Omega - Installation Manual

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A 4724 Neukirchen/W, Salling 8 Tel: 07278/3514-15, Fax: 07278/3514-12Email: [email protected] Mobil: 0664/3526190

Ins ta l la t ion Manual

MEGAs t a i r l i f t

ttp://www.salvaescalerasyascensores.es/ http://www.creacionesvilber.com/


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OMEGA Installation Manual Edition Dec. 2004

Omega platform lift page 1 of 24

CONTENTS

OBSERVE THE FOLLOWING POINTS BEFORE INSTALLATION!......................................2BEGINNING THE INSTALLATION................................................................................................3INSTALLING THE RAILWAY..........................................................................................................3INSTALLING THE DRIVE BOX......................................................................................................7INSTALLING THE ROPE SYSTEM...............................................................................................9MOUNTING THE CARRIAGE.......................................................................................................13INSTALLING THE ELECTRIC AND THE CALL STATIONS .................................................16TURNING ON THE POWER .........................................................................................................18

MOUNTING THE MECHANICAL LIMIT SWITCHES ...............................................................19MOUNTING THE CONTROL CAMS ...........................................................................................20MOUNTING THE ULTIMATE LIMIT SWITCH............................................................................20ADJUSTING THE PLATFORM ....................................................................................................21ADJUSTMENT OF THE LOADING RAMPS..............................................................................23LAST CHECKS BEFORE USING THE STAIRLIFT.................................................................24



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Observe the following points before installation!

This installation manual is written for all installation teams authorised by Lehner-Lifttechnik.

Installation teams must have a general knowledge in

working on electric controls. reading and understanding circuit diagrams and wiring schematics.

In order to save time and energy, it is wise to be properly prepared before installing theOMEGA-platform lift. The following points will assist in completing the installation efficiently andon schedule.

Have a complete tool kit on hand.

Check the packages for shipping damage and missing parts before bringing the lift tothe site.

Open the installation package (which is in the box of the OMEGA lift). Review theenclosed Installation notes, if supplied. In some cases, additional components must bebrought to the site.

Contact the customer and arrange a time for installation. Ensure that the main power will

be supplied on time.

Assemble a team of two technicians to mount the plant.

Inform the customer once you arrive that you will be occupying the stairway, and that youmay need to rope it off.

Read the sections for any optional equipment that is supplied with the lift beforebeginning the installation.



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Beginning the Installation

There may be special installation notes enclosed with your particular lift. Read these

instructions thoroughly before proceeding.

Refer to the tube layout drawing and familiarise yourself with the tube configuration.

Ensure that the main power hook-up will be completed before the end of the installation.

Bring the drive box and the rail parts to their installation location.

Caution: The large drive box is heavy; it weighs approximately 120 kg.

A dolly might be necessary.

Installing the Railway

Note: See the following diagrams for some typical mounting arrangements. The

bows between the tubes of the railway can be mounted on pillars or on the wall.

Mounting onto the wall.

Mounting on pillars. Mounting on pillars.Pillar screwed on the wall Pillars mountedof the staircase. in the well hole.



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Mounting on pillars. Mounting on pillars.Pillar mounted onto the steps. Pillar screwed onto the side of the

stairs.

Wall Mounted Unit: Place the first tube section onto the wall, in reference to themeasures of the first step shown in the layout drawing. Affix the first section to the wallprovisionally and be sure the bows behind the railway are in plumb line. Take the secondtube section and connect it with the first one. Look at the plumb of the bows, at themeasures shown in the layout plan and fix the rail section provisionally. Continue in thismanner until reaching the last section. Then check the measures between the staircaseand the railway. Fix the wall mounted units with dowels, adhesive anchors, wood screws,etc., depending on the material of the wall.

Pillar Mounted Unit: Fix the first pillar as

shown in the layout plan on the bottom oron the side of the stairs. It will now bepossible to place the first tube section andsecure it onto the first pillar with a screwclamp. Adjust the rail into its right position,then drill a thread M10 into the pillar (thepillar requires a minimum of 4mm wallthickness). You can go on with the next railsection and the next pillars as describedabove.

Note: The support pillars have the serialletters stamped on the base. You can findthe corresponding serial letters in thelayout drawing.

