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Flow2 stairlift service & Installation

Updated: Jun 3, 2023

By Thyssenkrupp


Flow2 stairlift service & Installation, Check using the installation drawings and the shipping receipt whether all the required parts of the drive unit are present and undamaged, especially:


Flow2 stairlift service & Installation

Installation




CAUTION Fit the legs and brackets solely to the rail sections. Do not fix them to the stairs yet



The floor bracket:

1. Insert two hammer-head bolts (1) in the openings in the rail flange (2).

2. Fix the floor bracket (4) to the rail flange with the two hammer-head bolts and two Tensilock nuts (3).



flow 2 service repair The floor bracket

 

The tread brackets:

Possibly prepare the support.

1. Fit the leg (5) to the foot (10). Do this by assembling it with the M10 bolt (15) and locknut (20).

2. Screw the bolt (6) and washer (22) into the wedge (3) in the sleeve (5) with the rail bracket (2) between 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



The landing brackets: 1. Fix the landing bracket (8) to the rail flange (10) with two Tensilock bolts (9).


TOP BRACKET

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 supply cable with a cable puller (2) through the rail section tube.

2. Pull the supply through the opening (1) in the flange for the charging contacts. Ensure that the length through the rail hole L is approximately 20 cm.


 


TIP - A rail section with a parking point will be fitted with an extra bracket with a feed-through opening. The two-core supply cable must also be fed to this.


2.4 Fitting and installing the charging contacts

The charging contact is installed as follows:


1. Strip approximately 9 cm of the supply 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.


Fitting and installing the charging contacts The charging contact

TIP For the parallel connection of multiple charging contacts, the cables can be connected with solder cap. When there are several floors, the join can best be made at the junction (see Fig. 2-11).



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 so-called reset point (see Fig. 2-10).



multiple charging contacts

Connecting and mounting the transformer

  1. Connect the transformer to the charging contacts closest to a 220V wall socket. Use an extension lead if necessary.

  2. Put the transformer plug in the wall socket.

  3. Check that the voltage is approximately 33 V and the connection is as indicated in the upper parts of the figures.

  4. Connect the building wires from the charging contacts to the transformer.

  5. Choose a suitable position for the transformer and secure it with four screws and washers.

TIP . Instead of extending the mains cable you can also extend the building wire and then fix it out of sight. Remove the plug from the wall socket.



 

Positioning the rail



1. Check the adjustment positions 'X', 'Y' and 'Z' using the installation drawing. The adjustment dimensions are measured from the wall or a tread to the centre of the rail’s pipe.

2. Check the gradient of the rail against the gradients shown on the installation drawing.

3. Locate the rail in the optimum position.

4. Adjust the legs and brackets such that the rail is stable on the stairs. Insert one or more spacers between the legs and the rail if so required.


Greasing the rail

1. Degrease the rail with degreaser if it is greasy.

2. For greasing, use 'Super Lube' grease and spread it on the rail with a brush. - Grease the bearing surfaces in the holes. - Grease the support wheel running surface.



 

Assembly

Fully assemble the lift. Do not yet secure the rail to the stairs.


CAUTION It is possible that the entire unit becomes somewhat unstable. In that case secure the rail temporarily (for example with glue clamps).


TIP When the driving-on point is at the top of the stairs, the drive unit will have to be carried to the top in its box. The other boxes can be unpacked downstairs. Bring the empty packaging material back downstairs again. You will then be certain that you do not forget anything or accidentally throw something away with the packaging.


For the 'commissioning' of the Flow2, the following procedure has been defined. It is extremely important to actually perform all the steps in sequence.


Procedure:

1. Prepare the drive unit.

2. Preparing to drive onto the rail.

3. Driving onto the rail.

4. Registering the radio frequency equipment.

5. Preparing the drive unit for use.

6. Fitting the chair base on the drive unit.

7. Installing the rail.



Prepare the drive unit

Place the drive unit, in its packaging, at the location where it will be driven onto the rail.

This is done as follows:

1. Open the packaging.

2. Remove the top frame from the box and place it next to the driving-on point on the rail. 3. Lift the drive unit out of the box and place it on the top frame so that the drive unit is in the right position to drive onto the rail.


 

Preparing to drive onto the rail

1. Remove the service cover.

2. Fit the fuse (40 A) in the drive unit, the fuse is located in the handle.

3. Turn on the drive unit by pulling the red main switch, on the rear of the drive unit, up a few millimeters.


TIP

When switching on the lift an audio signal will be heard. The three-digit release number will also be shown in the service unit display.

