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OTOLIFT Modul-Air Installation Manual

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Otolift Modul-Air
Installation manual
19-01-2017

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Summary of Contents for OTOLIFT Modul-Air

  • Page 1 Otolift Modul-Air Installation manual 19-01-2017...
  • Page 2 Otolift Stairlifts Postbus 64 2860 AB Bergambacht The Netherlands Tel: +31 (0) 182 352544 E-mail: info@otolift.com Internet: www.otolift.com...

  • Page 3: Table Of Contents

    Installation rules Requirements 2 Installation drawing explained 6-11 3 Rail coupling 12-13 4 Location of leg supports 5 Coupler leg support 6 Leg support 7 Coupler plate 8 Coupler BOP support 9 BOP support 10 Extra charge point straight 11 Extra charge point curve 12 Dropstart 22-23 13 Incline start...

  • Page 4: Installation Rules

    Save a copy for your own and company account. 7. All screws and nuts may only be used one time. In case of second life always replace screws and nuts. 8. Never use screws and nuts other than specified by Otolift. Always order screws and nuts at spareparts@otolift.com...

  • Page 5: Requirements

    1 - Requirements Otolift Stairlifts Installation manual Installation may only be performed by trained Installation drawing is required before start. engineers. Installation tools (tube 403060616 and cross Servicebox is required for programming chairlift. 200060042) are required for placing drive unit at rail.

  • Page 6: Installation Drawing Explained

    2 - Installation drawing explained Otolift Stairlifts Installation manual Drawing shows type of required rail sections. Picture shows Rail section OK-252-06. Drawing shows the position of the leg support at In the drawing and in this picture the location is position.
  • Page 7 2 - Installation drawing explained Otolift Stairlifts Installation manual Drawing shows a leg support at position 8. Always Picture shows a Leg support set 200060052 mount a leg support. mounted at pos x. NOTE It is forbidden to place 200060052 at position 1 Drawing shows no legsupport at rail coupling.
  • Page 8 2 - Installation drawing explained Otolift Stairlifts Installation manual Drawing shows a BOP support at position 9. Picture shows BOP support set 200060056 Always mount a BOP support. incl. BOP mounted at pos x. NOTE It is forbidden to place 200060056 at...
  • Page 9 2 - Installation drawing explained Otolift Stairlifts Installation manual Drawing shows an BP250. BP250 verified with measuring tape. Length 250mm. Drawing shows an BP250SP1. BP250SP1 verified with measuring tape. Length 250mm. Drawing shows an LF200. LF200 verified with measuring tape.
  • Page 10 2 - Installation drawing explained Otolift Stairlifts Installation manual Drawing shows a (standard) rail connector. Picture shows a mounted rail connector. Drawing shows a rail connector offset. Picture shows a mounted rail connector offset. Drawing shows a dropstart as rail start.
  • Page 11 2 - Installation drawing explained Otolift Stairlifts Installation manual Drawing shows an incline start as rail start. Picture shows a mounted incline start. Drawing shows an horizontal finish as rail finish Picture shows a mounted horizontal finsh (start). (or rail start).

  • Page 12: Rail Coupling

    3 - Rail coupling Otolift Stairlifts Installation manual Rail Coupler service set 200000041 Place Nuts. Note orientation of nuts. (200000040). Assembly ready for mounting. Mount coupling, start assembling in direction of rail start. Note position of cable at toothed rack side.
  • Page 13 3 - Rail coupling Otolift Stairlifts Installation manual Assemble set screw with hexagon 5mm tool. Tighten both set screws. Use a level to make sure that parts are in line.

  • Page 14: Location Of Leg Supports

    4 - Location of leg supports Otolift Stairlifts Installation manual At bottom of drawing the postion of leg support When position 1 is indicated always mount is indicated (1, 3, 4,….). coupler leg support set 200060051. In case of position 3, 4 or higher, mount a Position 2.