Depending on the order, the pillars and distances can be delivered from Lehner-Lifttechnik or you can produce them yourself by referring to our layout drawing. If the lift issupplied with mounting brackets, install them with the corresponding tube section.



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Note: It is necessary to distinguish between brackets (to bridge the distance to the wall

or pillar) and distances (for unevenness of walls or mounting tolerances). Brackets canbe ordered from Lehner-Lifttechnik, but for distances you must use washers or shimswith 50 mm in outside diameter.

Drill the mounting holes, starting at the bottom with Pillar A and working up the system. Agood quality hammer drill is useful when drilling into concrete.

When mounting in concrete, use a 10 mm diameter masonry bit and withdraw the drillperiodically to remove dust from the cutting area. (When using a dowel, drill a 12 mmhole!). When mounting in wood, use a standard 6 mm wood drill.

Pass the lag bolt (screwmaterials like lag bolts, nuts,

washers, etc., are not includedin Lehner-Lifttechnikdelivery-specification) through a washer,and screw it into the end of aplug anchor. The anchor canthen be tapped into positionusing a small hammer. Avoidspilling dust into the hole. Donot use plug anchors whenmounting

into wood.

Note: Lag bolts used for

mounting into concrete are longer thanthose used for wood.

Drill and fasten each hole in turn; this will prevent the tower from shifting.

Check each splice for damage and lightlygrease both ends before joining the tubesections. Fasten the splices with the splice

bolts and nuts provided.

Check the clearance dimensions. Ensure thatthe actual measurements correspond with theclearance dimensions on the layout drawing. Ifthey do not meet the required clearances, have

the lift serial number on hand and call Lehner-

Lifttechnik.

Remember: Vertical clearances are measured from the centreline of the tube (this is

also the lower point of the bows on the railway) to the stair nose or to the floor.



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Installation Tip: The clearance dimension at the lower landing is often 42 mm from the

centreline to the bottom. You can therefore use a shim to support the tube at the lowerlanding.

Install the rest of the pillars if you are installing a pillar mounted lift. Remember to checkthe pillar numbers with those shown on the tube layout drawing.

Clean any debris from the inside of the tubes.

With the tubes in position, check all splice connections for alignment. Note that theproper fit of the splices is critical to ensure smooth lift operation. When fixing the lift inplace, smooth out any misalignment using shims behind the mounting struts.

On longer lifts some discrepancies may occur. Try to average them out while making a

final check for landing clearances, splice alignment and fit.

With the system in place, check that all struts and support pillars are plumb. Use a waterlevel for this work!

Note that when a lift is supplied with distances that must be located in core-drilled holes,it will be necessary to mark the holes and remove the tubes for core drilling at this stage.The lift can then be relocated for installation.



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Installing the drive box

When the tube system is anchored in place and you are satisfied that everything is as it should

be, mount the drive box.

It is possible to have either a small or a large drive box, depending on the size of the gear.

If you are using a small drive box, dismantle the cover as shown on the picturesbelow.

Fix the drive on the railway.

Do not close the box yet, the rope and the electric must be installed first.

Sa

Ra



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If using a large drive box, pay attention to the following instructions.

Adjust the drive box to the appropriate height in reference to the railway and fasten the

box on the support construction.

Move the drive box with the support construction into the correct position and mark theholes on the bottom for fixing the support.

Move the drive box out of the way, drill the mounting holes, and tap the anchor plugs inplace. Now anchor the drive box in place.

Mount the gear motor into the drive box.

1. gear motor2. lever for unbreak3. hand wheel4. upper tube of railway5. lower tube of railway6. tube for electric installation

(in option only!)7. device for tensioning therope

8. slack rope switch



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Installing the rope system

After installing the drive box, move on to the rope.

Note: It is important now to select either a 7 mm rope for short railways or a 9 mm rope

for long railways. You can see the appropriate rope diameter in the technical details onthe layout drawing.

The following instructions are for using a 7mm rope.

Connect the tension rope with the support rope.See illustration below.

1. tension rope2. support rope

3. plastic glide part

Lay the complete support rope on thebottom. Open the rope clamp on the endand compress the plastic support parts (inorder to avoid any clearance between thesupport parts) before fastening the ropeclamp again.

