ThyssenKrupp Flow2A Installation Manual
Flow2A chairlift
Installation manual
© 2015 ThyssenKrupp Accessibility BV
Version 2.0
All rights reserved.
Specifications and illustrations are subject to change without prior notice. ThyssenKrupp Accessibility
BV will not accept liability for any alteration or typing error.
Subject to the exceptions provided by law, this publication and/or its contents may not be, whether
entirely or partly, reproduced, copied, and/or published in print, by photocopying, on microfilm,
electronically or in any other way without the prior written consent of ThyssenKrupp Accessibility BV.
Table of contents
1 Preparations ...................................................................................................................... 4
1.1 At the branch .............................................................................................................. 4
1.2 At the customer’s home ............................................................................................... 4
2 Installing the rail ................................................................................................................. 5
2.1 Fitting the legs and brackets ......................................................................................... 5
2.2 Connecting the rail sections with a section bush ............................................................. 7
2.3 Installing the feeder cable ............................................................................................ 7
2.4 Fitting and installing the charging contacts ..................................................................... 8
2.4.1 Fixed charging contacts ........................................................................................ 8
2.4.2 Movable charging contacts .................................................................................... 9
2.4.3 Connection of charging contacts .......................................................................... 10
2.5 Connecting and mounting the transformer ................................................................... 11
2.6 Positioning the rail..................................................................................................... 11
2.7 Greasing the rail........................................................................................................ 11
3 Assembly ........................................................................................................................ 12
3.1 Prepare drive unit...................................................................................................... 12
3.2 Drive onto the rail ...................................................................................................... 14
3.3 Calibration of level sensors......................................................................................... 15
3.4 Basic installation with rail data .................................................................................... 15
3.5 Preparing the drive unit for use ................................................................................... 16
3.6 Fit the chair base ...................................................................................................... 16
3.7 Installing the manual swivel seat fitting ........................................................................ 17
3.8 Chair base height adjustment ..................................................................................... 18
3.9 Height of the footrest ................................................................................................. 19
3.10 Adjusting the length of the safety belt .......................................................................... 20
3.11 Fixing the rail to the stairs .......................................................................................... 20
3.12 Registering controls ................................................................................................... 21
3.13 Setting mode -8-, Assign Call/Park .............................................................................. 22
3.14 Safe point ................................................................................................................ 23
3.15 Installation without raildata provided ........................................................................... 23
4
1 Preparations
1.1 At the branch
Check using the installation drawings and the shipping receipt whether all the required parts of the
drive unit are present and undamaged, especially:
The rail sections and
the section bushes.
The chair base with
control unit.
The drive unit.
Various loose
components, such
as: call and park
units with joysticks,
transformer, flash
card, two-core power
cable, charging
contacts, rail
brackets with fixing
materials and an
installation drawing.
Consult the installation drawing and the bill of materials to check:
the colour of the rail.
the type and colour of the upholstery.
1.2 At the customer’s home
Inspect the area in which you plan to install the stairlift to verify that all the necessary and
agreed structural alterations have been carried out. If these alterations have not been carried
out, then you should consult the Chief Engineer or the Service Manager.
Inspect the area where you plan to install the drive unit for damage. Inform the customer of
any damage you find, and make a note on the requisite form. Have the customer sign the
form.
To ensure that you will be able to work without having to wait, you will need to go through all
the points for which you need information from the customer, i.e.:
o What is the best position for the transformer?
o What is the best place for the call and park units?
o Is there anything that you will need to remove or relocate (such as a painting, or a hat
rack)?
o Are there any structural points you will need to take into account?
NOTE
Give the
customer
the user's manual to read right away.
5
2 Installing the rail
During the preassembly you fit the entire rail together without fixing it to the stairs.
1. Sort the rail sections, brackets and legs by number (refer to the installation drawing).
2. Assemble the rail section for section from the bottom of the stairs to the top:
a. Fit the relevant legs and brackets to the rail section.
b. Insert a section bush into the upper end of the rail section.
c. Lay the rail section in position and draw the feeder cable for the charging contacts through
the rail section. When charging contacts are to be fitted to the relevant rail section make
sure that the feeder cable projects from the position of the charging contacts, and then
draw the remainder through the rail section.
d. Slide the rail section over the section bush of the previous rail section and clamp the
section bush.
e. Drive a locking pin into the rack coupling.
f. Repeat steps a to e inclusive for the next rail section.
g. Fit a cap to the top and bottom ends of the rail.
h. Assemble and install the charging contacts.
i. Connect the transformer.
j. Position the rail.
NOTE
The above is a recommended sequence. Usually, assembly from the bottom to the
top will be preferable; however, this is not always the case. Decide for yourself which
one you find is the simplest.