  • Page 15: Coupler Leg Support

    5 - Coupler-leg support Otolift Stairlifts Installation manual Mount coupler. Coupler leg support set 200060051. NOTE this parts must always be assembled at position 1 (rail coupling). Coupler in position. Place nuts, tighten with Hexagon 5mm Note that fitting has some friction.

  • Page 16: Leg Support

    6 - Leg support Otolift Stairlifts Installation manual Leg support set 200060052. Mount Leg support. NOTE It is forbidden to assemble this part at position 1 (rail coupling). Leg support in position. Place nuts, tighten with Hexagon 5mm and socket wrench 10mm.

  • Page 17: Coupler Plate

    7 - Coupler plate Otolift Stairlifts Installation manual Coupler plate set 200060050. Mount coupler. NOTE This part must always be assembled at rail coupling. Coupler in position. Place nuts, tighten with Hexagon 5mm Note that fitting has some friction. and socket wrench 10mm.

  • Page 18: Coupler Bop Support

    8 - Coupler BOP support Otolift Stairlifts Installation manual Coupler BOP support set 200060055. First position outer bolds m6x20 and start NOTE This part must always be assembled at tighten inner m6x16 with hexagon 5. position 1 (rail coupling). Note that fitting has some friction.

  • Page 19: Bop Support

    9 - BOP support Otolift Stairlifts Installation manual BOP support set 200060056. Mount BOP support. NOTE It is forbidden to assemble this part at position 1 (rail coupling). Tighten with Hexagon 5mm . BOP support mounted. Mount BOP and tighten with Hexagon 5mm.

  • Page 20: Extra Charge Point Straight

    10 - Extra charge point straight Otolift Stairlifts Installation manual Chargepoint straight set 200060060. Hold the extra charge point at recommended position. Holes of chargepoint should be in line with holes rack. Mark middle of charge point. Drill a 8,5mm hole in the tube. Hole as close as Guide cable through hole, and guide cable to possible to the railstrip.

  • Page 21: Extra Charge Point Curve

    11 - Extra charge point curve Otolift Stairlifts Installation manual Hold the extra charge point at recommended Chargepoint curve set 200060061. position. Mark middle of charge point and holes for drilling into railstrip. Drill a 8,5mm hole in the tube. Hole as close as Drill a 4mm hole in the railstrip.

  • Page 22: Dropstart

    12 - Dropstart Otolift Stairlifts Installation manual Dropstart service set Buffer not assembled. (406060600 / 406060601 + 200060057). Buffer assembled. Mount rail coupling. NOTE position of cable. Mount dropstart, do not tighten set screw. Mount m6 screws and nuts.
  • Page 23 12 - Dropstart Otolift Stairlifts Installation manual Mount 2nd set screw. Tighten both set screws. Use a level to make sure that parts are in line. Tighten with Hexagon 5mm and wrench 10mm. Dropstart assembled. Continue with assembling charge contact.

  • Page 24: Incline Start

    13 - Incline start Otolift Stairlifts Installation manual Incline start set (406060602 / 406060603 + Buffer not assembled. 403060606 + 200060058). Buffer assembled. Mount rail coupling. Note position of cable at toothed rack side. Mount incline start, do not tighten set screw.
  • Page 25 13 - Incline start Otolift Stairlifts Installation manual Mount 2nd set screw. Tighten both set screws. Use a level to make sure that parts are in line. Tighten with Hexagon 5mm and socket wrench Mount floorplate. 10mm. Tighten screw and nuts with socket wrench Incline start assembled.

  • Page 26: Charge Contact

    14 - Charge contact Otolift Stairlifts Installation manual Guide cable (2 cables in case of extra chargpoint). Cables correctly positioned. Chargepoint assembly. Untighten bolds with hexagon 2.5mm, Separate movement of plate should be possible. Mount chargepoint with hexagon 3mm. Cut cables according picture.
  • Page 27 14 - Charge contact Otolift Stairlifts Installation manual Strip wires and connect red to red, black to black. Use plier to mount cable shoes. Connect wires to contact block. Untighten screw. Mount coverplate and tighten screw. Coverplate mounted.
  • Page 28 14 - Charge contact Otolift Stairlifts Installation manual Adjust chargepoint, pin against thoothed rack. Chargepoint correctly adjusted.

