supply and RCD protected as specified on drawing Ensure the site i...

Page 8: ...both directions and also level the surrounding area that the lifs car will land on Do not fix down yet 3 22mm Diameter holes Jig 2 Drill through two small fixing holes and use screws and plugs to sec...

Page 9: ...top surface to the upper level plinth top surface Distance X For a 2m lift 2000 Distance X calculated length amount to cut off For a 3m lift 3000 Distance X calculated length amount to cut off Now cut...

Page 10: ...nd guide and top cap to the left hand upright If the lift is a 3m model an upper extension box section needs to be fixed onto the top end of each upright This is secured with M8 bolts inside and M8 co...

Page 11: ...the upright This is to allow the trailing cables to exit the upright 6 Upper Right Hand Guide Attach the right hand upper guide upright assembly to the upper level plinth in the same way 7 Lower Right...

Page 12: ...s are facing the correct way 9 Lower Left Hand Guide Fix the guide in place using M10 screws into the uprights Fit the fish plate by applying chemical fixing to the area around the fixing holes in the...

Page 13: ...ot boss before the gate is fitted over it Fit the upper level gate ensuring the glass is on the carriage side flush with the lifting face Secure top hinge bracket securely and align gate beak to gate...

Page 14: ...fitted to the main upright n additional call station free standing post flush or surface mounted can be fitted if specified 12 Lower Call Station Fit the lower call station in a suitable position 1000...

Page 15: ...g this out of the way secure the ram head into position using a M6 x 60 CSK bolt CB097 as pictured After fitting the ram to carriage bracket as above place the anti creep support bracket behind the ca...

Page 16: ...t is in operation This means that a absolute maximum distance of 64mm is allowed between the underside of the top plate and the top of the tapped boss of the chain hanger See diagram 16 Carriage Assem...

Page 17: ...on inside of carriage 17 NOTES 2 x CB303 2 x CZ107 Each side 2 x CB243 Ensure very tight NOTE Box spanner supplied in fixing kit The beak bracket on the carriage is now a floating beak There is no ne...

Page 18: ...ight hand carriage backpillar into the roller assembly in the right hand guide Fit the 2 x M12 bolts through the left hand carriage backpillar into the ram head assembly Tighten all 7 M12 bolts fully...

Page 19: ...eep Switch 2 Latch Switch 3 Top Limit Switch 4 Dump Switch 5 Final Limit Switches Switch Functions 1 Re levels in the UP direction 2 Cancels the Creep Dump Signals 3 Stop Lift if Creep System Disabled...

Page 20: ...creep lug on the left hand gate post when the lift carriage is in the upper level position and the platform is flush with the upper landing Adjust the Gate Activation Switches to achieve full engagem...

Page 21: ...ose of illustration To bring the bracket and the Anti Creep Assembly parallel to the edge of the guide 1 The lift must be built up to the point where the floor frame can be suspended off the floor by...

Page 22: ...ram will resync when the lift is down 21 Connecting the wiring in the powerpack Fit the car control call station and connect wiring blocks see Carriage Wiring Diagram pg34 Turn the mains on and check...

Page 23: ...lift up a minimum of 300mm and then allow it to sink all the way down Replace the cap on this port and then repeat the process on the other port WARNING Keep fingers clear of moving parts and trapping...

Page 24: ...rough D not fitted with any jumper links in this mode of operation the unit will simply toggle on off as the key fob is pressed N B The key fob button must be released before re pressing in order to a...

Page 25: ...e final limit Align the upper gate beak with the latch Adjust if necessary When the lift is at the lower level adjust the lower gate beak with the latch and adjust as necessary Send the lift up and fi...

Page 26: ...outputs of the CE1466 board Similarly the pumps pressure switch and solenoid unit connect to the Control Box via a single 4 core cable Battery Backup for use in a power loss situation is provided by...

Page 27: ...the lifting platform approaches the upper level the Zone switch is enabled providing power to the Upper Gate Enable circuitry and in addition to the Creep Dump Enable circuitry The creep signal is la...

Page 28: ...tform provides the Emergency feed to the Carriage Control Station The same voltage passes through the isolate remote control before passing through the safety circuits within the Upper Level and Carri...

Page 29: ...lation Manual Issue f The following flow chart highlights the route of the power ciruit of the lift Diagnostic Flow Charts Power Supply K s hdK h Z d h Z DKd KEdK hE d WKt Z EWhd W h d Z KZ d ZZ E D d...

Page 30: ...1466 TB5 EMG Trailing Cable 8 TC2 ORANGE Trailing Cable on Car 9 CAR CALL STN FEED 10 CAR CALL STN RETURN 11 LOW GATE FEED Interlock 12 LOW GATE RETURN Interlock 13 CE1654 EMERG Safety Circuit s ZKD d...

Page 31: ...P LIMIT SW RETURN 20 TC1 BROWN Trailing Cable 22 CE1466 TB7 PRESS SW In Out 21 CE1466 TB5 UPHLD Trailing Cable 23 CE966 CB1 TIMER FINAL DOWN RELAYS 30 CE966 CB9 OUTPUT W W W The following flow chart h...