4. Check that the mode knob on the service board is set to mode 3.


5. If there is no end cap, fit an end cap on the end of the rail. 6. Turn the handle on the support bracket, shown in the figure, two ways to check whether the motor runs. You use this handle for driving on the drive unit


CAUTION

Take ESD precautions, such as a mat, strap and shoes. Never touch a circuit board without taking these precautions.


CAUTION

Check the wiring if the motor does not run.


 

Driving onto the rail

The drive unit is positioned on the top frame at the driving-on point, it can now be easily driven onto the rail. Ensure that you are standing in front of the drive unit as shown in Fig. 3-9.

1. Ensure that the transformer plug is not plugged into the wall socket.

2. Position the forks of the loading assembly straight under the drive unit so that they are in line with the rack while driving onto the rail.

3. Grasp the drive unit by the support bracket and the undercarriage.


4. Push the first undercarriage onto the rail.


5. Keep the drive unit horizontal and push it onto the rail until the drive pinion touches the rack.



6 . Carefully drive the drive unit onto the rail using the handle on the support bracket. During this, check the position of the forks; they should be on either side of the pinion. Correct the position if necessary.


7. Keep the drive unit horizontal so that the rear undercarriage can drive onto the rail properly.


CAUTION

Ensure that the drive unit is kept horizontal while driving it onto the rail to prevent the drive unit becoming stuck on the rail.


8. Put the transformer plug in the wall socket.


9. Drive the drive unit from the top to the bottom to the reset point (lowermost charging contact) and stop a few millimeters above the centre of this charging contact. At the moment that the charging blades come into contact with the reset point the message 'rSt' must appear briefly in the display. If this does not occur, check whether the reset point has been correctly connected and that there is a voltage at the contact.


WARNING

A reset must be done in the downwards direction. For driving onto the rail downwards this means: first drive past the reset point and then drive back again. The ‘rSt’ message only appears when the drive module is moving.


WARNING

Driving on mode (-3-) and programming mode (-6-) take no account of the position on the rail. Ensure that the lift does not drive into the ground or off the rail.


Registering the radio frequency equipment


Now the radio frequency (RF) equipment can be registered. The Flow2 has a number of standard and a number of optional RF equipments.


Standard: - armrest control - call and park units

Optional: - attendant control unit - repeater.


When an RF equipment is registered, it receives a specific code. The code ensures that a specific equipment can only operate the associated drive unit and not that of a neighbour. If there is another Flow2 in the vicinity or another RF equipment, it is possible for this to be on the same channel and interfere with one another with the result that the lift stops or will not move. In this case you must change the channel. To choose a different channel, carry out the following actions: - go to menu -9- for CH1, now choose CH 2 or CH3 - register all RF boxes again as described below.


TIP

When you operate the park button on the call and park unit, the stairlift will not go further than the programmed parking contact. If the stairlift should be ridden further, an attendant control unit must be used.


CAUTION

For registration, both the drive unit and the RF equipment must be switched to registration mode.


Registering control boxes


1. Make it possible for you to identify the boxes by coding them: -

  • '0' for the call and park unit at the bottom. -

  • '1' for the unit fitted a bit higher. -

  • '2' for the next higher unit, and so on. -

  • 'Att' for the attendant control unit.



TIP

A maximum of nine call and park units can be registered (codes ‘0’ to ‘8’).


2. Place the batteries in the battery holder.

3. The RF equipment is in register mode as standard. Select mode 7 and press the [E] button on the service board. A question mark appears on the service board display ( -p- ). This indicates that the drive unit is waiting for a signal from the RF equipment to be registered. If this does not happen, go to the next section.


4. Move the joystick in the control unit, the red LED flashes. Depending on the type of RF equipment, the following message appears in the display:

Ui Armrest control (ui).

CPU Call and park (CP0).

rEP Repeater (rEP).


5. When registering a call and park unit, for example, at step 4 'CP0' in the display indicates that the drive unit gives the RF equipment code '0' for further programming. If this does not match the code you set yourself, go to step 7.


6. If the code does not match, the last digit in the display must be set so that it does match with the [I] and [D] buttons. The [I] button increases the digit, going from '0' to '8' and then 'Att' for the attendant control unit. The number is decreased with the [D] button.


7. Press the [E] button for 2 seconds. Registration is now carried out. The display now shows '7' and the flashing red LED on the control unit goes out.


8. Check that the green LED lights when the control is operated on the control unit. This indicates that the RF equipment has been programmed.


9. Carry out steps 2 to 9 for each control unit.


Re-registering a control unit


This section can be skipped when the control units have been registered without any problems.

If the red LED does not flash during registration when the joystick on the control unit is moved, there is a good chance that it has already been registered. This can be undone by carrying out the following actions.