  • Page 29: Rail Support Assembling

    15 - Rail support assembling Otolift Stairlifts Installation manual Rail support. Length is 250 mm. Rail support kit 210000025. Rail support parts. Rail support assembled. Inner rail support. Length is 200 mm. Leg filler parts 210000081.
  • Page 30 15 - Rail support assembling Otolift Stairlifts Installation manual Inner rail support parts including rail connector. First mount legfiller, then push in rail connector. Push in rail connector. Mount and tigthen set screw with hexagon 4 mm tool. Mount inner rail support. Tighten set screws Number the rail support.

  • Page 31: Rail Assembling

    16 - Rail assembling Otolift Stairlifts Installation manual Start with a straight rail part and build towards Every tube will be coupled, with a rail coupling. railstart. When one of the bottom railparts has an extra chargepoint start with this part.
  • Page 32 16 - Rail assembling Otolift Stairlifts Installation manual Tighten rail coupler set screws with torque Tighten all leg support screws with torque wrench wrench set to 25 Nm. set to 15 Nm. Tighten coupler plate screws with torque wrench Legs are assembled and length are according to set to 15 Nm.
  • Page 33 16 - Rail assembling Otolift Stairlifts Installation manual Depending if installation is done by one person or two persons, you can decide to 2. Continue assembling the rail step by 1. Assemble second “big” railpart in the workbench step at the staircase.
  • Page 34 16 - Rail assembling Otolift Stairlifts Installation manual Tighten coupler (rail support). Mount rail support. Tighten rail coupler set screws with torque Tighten all leg support screws with torque wrench wrench set to 25 Nm. set to 15 Nm. Tighten coupler plate screws with torque wrench...

  • Page 35: Mount Rail To Staircase

    17 - Mount rail to staircase Otolift Stairlifts Installation manual Use this installation drawing for information Verify incline and when needed adjust. about incline of rail. Tighten set screws of rail supports. Tighten screws. Use this installation drawing for information Dimension is from front side rail to wall or obstacle.
  • Page 36 17 - Mount rail to staircase Otolift Stairlifts Installation manual Mount rail support to staircase, verify the level of Assemble BP covers. the rail support. Covers assembled.

  • Page 37: Mount Drive Unit

    18 - Mount drive unit Otolift Stairlifts Installation manual Assemble rail coupler in top railpart. Place installation tube. Slide drive unit at rail. Prepare drive unit for mounting on rail. Push until toothed wheel of drive unit is against Use 8mm socket wrench to drive the lift at the rail.

  • Page 38: Assembling Frontframe

    19 - Assembling frontframe Otolift Stairlifts Installation manual Drive unit ready for assembly frontframe. Remove both M8 screws. Use hexagon 6. Remove both M8 Nuts. Use socket wrench 13. Remove cover spring. Remove cover spring. Remove screw left side cover. Use hexagon 3.
  • Page 39 19 - Assembling frontframe Otolift Stairlifts Installation manual Take off left side cover. Remove screw right side cover. Use hexagon 3. Take off right side cover. Verify if studs are horizontal. Remove cover level motor. Use 8mm wrench for adjusting level.
  • Page 40 19 - Assembling frontframe Otolift Stairlifts Installation manual Adjust level of studs to horizontal. Place frontframe. Mount both M8 screws including rings (do not Mount both M8 nuts including rings and tighten. tighten). Tighten both M8 screws including rings.