Remove the arrestor section (at the bottom

of the system).

Then feed in the support (lower)rope, starting with the splice endand work your way down from thedrive (top) to the bottom of thesystem. Lubricate every third tofifth plastic part lightly with specialgrease! Do not overgrease usea plastic glove and put on only athin

lubrication grease film.

1 2



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At the bottom, use some clean paperto protect the rope against dust!

Now feed the tension (upper) ropeinto the upper tube.Lubricate each ball lightly as itgoes into the tube except for thefirst three; this will remove debrisfrom the tube before it is trapped inthe grease. Pull the rope out of thelower end and complete theconnection of the end parts.

Note: It is particularly important to

lubricate long lifts.

Feed the lower rope through the arrestor section.

Complete the ends of both ropes with the rope levers shown in the illustration below.

1. tension rope 9. plastic ring (distance)2. support rope 10. plastic part3. sliding contact 11. rope lever4. plastic part 12. rope clamping system5. metal half ring 13. plastic part6. rope lever 14. plastic part7. secure ring 15. rope clamp8. plastic cover 16. plastic tube



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Draw back the tension rope while inserting the rope lever into the slot on the lower sideof the upper tube. Install the sliding contact into the tube below the upper rope lever andpull the support rope up into the upper tube. The sliding contact will then be positionedbetween rope levers, as shown in the diagram on this page.

Now check the distance between the rope levers. This must be a distance of 90mm. Therope may be too long. In this case pull the support rope out from the upper tube, thendismantle the end of the support rope and remove one (or more) plastic support part.Begin the installation of the support rope once more.

If using a 9 mmrope, follow the ensuing instructions.

Connect the tension rope with the support rope. See illustration below.

1. tension rope2. support rope3. secure ring

Remove the arrestor section (at the bottom of the system).

Then feed in the support (lower) rope, starting with the splice end and work your waydown from the drive (top) to the bottom of the system. Lubricate every plastic part lightly

with special grease! Do not overgrease use a plastic glove and put on a thinlubrication grease film.

At the bottom, use some clean paper to protect the rope against dust!

Now feed in the tension (upper) rope into the upper tube. Lubricate each ball lightly as itgoes into the tube except for the first three; this will remove debris from the tube before itis trapped in the grease. Pull the rope out of the lower end and complete the connection

of the end parts.

Note: It is particularly important to lubricate long lifts.

Feed the lower rope through the arrestor

Complete the ends of both ropes with the rope levers according to the illustration on thenext page.



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1. tension rope 7. secure ring2. support rope 8. plastic cover3. sliding contact 9. plasic part4. plastic part 10. rope lever5. metal half ring 11. spring6. rope lever

Draw back the tension rope while inserting therope lever into the slot on the lower side of theupper tube. Install the completed sliding contact(see picture) into the tube below the upper ropelever and pull the support rope up into the uppertube. The sliding contact will then be positionedbetween the rope levers, as shown in thediagram above.

Now check the distance between the rope levers. There must be a distance of 90mm. Ifthe rope is too long, cut it as shown in the illustration on this page.

If you have difficulty in bringing the ropes together, relax the rope tension device as muchas possible. The rope levers must be brought to within 90 mm of each other to beconnected to the carriage.



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Mounting the carriage

When the tube system is securely in place, beginmounting the carriage. Complete the following steps:

Bring the carriage to the bottom of the tubesystem and unwrap it.

Remove the shoulder bolts for the conicalrollers and the rope liners.

Carefully lift the carriage into position, guiding

the upper carriage rollers onto the upper tube. Ensure that the rope levers fit between thebosses of the upper carriage. Be careful not to scratch the paint on the tubes.

Note: The carriage weighs about 90 kg, so two people should install it to ensure safety

and avoid damage.

Screw the carriage on the rope levers of the tensionand support rope.

Install the conical rollers on the lower tube. Put somegrease on the area of the shoulder bolt on which theconical rollers will rotate.

This diagram on the right side shows the carriagearrangement on the lower tube.

Open the upper front side of the carriage by using ahexagon socket wrench.Note: Remove the four-pole plug from the socket and

put the special plug for mounting only (delivered from

Lehner-Lifttechnikwith the first plant) into the socket.

Now you have bridged key switch and emergencystop.