1. Push the joystick on the control unit in a little


2. Move the joystick to the left until the LED lights green for a few seconds and then release it.


3. After a few seconds the LED goes out: then move the joystick to the right until the LED flashes red.


4. Go back to the previous section and continue with step 5


Registering a repeater


A repeater acts as a sort of radio signal amplifier so that the RF equipment can communicate over greater distances with the stairlift. A repeater is only necessary when the distance between the call and park units and the stairlift becomes so great that the stairlift will move jerkily.

The installation of a repeater consists of the following steps:

1. Go to mode 9 and choose option 'rPt'.

2. With the [I] or [D] button you can now choose from: - 'rP0': control does not account for a repeater. - 'rP1': control expects a repeater in the system.

3. Press the [E] button for a few seconds to save the setting.

4. Go to mode 7 to register the repeater. The procedure is the same as for the armrest control, only 'rPt' appears in the display. A flashing 'rPt' means that the control does not yet make account for a repeater. Steps 1-2-3 have therefore not yet been carried out.

5. Finally, all other RF equipment must be registered again, including the attendant control unit. If you forget this, the result with be jerky operation and incorrect LED indication of the equipment.


 

Setting the call and park positions

The call and park positions (or charging positions, see Section 3.4.1) of the call and park units just registered must now be entered.


1. Choose mode 8 and press the [E] button. The numbers in the display have the following meaning:

2. The number can be increased by pressing the button indicated. It is not possible to

decrease the number here. In this case you must keep the button pressed until the numbering starts at '0' again.


3. Check whether the call and park positions are correct for the call and park units just registered. If not, the positions can be changed with the [D], [E] and [I] buttons. Press the [E] button for 2 seconds to save all the positions that have been entered.



The RF equipment is now registered and assigned.


 

Preparing the drive unit for use


1. Remove the handle: - Remove the four M8 nuts. - Remove the cables from the service module with a pair of pointed nose pliers. - Pull the cable out.

2. Use a spirit level to check whether the chair flange is horizontal.


3. Select mode 4 if correction is required. - Press button [E] briefly. The current setting is shown in the display. - Set the flange horizontal with the [D] and [I] buttons (from -99 to 99). - Press button [E] for a long time to save the new setting.


4. Repeat this step for the three axes of the seat. The locking pin on the flange must point straight forwards. Choose mode 5 if correction is necessary.

TIP

Steps 3 and 4 can easily be checked by pressing the [E] button in mode 3


5. Switch the drive unit to mode 0 by turning the mode switch.

6. Fit the service cover. - Position the underside of the service cover in the drive unit (1).

- Push the cover against the drive unit (2).

7. Switch the lift off and then on again by operating the red main switch.


TIP

The drive unit is now in operating position. This means that the display is switched off


 

Fit the chair base


For a fixed seat, go to Section 3.6.1. The height of the seat is set as standard in the factory to the middle position. This can be adjusted according to the customer. First the seat first (Section 3.6.1) and check if the height is correct, after which it can be adjusted.



1. Remove the chair base from the box.


2. Remove the cover under the seat on the chair base.


3. Lift the seat onto the swivel seat.


4. Screw the M8 nuts onto the protruding threaded ends on the flange.


CAUTION

The pin on the flange locates in the extra hole in the chair base frame.


5. Refit the cap under the chair base


6. Estimate the size of the user


7. Adjust the seat height as necessary (Section 3.6.1).


8. Check the length of the safety belt. Adjust this if necessary (Section 3.6.2).


Installing the fixed seat and manual swivel seat


Fitting fixed seat - A filler plate is positioned between the Squeeze unit and the seat. This is supplied in the accessories box.









 


Fitting manual swivel seat

  • 1. Remove the standard screws and the seat screw from the squeeze unit flange and position the 4 threaded ends of the squeeze unit over the swivel adjustment unit, see Fig. 3-19.

  • 2. Remove the ball head assembly from the adjustment unit, see Fig. 3-20.

  • 3. Screw the ball head to the squeeze unit on the opposite side to the swivel side. Click the ball head onto the piston. Using the locking pins, see Fig. 3-21.

  • 4. Slide the ball with holder into the sleeve and screw the swivel frame tightly to the squeeze unit, see Fig. 3-22.

  • 5. Fit the box on the piston, see Fig. 3-23. Attach the holder to the lever, see Fig. 3-24 and Fig. 325.

  • 6. Check that the box is in line with the leg, see Fig. 3-26.

  • 7. Adjust the buffers, see Fig. 3-27.



 

Chair base height adjustment

The height of the chair base can be adjusted for the customer. This is done by choosing one of the five positions. Each position corresponds to a certain height. The stairlift leaves the factory in the middle position (position 3). One position is roughly 2 cm higher or lower. The following rule of thumb applies for raising the chair base: - An increase of one position of the seat height is accompanied by setting the footrest one position lower.