Page 32: ...e lift Numbers shown refer to test point on the ciruit diagrams on pages 30 and 31 of this document All down hold wires are coloured yellow 24 CE1654 DNHLD Safety Circuit 25 U PAN S E FEED 26 U PAN S...

Page 33: ...W Z Z d t D dE d hddKE D dE d hddKE Z Kt d E t hWW Z d E t d Kt d E t Z dhZE s hWW Z d E t Z dhZE t hW Z d Z d K d E d WKt ZW Door Enable Circuit The following flow chart highlights the route of the D...

Page 34: ...34 Melody 2 Hydraulic MK2 Installation Manual Issue f Wiring Diagrams FIG 2 CONTROL BOX WIRING See Figure 5 Page 36 for actual Layout of connectors L O R in the Powerpack L R o...

Page 35: ...35 Melody 2 Hydraulic MK2 Installation Manual Issue f FIG 3 CARRIAGE WIRING...

Page 36: ...36 Melody 2 Hydraulic MK2 Installation Manual Issue f FIG 4 CONTROL SYSTEM COMPLETE WIRING...

Page 37: ...dy 2 Hydraulic MK2 Installation Manual Issue f FIG 5 Interface Panel Layout O R L CALL STATIONS O DOOR LOCKS PRESSURE SW R TRAILING CABLES D CALL STATION DOOR BUTTONS See page 33 for full wiring detai...

Page 38: ...vel and the gate is opened and closed the Carriage Resync Timer is activated After approximetely 3 minutes of inactivity this time outputs a 5V pulse for 1 second on the DNsig of the lift This causes...

Page 39: ...39 Melody 2 Hydraulic MK2 Installation Manual Issue f CARRIAGE CREEP INTERFACE Creep Disable Creep CTL Relay CE1651 PCB...

Page 40: ...40 Melody 2 Hydraulic MK2 Installation Manual Issue f POWER PACK CREEP INTERFACE VOLTAGE INVERTER CE1652...

Page 41: ...ing points on the Lift Carriage a to e and Powerpack f a USE Up Safe Edge b TL N O Top Limit FLTFD and FLTRT Final Limit c DSE Down Safe Edge d TRAILING CABLE TC1 e TRAILING CABLE TC2 f Pressure Switc...

Page 42: ...42 Melody 2 Hydraulic MK2 Installation Manual Issue f...

Page 43: ...ft reference Location Manufacturer Terry Group Ltd Longridge Trading Estate Knutsford Cheshire WA16 8PR Date of Manufacture Length of travel mm Lift serial No Other identification Safe working load 50...

Page 44: ...ath to the carriage and guides exceed 0 1ohms Yes No B 2 1 2 Insulation resistance to earth a Power circuits M b Safety circuits M B 2 1 3 Voltages a Creep Control voltage 8 1V V b Mains voltage at ti...

Page 45: ...atform Yes No B 2 2 2 Safety gear and breaking system if fitted a Does the mechanical safety gear operate effectively Yes No B 2 2 3 Limit switches a Do the terminal stopping switches stop the lifting...

Page 46: ...ptions B 5 DECLARATION A I WE certify that on this lift was installed to the latest installation instructions and thoroughly examined and found to be free from obvious defects and to comply with the r...

Page 47: ...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 7 Was the end user satisfied with the product If not please det...

Page 48: ...48 Melody 2 Hydraulic MK2 Installation Manual Issue f...

Page 49: ...ty EMC BSEN 55011 2007 Electromagnetic Compatibility EMC BSEN 61000 series Electromagnetic Compatibility EMC BS6440 2011 Powered Lifting Platforms for use by Disabled persons Person authorised to comp...

Page 50: ...50 Melody 2 Hydraulic MK2 Installation Manual Issue f...

Page 51: ...asure battery voltage for the lifts full down journey it should not fall below 11 5V Check trailing cable Check no debris around or under the lift Check emergency lowering system Check gate emergency...

Page 52: ...obstructed in each corner Check lift rides away from obstruction in each corner Check no sticking edges in each corner Check carriage piller up safe edge operation x 2 Check lift stops when obstructed...

Page 53: ...eaks are Secure C Check Call Station Operation Check all buttons work when radio isolate or enable is on and that stop works when off D Check Underpan S E Operation x 4 a Check that the lift will stop...

Page 54: ...54 Melody 2 Hydraulic MK2 Installation Manual Issue f...

Page 55: ...55 Melody 2 Hydraulic MK2 Installation Manual Issue f Melody 2 hyd 900 x 1400 Platform Details Ref ED20127e 23 08 2011...

Page 56: ...56 Melody 2 Hydraulic MK2 Installation Manual Issue f Melody 2 hyd 1100 x 1400 Platform Details Ref ED20127e 23 08 2011...

Page 57: ...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 reference le...

Page 58: ...58 Melody 2 Hydraulic MK2 Installation Manual Issue f ED20431 23 08 2011 Bulletins...

Page 59: ...59 Melody 2 Hydraulic MK2 Installation Manual Issue f O O S U _ 00 60 D D W W D D E D E t D D Melody 2 Plinth No Pins XB00160B...

Page 60: ...60 Melody 2 Hydraulic MK2 Installation Manual Issue f...

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TERRY Melody 2 hydraulic MK2, Installation Manual

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