Open the lower front side of the carriage by using ahexagon socket wrench.

Note: Dismantle the connection between slider and

platform first!

Caution: The barriers are without support now they willfall down watch your head!

conical

rollers



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When you dismantle the lower front side part, fix the connection between platform andslider again.

Connect the carriage power wires to the rope and sliding contact connections. Connectthe black wire from the rope to the black wire in the carriage. Then connect the brownsliding contact wire to the brown wire in the carriage.

Do not close the carriage yet. It needs to be open in order to test the power functionsafter the installation has been completed.

When the carriage is mounted, the rope must be tensioned. It is necessary to distinguishbetween a large drive box with 9mm rope and a standard drive box with 7mm rope.

The following points are valid for tightening a 7mmrope.

Feed the support rope into the rope clamping system on the upper carriage of theplatform.

Note: Close the cover of the

drive box before tighteningthe rope! The cover of thedrive box is the bearing for

the drive wheel!!!

Use the special tool for ropetightening. Put it on the ropeand secure the rope with arope clamp (see illustration).Now you can turn the threadout of the main body therope will be tightened. If it is too loose, it may short against the tube.

When you have the right tension, clamp the rope in the clamping system and secure the

rope with two rope clamps.

Note: Do not cut the rest of the support

rope!!!

Take the plastic tube, put it over the rest of the support rope,turn it to a circle (see illustration) and fix it with cable bindingscrews.

screw fixed

screw loose



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The following points are valid for tightening a 9mm rope.

After connecting the 9mm rope, use the rope tension device in the drive box (see

chapter Installing the drive box) to tighten the rope.

Adjust the slack rope switch in the drive box after tensioning the rope.

Rope tensiondevice



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Installing the Electric and the Call Stations

Instruct the person who will be supplying the main power to connect the drive box main

leads. Refer to the electric diagram (and the layout drawing).

Note: Stairlifts require a 230/400V service.

Caution: Ensure that the fuses F1/F2 in the control cabinet are deactivated.

Note: Check the drive direction of the motor after connection to the

electricfield!

Complete the field wiring in accordance with the electrical drawings supplied in theinstallation package. The following pictures show a typical arrangement, but note that notwo systems are the same; you must choose the most effective method of wiring in yoursituation.



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Set up a ground connection if required.

Mount the Call Stations, starting with the Call Station at the lowest landing.

When mounting the Call Station, remember to allow enough clearance for the carriage atthe lower landing. The height of each Call Station should be 1 m, measured from thefloor to the centre of the Call Station.

Wire the Call Stations according to the electrical drawings.

On outdoor lifts, install the hood that is supplied with each Call Station.

If the Call Station is supplied with a pedestal, ensure that the pedestal is plumb beforemounting the Call Station.

Connect the current collector with the Ra and Sa connections in the control cabinet asshown in the picture below. (The current collector is also shown on page 7.)

Ra

Sa

Currentcollector



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Turning on the Power

Before turning on the power, check the following items:

Ensure that the rope is tensioned properly. If it is too loose, it may short against the tube.

All station boards should be wired and plugged in.

All safety and final limit circuits should be wired.

The wires to the carriage should be properly connected and the carriage emergencystop switch should be released.

All support pillars (if supplied) should be secure and the strut fasteners should be snug.

Note: The strut fasteners will be fully tightened once the carriage landing locations

and stair clearances are checked.

Caution: Do not ride on the lift until all of the fasteners have been fully

tightened!

Now you can switch on the building breaker, the drive box main switch. Look for the two fusesF1/F2 in the control cabinet to be active.

If you encounter problems, refer to the user handbook or technical documentation.

Unfold the platform and run the unit out of the lower landing for a short distance using theremote control.



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Mounting the mechanical limit switches

Mount the plate with the limit switch on the C-profile on the lower tube of the railway.

Adjust the position of the plate in reference to the stop position of the platform.

Note: The carriage must touch down slightly on the bottom with the buffers on the lower

end of the backside of the carriage in the lower stop position.

In the upper stop position (and also intermediate stop positions) the platform should bein one line with the landing height.

Adjust bolt 1 and bolt 2 now, in reference to the bypass switch (see description in thetechnical documentation, chapter 2.4.3 Bypass switch).