  • Page 41: Assembling Seat

    20 - Assembling seat Otolift Stairlifts Installation manual Remove battery cover. Use hexagon 3. Remove battery cover. Use hexagon 3. Seat ready for assembling on frontframe. Screw set for mounting seat. In case of manual seat an extra screw provided for mounting spacer.
  • Page 42 20 - Assembling seat Otolift Stairlifts Installation manual Powered swivel. No spacer. Powered swivel. Push in plastic part. Place seat (in case of powered swivel watch the Manual and powered swivel. Mount the 4 m6 position of toothed wheel). bolds including ring. Use hexagon 5.
  • Page 43 20 - Assembling seat Otolift Stairlifts Installation manual Connect cable to sensors. Guide blue labeled cable into tube. Start with ring terminal. Next guide connector X1, C2a and C1a into tube. Keep blue labelled cable like shown in picture (outside isolation not in tube).

  • Page 44: Wiring Manual Swivel

    21 - Wiring manual swivel Otolift Stairlifts Installation manual Remove plastic ring. Mount panel connectors C2b and C1b. Place tie wrap according to picture. Arround Guide C2b, C1b and ring terminals through plastic cables which come out tube. Do not tighten.
  • Page 45 21 - Wiring manual swivel Otolift Stairlifts Installation manual Connect connectors C2a and C1a. Mount ring terminals. Use screws which are in screwset mounting seat. Connect X1 (supply) and X3 (motor). Connect X2 (Swivel seat). Mount tie wrap according to picture.

  • Page 46: Wiring Powered Swivel

    22 - Wiring powered swivel Otolift Stairlifts Installation manual Remove plastic ring. Place tie wrap according to picture. Arround cables which come out tube. Do not tighten. Mount panel connectors C2b and C1b. Guide all cables (except Batt + and Batt -) to the front.
  • Page 47 22 - Wiring powered swivel Otolift Stairlifts Installation manual Connect connectors C2a and C1a. Connect X1 (supply), X2 (swivel seat), X5,X4 (motor swivel) and X3 (motor footplate). Connect X7 (footplate down), X6 (seat down) Guide X8b 2cm back through plastic ring and X8a (control footplate up/down).

  • Page 48: Power Up Chair Lift

    23 - Power up chair lift Otolift Stairlifts Installation manual Verify torque settings of m6 bolds (8 Nm). Verify torque settings of m8 screw (20Nm) and nuts (15Nm). Verify if seat is level (horizontal). Use 8mm wrench for adjusting seat to horizontal.
  • Page 49 23 - Power up chair lift Otolift Stairlifts Installation manual Mount batteries. Place fuse holder like picture and connect. NOTE Chair will power up after connecting fuse. Wait 10 seconds after connecting fuse. Calibrate sensors by pushing both buttons for 5 NOTE Do not control lift.
  • Page 50 23 - Power up chair lift Otolift Stairlifts Installation manual If LED not active during movement adjust Connect servicebox. tiltsensor. Verify if OK and tighten bolds after NOTE verify if service and teach are not active adjustment. (switch down). Set service on and control left.

  • Page 51: Rail Finish Assembly

    24 - Rail finish assembly Otolift Stairlifts Installation manual Rail finish assembly (406060602 / 406060603 Mount rail finish. + 200060006 + 200060059). Mount m6x20. Mount m10 set screw. Tighten set screws. Place nuts.
  • Page 52 24 - Rail finish assembly Otolift Stairlifts Installation manual Tighten with Hexagon 5mm and wrench 10mm. Guide rail cable and cut. Use plier to mount cable shoes. Connect cable to charge point. Mount charge point with hexagon 3mm. Adjust chargepoint, pin against toothed rack.
  • Page 53 24 - Rail finish assembly Otolift Stairlifts Installation manual Mount cover plate. Assemble floor plate, Hexagon 4mm. Place plate and mount screws. Tighten with Hexagon 6 mm and wrench 13mm. Mount floor plate to floor.

