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liftup FlexStep V2 Installation & Service Manual

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Installation & Service Manual
FlexStep V2
INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 1.7
Liftup A/S | Hagensvej 21| DK-9530 Støvring | Denmark | T: +45 9686 3020 | M: support@liftup.dk | www.liftup.dk

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  • Page 1 Installation & Service Manual FlexStep V2 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 1.7 Liftup A/S | Hagensvej 21| DK-9530 Støvring | Denmark | T: +45 9686 3020 | M: support@liftup.dk | www.liftup.dk...

  • Page 2: Table Of Contents

    Setting of Lifting Height and Stair Position ............. 40 5.1 Definition ..............................40 5.2 Settings of the 2 stops using the “Liftup Service Tool” ............... 40 5.3 Setting virtual top stop by “Service Mode” ..................42 Service mode ....................... 43 6.1 How to set the System into Service Mode.
  • Page 3 7.5 Audible alarms ............................50 7.6 Automatic ramp/roll-off protection ....................51 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 ...........................

  • Page 4: Unpackning & Moving The Flexstep V2

    In order to simplify the reading of this manual, or any conversation with us, it is important to set some basic definitions in place. The FlexStep V2 is a lifting platform capable of transferring a wheelchair or disabled people between 2 levels (max 1250 mm). After transfer the product will in most cases automatically return into staircase position.

  • Page 5: Unpacking And Moving The Product

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 1.2 Unpacking and moving the product The FlexStep V2 is equipped with batteries so even if the power supply is not connected to the lift, the lift can move (not the case 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.
  • Page 6 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Use the 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.

  • Page 7: Attachment To Building

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 2 Attachment to building 2.1 Mounting of Wall Profiles without a vertical safety barrier. If your FlexStep V2 is fitted with a vertical safety barrier – go to chapter 2.2. The FlexStep V2 lifting platform/staircase is delivered almost fully assembled.
  • Page 8 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Make sure that the wall profile is vertical (front view and side view) (use shims between the wall and the profile if necessary). Once the position and the dimensions are correct. Fit the first wall profile to the wall through the mounting holes.
  • Page 9 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Mount cover plate to left hand side wall profile, using two M4 screws – top and bottom. Mount cover plate to right hand side wall profile, using two M4 screws – top and bottom.
  • Page 10 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. Wall profiles are now ready for mounting the FlexStep V2. (Go to chapter 0) Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark | +45 96 86 30 20 | support@liftup.dk | www.liftup.dk | CVR DK-1015 3964...

  • Page 11: Mounting Of Wall Profiles With A Vertical Safety Barrier

    2.2 Mounting of Wall Profiles with a vertical safety barrier The Vertical Safety Barrier can be delivered as an add-on solution, which can be fitted to an existing FlexStep V2, To do this you need to change the wall profiles, as they are different.
  • Page 12 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Make sure that the wall profile is vertical (front view and side view) (use shims between the wall and the profile if necessary). Once the position and the dimensions are correct, fit the first wall profile to the wall through the mounting holes.
  • Page 13 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Mount cover plate to left hand side wall profile, using two M4 screws – top and bottom. Mount cover plate to right hand side wall profile, using two M4 screws – top and bottom.
  • Page 14 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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. Wall profiles are now ready for mounting the vertical safety barrier.

  • Page 15: Dismantling Timing Belt System

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 2.2.2 Dismantling timing belt system The 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.
  • Page 16 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Pull the timing belt up from the left hand wall profile leaving 20 – 25 cm hanging outside the wall profile. Fasten the timing belt to the wall profile with masking tape or similar.

  • Page 17: Fitting The Vertical Safety Barrier

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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.
  • Page 18 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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...

  • Page 19: Assembling Timing Belt And Motor To Vertical Safety Barrier

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 2.2.4 Assembling timing belt and motor to vertical safety barrier Remove the masking tape holding the timing belt against the wall profile. Carefully slide down timing belt, grey wire and top mounting bracket.
  • Page 20 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Remount top cover on the wall profiles in left hand side Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark | +45 96 86 30 20 | support@liftup.dk | www.liftup.dk | CVR DK-1015 3964...

  • Page 21: Timing Belt Tension

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 2.2.5 Timing belt tension Tension on the timing belt should be "firm". The timing belt 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.