CAUTION
Ensure that the locking pin is securely seated in the rack coupling, it must not
protrude underneath the rail.
2.1 Fitting the legs and brackets
Three types of brackets are used:
Floor brackets (for a vertical stop at the bottom of the stairs).
Tread brackets (on the stairs).
Landing brackets (for landings and horizontal sections).
CAUTION
Fit the legs and brackets solely to the rail sections. Do not fix them to the stairs yet.
6
The floor bracket:
1. Insert two hammer-head bolts (1) in the
openings in the rail flange (2).
2. Fix the floor bracket (3) to the rail flange with
the two hammer-head bolts and two
Tensilock nuts (4).
The tread brackets:
1. Prepare the support if necessary.
2. Fit the leg (12) to the foot (10). Do this by
assembling the M10 bolt (13) and locknut
(9).
3. Screw the bolt (7) and washer (11) into the
wedge in the leg (12) with the rail bracket (6)
between them at the right height.
CAUTION
Always fit the nut out of sight on the side
facing the wall. Fit the bolt on the side facing
the stairs.
The landing brackets:
1. Fix the landing bracket (14) to the rail flange
(16) with two Tensilock bolts (15).
7
2.2 Connecting the rail sections with a section bush
1. Tighten (loosely) the four socket-head screws
in the section bush so that the four nuts are
trapped in the slot on the inner surface.
2. Fit the section bush in the end of a rail
section and adjust it to the correct position.
3. Lock the section bush by tightening the first
socket-head bolt (do not over-tighten).
4. Slide the other rail section over the section
bush and make sure that the two sections
mate properly.
5. Position a locking pin in the uppermost hole
in the rail section.
6. Push the locking pin using a welding clamp
or adjustable wrench into the rack.
2.3 Installing the feeder cable
1. Pull the two-core feeder cable with a cable
puller through the rail section tube.
2. Pull the feeder cable through the opening in
the flange for the charging contacts. Ensure
that the length through the rail hole L is
approximately 20 cm.
NOTE
A rail section with a parking point will be
fitted with an extra bracket with a feedthrough opening. The two-conductor feeder
cable must also be fed to this.
8
2.4 Fitting and installing the charging contacts
2.4.1 Fixed charging contacts
The positions of the fixed charging contacts are
prepared on the rail at the factory. The charging
contact is installed as follows:
1. Strip approximately 9 cm of the feeder cable.
2. Attach a Faston connector to the cable ends.
3. Feed the cables through the charging
contact.
4. Secure the Faston connector on the lips in
the charging contact.
5. Fit the charging contact to the rail with (2x)
M6x16.
6. Adjust the position of the charging contact so
that it is in line with the drive unit spring
contact. Adjustment is always necessary for
a vertical start.
7. For the polarity of the contacts, please see
section 2.4.3
9
2.4.2 Add-on charging contacts
There are also charging contacts that can be
fitted afterwards by a technician. The bracket for
this charging contact is attached to the rail with
two screws.
Make sure that when you order this charging
contact you also specify the color of the rail.
Only mount the movable charging contact at the
following places:
straight sections of the rail.
vertical bends in the rail.
horizontal bends in the rail.
The bracket cannot be mounted on combined
bends (Spirals). The center of the bracket must
be a minimum of 130 mm from the beginning or
end of a Spiral.
Fit this charging contact as follows:
1. Select a hole in the tooth rack to which the
movable charging contact can be fitted.
2. Drill holes (5 mm) next to this hole in the
tooth rack (23.5 mm apart, 34 mm to
underside of rack) for attachment of the
bracket.
3. Tap these holes with M6 threads.
4. Drill a hole (16 mm) in the rail for the cable
feed-through (15 mm from the tooth rack).
5. Fit the supplied rubber grommet in the hole
through the rail.
6. Fit the bracket to the tooth rack using the two
screws and two spacers.
7. Connect the charging contact and fit the
charging contact on the bracket.
8. Feed the wiring through the grommet and
through the tube and connect the wiring to
the power supply.
9. Adjust the position of the charging contact so
that it is in line with the drive unit spring
contact.
10
2.4.3 Connection of charging contacts
CAUTION
The connections to the + and - terminals
of the bottom charging contacts must be
reversed as compared to those of the
other charging contacts. This is
necessary to enable the drive unit to
detect that it has reached the bottom of
the stairs and must stop. This is the socalled reset point.
NOTE
For the parallel connection of multiple
charging contacts, the cables can be
connected with splice connector. When
there are several floors, the connection
can best be made at the junction.
CAUTION
Only use original supplied transformer.
Transformer
Charging contact
Charging contact
Charging contact
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