  • Page 54: Connect Transformer

    25 - Connect transformer Otolift Stairlifts Installation manual Decide where to connect transformer, Connect transformer to charge point. disassemble coverplate. Brown to red and Blue to black. Use tie-wrap to prevent pull cable loose after Mount coverplate. instal.

  • Page 55: Teach In - Rail Profile

    26 - Teach in - Rail profile Otolift Stairlifts Installation manual Fold up seat. Drive “slowly” service left/right to verify if travel is Set speed 1 and 2 when lower speed is required at Drive with service active and left pressed in certain railparts.
  • Page 56 26 - Teach in - Rail profi le Otolift Stairlifts Installation manual Switch on Teach and press right (keep right Switch between 1, 2 and max speed when pressed in until stopped at right endstop) required. (max 35 times posible) Do not change set speed during teach in.

  • Page 57: Teach In - Extra Charge Contact

    27 - Teach in - Extra charge contact Otolift Stairlifts Installation manual Move the chair to middle of chargepoint. Switch on service and teach, one beep will be heard. Switch off service and teach. Upper can be repeated for max 5 extra chargepoints (number of beeps gives indication for number of programmed extra charge points).

  • Page 58: Powered Swivel - Teach In Drive Position

    28 - Powered swivel - Teach in drive position Otolift Stairlifts Installation manual Move the lift away from endpoint. Release set screw at upper ring so, that ring can rotate freely. Use hexagon 2.5. NOTE DO NOT release bottom ring.
  • Page 59 28 - Powered swivel - Teach in drive position Otolift Stairlifts Installation manual Put down the seat. Program the drive position by pushing S1 and S2 both for 3 seconds. Release both switches when yellow LED is active. The seat will rotate shortly to determine precise...

  • Page 60: Powered Swivel - Teach In Endpoint

    29 - Powered swivel - Teach in endpoint Otolift Stairlifts Installation manual Move chair to an endpoint, until chair has stopped Rotate the seat to the preffered position by using and end beep is heard. As indication the yellow switches at swivel PCB.

  • Page 61: Powered Swivel - Teach In Intermidiate Stop

    30 - Powered swivel - Teach in Intermidiate stop Otolift Stairlifts Installation manual Move the lift the intermidiate stop. Rotate the seat to the preferred position by using S1 and S2 switches at swivel PCB. Chairlift in preferred intermidiate stop position.
  • Page 62 30 - Powered swivel - Teach in Intermidiate stop Otolift Stairlifts Installation manual Release both switch when yellow LED is active. Place jumper back at JP2. Verification of position can be done bij controling footplate up/down when lift is not on an endpoint.

  • Page 63: Remote Control - Mounting

    31 - Remote control - Mounting Otolift Stairlifts Installation manual Use drilling template for location of screws. Mount the 2 top screws. Head of screw 4mm from surface. Place remote and mount bottom screw. Tighten all screws. Place battery. Place bottom knob.

  • Page 64: Remote Control - Teach In

    32 - Remote control - Teach in Otolift Stairlifts Installation manual Push switch at receiver PCB, Led will light up. Push up and down button of remote for 5 seconds, until led receiver goes off. Led remote control will blink as indication that teach in was succesful.

  • Page 65: Remote Control - Key Fob

    33 - Remote control - Key fob Otolift Stairlifts Installation manual The set 200000261 is required for key fob. Push switch at receiver PCB, Led will light up. Push lock and unlock button for 1 second, until Repeat upper steps for each key fob (max of 30 led receiver goes off.

  • Page 66: Remote Control - Pincode

    34 - Remote control - Pincode Otolift Stairlifts Installation manual The set 200000260 is required for pin code. Cut the triangle shaped ribs. Mount buttons and paste sticker. Keep button 1 and 3 pressed in for 5 seconds (Until ed remote will start blinking).

  • Page 67: Setting Dipswitches

    35 - Setting dipswitches Otolift Stairlifts Installation manual Manual operated swivel, Dipswitch 2 OFF. Powered swivel, dipswitch 2 ON. Chair stop at programmed charge contact when Chair stop at programmed charge contact when controlled by remote Dipswitch 4 ON. controlled by armrest Dipswitch 5 ON.