  • Page 22: Connecting The Vertical Safety Barrier And Testing It

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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.
  • Page 23 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Remove the jumper placed on “Upper Gate SW”. Release the emergency button from the FlexStep and push the “UP” button. The Vertical Safety Barrier should now go up. Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark | +45 96 86 30 20 | support@liftup.dk | www.liftup.dk | CVR DK-1015 3964...

  • Page 24: Mounting Of Flexstep V2 To Wall Profiles

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 2.3 Mounting of FlexStep V2 to Wall Profiles Place the FlexStep V2 30-40 cm from the wall profiles and connect the E chain with the 2 x M5 screws. Attach the cover plate.
  • Page 25 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Approach the lift close to the wall profiles. Place the 2 connecting brackets on the left and right hand side wall profiles. Glide the connecting brackets all the way down. Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark | +45 96 86 30 20 | support@liftup.dk | www.liftup.dk | CVR DK-1015 3964...
  • Page 26 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Fix the connecting brackets with 4 M5 screws (2 on the left hand side and 2 on the right hand side). LH Top RH Top LH Bottom RH Bottom Finish the installation by fixing on both sides:...

  • Page 27: Control Unit

    The control unit consists of the power supply unit (103080), the PCB for connection box (102726), both factory mounted on the bottom rail and two control boards (103252) mounted inside the two control boxes, placed on each side of the FlexStep V2 . 3.1 Bottom rail...

  • Page 28: Control Boards

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 3.2 Control Boards The FlexStep V2 control boards (102352) are mounted inside the two control units, placed on each side of the FlexStep V2. Remove covers for control box to access control boards.

  • Page 29: Control Board Jumpers Jp1

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 3.3 Control Board Jumpers JP1 IMPORTANT! Remove all jumpers to reactivate all safety functions. (Except “Ignore GO”) Jumpers and LED is only valid on PRIMARY control board – right hand side.

  • Page 30: Control Board Led Signals

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 3.4 Control Board LED signals Control board (102352) H-BRO SUP Yellow H-BRO3 SUP Yellow OC. H-BRO3 +12V Yellow Under Pan SW. AC ON Green Yellow Lower Gate SW. BATT. FLOAD Green Yellow Upper Gate SW.

  • Page 31: Control Board Microswitches

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Description Action Primary / Colour Secondary H-BRO SUP. Yellow Supply for actuator ready P + S H-BRO3 SUP. Yellow Supply for ramp (Secondary) / safety barrier (P)+(S) ready (Primary) OC. H-BRO3...

  • Page 32: On/Off Switch

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 3.6 ON/OFF Switch The FlexStep V2 is mounted with an ON/OFF switch for mains supply. The ON/OFF switch is placed on the bottom of the right hand side control box. Access the switch from below.

  • Page 33: Call Stations

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 4 Call stations The FlexStep 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.
  • Page 34 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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)

  • Page 35: Key Operated Call Stations (2 Ways)

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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 Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark |...

  • Page 36: Wireless Call Stations (Wall Mounted)

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 4.3 Wireless Call Stations (wall mounted) 2 ways: Lower Call station Upper Call station Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark | +45 96 86 30 20 | support@liftup.dk | www.liftup.dk | CVR DK-1015 3964...

  • Page 37: How To Pair Transmitter And Receiver

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 4.4 How to pair transmitter and receiver 4.4.1 Wireless call station and receiver The transmitter and receiver must always be paired in order to work. The receiver will not react to a transmitter which is not paired with it.

  • Page 38: Handheld Remote Control And Receiver

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 4.4.2 Handheld Remote control and receiver The transmitter and receiver must always be paired in order to work. The receiver will not react to a transmitter which is not paired with it.

  • Page 39: On/Off Key Switch (Optional)

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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.

  • Page 40: Setting Of Lifting Height And Stair Position

    (102352) on the FlexStep V2 (RH side of the lift). 2. Start the Liftup Service Tool on PC (make sure you know the name of the COM port, see Annexe to see how). You should see the “Connected” box with green background (see below, USB detected on COM 4) (*) PC must be Windows 7 or newer.
  • Page 41 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 3. In the Stroke area, set the value of actuators: o Platform Lifting height , in mm (see NOTE) o Stair Position, in mm (see NOTE) 4. Push the “Write system parameters to device”.

  • Page 42: Setting Virtual Top Stop By "Service Mode

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 5.3 Setting virtual top stop by “Service Mode” When the system is in service mode (see 6.1) it is possible to set the virtual top stops. 1. Set the system into service mode.