Run the carriage down to the lower landing again and stop it in the desired loadingposition. The remote control will allow you to watch the platform.

Note: Allow the carriage to bottom out on the lower landing.

Run the carriage out of the landings and back again. If the lift does not stop in the correctposition, adjust it as necessary.



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Mounting the control cams

Mount the control cams on the profiles between the upper and lower tube of the railway

in the area of the platform stop position.

Adjust the control cams - the levers for unclamping the barrier should be in the middle ofthe control cams when the platform arrives in the stop position.

Note: Mount the control cams according to the description on the layout drawing. Under

some circumstances, it may be necessary to unclamp both barriers in the lower stopposition. Use two control cams in this situation.

Caution: Do not mount two control cams in the upper stop position

(or intermediate stop positions)!

Check the power functions on automatic type platforms. Or check the operations on themanual platform.

Check each operation again for each landing in the system.

Mounting the ultimate limit switch

Adjust the mechanical limit

block so that it is properlyaligned with the sensor on thecover of the upper carriage.

Adjust the ultimate limitswitch and the mechanicallimit block together!



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Adjusting the platform

For the following chapter, first look over the Technical Documentation, chapter 2.4.2

Barriers, illustration 23, to know the definitions of the components.

To adjust the platform correctly it is necessarythat all electric installations (limit switch,emergency limit switch, overspeed governor,landing controls, electrical connection of thecarriage, etc.) are finished. The front side of thecarriage should be opened!

Adjust the platform into horizontal position first.It is necessary to dismantle the connection

between the platform and the slider in thecarriage again. Use a water level!

Counter the adjusting screw with the counter nutafter successful adjustment.

Note: Check the horizontal line of the platform only

in loaded condition!

Caution: Check if both adjusting screws are

supporting the platform!

Adjust the slider for platform.

Mount the connection between platform and carriage again. The platform slider musthave contact to the bearing support on both sides (see illustration). This can be adjustedby changing the length of the connection between the platform and the carriage.

Note: Every time you modify the horizontal adjustment of the platform, it is

necessary to adjust also the slider again!

Left and right side, theslider must have contactto the bearing support.

Bearing for lifting theplatform



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Move the limit switch S11p,until it makes contact with the platform slider.

Check the horizontal position of the barriers.

They are pre-adjusted from Lehner-

Lifttechnikalready, but it could be necessaryto finish them on site.

It is possible to adjust both barriersseparately. Open the screw shown in theillustration, adjust the barrier and lock theadjustment with the screw again.

Adjust limit switch S11m, so the barriers are in

horizontal position when the automaticplatform is opened.

Adjust limit switch S11o, so the platform ispressed towards the carriage by theautomatic drive when the platform is closed.

Screw foradjusting



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Adjustment of the loading ramps

Be sure the control ramps on the railway and all limit switches are adjusted before

looking for the ramps.

Adjust the ramps to achieve a 45 angle between the platform and rampwhen the barrier is in horizontalposition. When the barrier is open, theramp has to fit to the bottom of thelanding area.

During closed and drive position of theplatform, the ramps are used as safety

pads also. To get a secure switchfunction it is necessary to move thefixing of the ramps as far outside aspossible.

Note: Look for a safety switch function, but do not adjust too secure!

This would require some service after a few weeks.

Check the loading ramps for proper operation.

Note: Remember to check the travel clearances of the carriage.

Do not let the unit run past the upper limit position.

Before you close the carriage, ensure that all screws fixing the limit switches aresecured.

bearing for

the bord Move the joint for the ramp as far aspossible into direction of the arrow.Check if there is enough space to openand to close the ram .



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O l tf lift 24 f 24

Last checks before using the stairlift

With all limit blocks and interlock cams in place, unfold the platform and run the carriage

up to the top of the system and back while checking the travel clearances of thecarriage. If you encounter any problems, have the lifts serial number on hand and call

Lehner-Lifttechnik.

Caution: Do not ride on the unit until the fasteners are tightened.

When you are satisfied that the lift clearances are correct, tighten all strut fasteners.

When the landing is uneven and the loading ramp does not rest properly on the floor,adjust the ramps on the platform once more.

To adjust the ramps, see chapter Adjusting the platform.

Omega - Installation Manual

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