  • Page 68: Testing Safety Switches

    36 - Testing safety switches Otolift Stairlifts Installation manual Verify the functionality of armrest stop switch. Display shows 0 when chairlift is stopped by armrest switch. Manual swivel, verify if the seat locks properly. Display shows 2 when chairlift is stopped by Verify if switch is pressed in when in swivelled swivel seat switch.
  • Page 69 36 - Testing safety switches Otolift Stairlifts Installation manual Display shows A when chairlift is stopped by Verify the functionality and direction of safety switch safety drive unit right. edge drive unit right. Verify the functionality and direction of safety Display shows b when chairlift is stopped by edge drive unit left.
  • Page 70 36 - Testing safety switches Otolift Stairlifts Installation manual Verify the functionality and direction of safety Display shows d when chairlift is stopped by edge footplate left. switch safety footplate left. Remove cover OSG. Rotate gripper. Display should show E08 and Led should be off.

  • Page 71: Testing Tilt Sensor

    37 - Testing tilt sensor Otolift Stairlifts Installation manual Remove top and bottom m4 screws at tilt sensor Top and bottom screws removed. mounting plate. Rotate the mountingplate clockwise to 7 degree 7 degree reference. reference. Control the lift 2 times for 15 seconds. Lift may Rotate the mountingplate counter clockwise not move.
  • Page 72 37 - Testing tilt sensor Otolift Stairlifts Installation manual 7 degree reference. Control the lift 2 times for 15 seconds. Lift may not move. Display mainboard will show E98, Sensor control board will show E60. Set mountingplate to 0 degrees (Neutral).

  • Page 73: Mounting Seat

    38 - Mounting seat Otolift Stairlifts Installation manual Mount backrest. Backrest mounted. Pre-mount screws in back of seatplate. Slide back of seat into holes. Tighten front-screws at seatplate. Tighten back-screws at seatplate.

  • Page 74: Mounting Covers

    39 - Mounting covers Otolift Stairlifts Installation manual Replace OSG cover. Front cover, remove white nuts. Slide cover into key hole. Mount white nuts. Mount battery cover. Press battery cover into Mount and tighten screws. Use hexagon 3mm. back slots.
  • Page 75 39 - Mounting covers Otolift Stairlifts Installation manual Mount and tighten screws. Use hexagon 3mm. Mount right side cover. Tighten screw. Use hexagon 3mm. Mount left side cover. Tighten screw. Mount cover spring. Use hexagon 3mm. Cover spring mounted.

  • Page 76: Verification And Completing

    40 - Verification and completing Otolift Stairlifts Installation manual Use “verification tests before use” document for Use “verification tests before use” document for verifying all torque settings (page 2). verifying all torque settings (page 3). Use “verification tests before use” document for Fill in page 1 of “verification tests before use”...

  • Page 77: Annex A Assembling Straight To Curved Armrest

    Annex A - Assembling straight to curved armrest Otolift Stairlifts Installation manual Wedges mounted for Straight version. Disassemble side cover. Note that round edges of wedges point to each other. Open cover plate by pushing pin against inside Use small screwdriver for further de‐assembling cover plate by using a plier.
  • Page 78 Annex A - Assembling straight to curved armrest Otolift Stairlifts Installation manual Note that in case of a straight version the 4mm Carefully disassemble wedges from pins. pins are mounted vertical. Remove pins. Remove bearing. Mount 4mm pins horizontal. Carefully mount wedges. Note that round edges of wedges point to each other.
  • Page 79 Annex A - Assembling straight to curved armrest Otolift Stairlifts Installation manual Mount bearing in half wedge. Mount 6mm pins and axle. Mount cover plate and push tree clip firmly into axle. Put cable behind spacer and mount side cover.
  • Page 80 Otolift Stairlifts...

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