  • Page 43: Service Mode

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 6 Service mode 6.1 How to set the System into Service Mode. To set the system into service mode, do as following: 1. Push emergency stop button. 2. A) Push and hold two buttons, while B) releasing the emergency stop button.

  • Page 44: Safety Features

    7 Safety Features 7.1 Infrared Sensors (IR) The FlexStep V2 is mounted with Infrared 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.
  • Page 45 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Yellow when IR is OK (Flashing or constant) Yellow flashing when IR is OK IR safety TX board. (103009) IR safety RX board. (103008) Ramp Lock green Power On yellow Yellow flashing when IR is OK IR termination board.

  • Page 46: Wiring Of Safety Switches To The Infrared Sensor Boards

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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. RH side girder IR termination board (103011) IR safety RX board.
  • Page 47 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION LH side girder IR safety TX board. (103009) Ramp motor, power IR safety TX board. (103009) IR safety TX board. (103009) Safety switch for steps Red wire to the marked side.

  • Page 48: Wiring Of Push Buttons And Emergency Stop

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 7.3 Wiring of push buttons and emergency Stop Speaker 103083 Platform up Platform down Emergency Stop Button 100339 Background light Platform up Emergency Stop Emergency Speaker Stop (GND) Platform down Background light...

  • Page 49: Safety Pressure Plates

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 7.4 Safety Pressure Plates Below all steps and 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.

  • Page 50: Audible Alarms

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 7.5 Audible alarms If “speak” is installed on the lift this will be activated in the event of an alarm. Otherwise an alarm tone will sound. Speak Activity/warning Opening The vertical safety barrier is opening.    ...

  • Page 51: Automatic Ramp/Roll-Off Protection

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 7.6 Automatic ramp/roll-off protection Ramp part numbers Lifting Ramp types Pipe for ramp platform Width steps >120mm steps >140mm steps >175mm Indoor Outdoor 700 mm 103318 103317 103316 103315 103379 800 mm...

  • Page 52: Disassemble The Flexstep V2

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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...

  • Page 53: Disconnecting The Wires

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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...
  • Page 54 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Disconnect Hall sensor actuator wires for the SLAVE actuator (H2) from connector X9 (1, 4, 6) 1 2 3 4 5 6 7 Disconnect control panel wires from connector (only on the...

  • Page 55: Removing The Wires

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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.

  • Page 56: Circlips For Steps

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 8.4 Circlips for steps Remove the circlips and washers from the two girders on all steps. Carefully remove the girders from the steps, while taking care of the wires. Please note it is important to hold the...

  • Page 57: Assemble The Steps

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 9 Assemble the steps 9.1 Mounting the girders Place the steps in the correct position (1-2-3-4- 5) and place the two girders near by the steps (app. 5-10 cm from the steps).

  • Page 58: Connecting The Wires

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 9.2 Connecting the wires Left hand side Right hand side 1 Pull flat wire and blue wires out 1 Pull flat wire out through upper step through upper step shaft and connect to shaft and connect to IR Safety RX board IR Safety TX board (103009).
  • Page 59 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Wires for Actuator (connector X9 1 2 3 4 5 6 7 1. Green H2 (Slave) 2. Green H1 (Master) 3. Red H1 (Master) Mount connectors from actuator wires to 4. Brown H2 (Slave) control board (102352).

  • Page 60: Check List

    All IR PCB must be checked individually. Green LED’s are ON. Check the emergency stop. Maneuvering the FlexStep V2 with the up and down buttons. Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark | +45 96 86 30 20 |...

  • Page 61: Enclosures

    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 Electrical Diagram #1 Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark | +45 96 86 30 20 | support@liftup.dk | www.liftup.dk | CVR DK-1015 3964...

  • Page 63: Electrical Diagram #2

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 10.2 Electrical Diagram #2 Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark | +45 96 86 30 20 | support@liftup.dk | www.liftup.dk | CVR DK-1015 3964...

  • Page 64: Pull Force

    INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION 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.
  • Page 65 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Factor of Safety > 3 Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark | +45 96 86 30 20 | support@liftup.dk | www.liftup.dk | CVR DK-1015 3964...
  • Page 66 INSTALLATION & SERVICE MANUAL – FLEXSTEP V2– UK VERSION Liftup A/S Hagensvej 21| DK-9530 Støvring | Denmark | +45 96 86 30 20 | support@liftup.dk | www.liftup.dk | CVR DK-1015 3964...

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