Height of the seat

The positions of the chair base are as follows (from low to high). The dotted line indicates the heights schematically:





Procedure:

1. Remove the chair from the drive unit - Remove the cover under the seat. - Remove the four M8 nuts. - Place the chair next to the drive unit.

2. Remove the service cover.

3. Remove the cover over the seat height adjuster

4. Adjust the height by moving the seat height adjuster to a position higher or lower than 3, see Fig. 3-28 to Fig. 3-32. - Unscrew the four M8 nuts with 13 socket spanner.



  • Move the height adjustment bracket frame to the correct position. -

  • For position 1: Turn the height adjustment 180º by holding the sensor board with cover at an angle in mode 3. This creates an extra low position. Place the bracket over these threaded ends and tighten the nuts on them. -

  • For position 2: Unscrew all the nuts, place the bracket on the right pins, fit the nuts and tighten them. -

  • For position 4: Turn the bracket around and tighten the nuts again. -

  • For position 5: Turn the bracket around and tighten the nuts again.

CAUTION The hole in the bracket frame must align with the height adjuster frame.


5. Refit the height adjuster cover.

6. Refit the service cover.



CAUTION Ensure that the cables are not trapped.



Height of the footrest

The position of the footrest depends on the height of the chair base. The following rule of thumb applies for setting the height of the footrest:

- An increase of one position of the seat height is accompanied by setting the footrest one position lower. To move the footrest one position lower, the footrest shaft must also be moved one position lower and the linkage one position higher.


Procedure:

1. Lay the chair as shown in Fig. 3-35 and use a clamp as necessary to stop the chair base folding up

2. Adjust the linkage following the rule of thumb by unscrewing the M6x16 bolt and sliding the linkage out. The post is in position

3. See Fig. 3-36. 3. Remove the two brackets by unscrewing the M6x16 bolt and sliding them out of the frame.

4. Set the correct position of the footrest shaft higher or lower than position 3, according to the rule of thumb, see Fig. 3-37.


5. Secure the linkage and the brackets again with an M6x16 bolt



CAUTION

The centre position is marked on the linkage by a rectangle and on the footrest by an arrow


Adjusting the length of the safety belt

1. Remove the cover on the left armrest with a flat screwdriver, see Fig. 3-38.

2. Move the pin to the right hole in the safety belt, see Fig. 3-39.

3. Refit the cover.



 

 

Fixing the rail to the stairs

After making a test ride, the rail position is optimal. The supports can now be fixed definitively.


1. Fit the rail system landing brackets with the correct mounting materials to the stairs. Drill holes if necessary.

2. Fit the rail system tread brackets with the correct mounting materials to the stairs. Drill holes if necessary.

3. Fit the rail system floor brackets with the correct mounting materials to the stairs. Drill holes if necessary.



 

Making a test run

The lift is in mode 0.


1. Sit on the chair base and operate the armrest control.

2. Make a number of trips and check that the chair does not touch the stairs.

  • a. If this does happen, go to Section 7: 'Extra information'.

  • b. If this does not happen, go to step

3. Check the entrapment protection mechanism.

  • a. Make sure there is an obstruction while moving, so that the chair turns around and the lift comes to a stop.

  • b. Turn the chair back by removing the obstruction.

  • c. Operate the lift again.

4. Check the call and park operation when the lift is folded up and driven upwards or downwards.

5. Check whether the lift stops roughly in the centre of the parking place/stop.

6. Check at every parking place/stop that the lift does not start peeping after 15 seconds.


CAUTION

The chair stops automatically at the bottom charging contact. The lift recognises this as the starting point because the polarity of the lowermost charging contact is the reverse of the other charging contacts. If this is not the case, drive the lift further as normal. In this case, check the polarity and the setting of the lowermost charging contact and reverse it.


7. Let the user make a test ride, change as necessary

  • - speed in menu 6

  • - sound setting in menu 9

  • - height adjustment of the seat

8. If the test ride is successful, a backup must be made of all the data on the flash card. Go to mode -9- of the service board, press the [E] button and then go to the 'bu' option with the [D] or [I] buttons. Then keep the [E] button pressed for 2 seconds. This is confirmed by a 'ping'.

9. Switch the lift back to mode '0' and then switch the lift off/on.

10. Remove the top cover from the drive unit.

11. Remove the flash card from the drive.

12. Secure the flash card in the cap with double-sided tape. Now the settings can no longer be changed via the service board.

13. Fit the emergency stop frame to the rack with two M6x16 bolts and two nuts.





 

Fitting the RF equipment


Call and park unit

The location of the call and park units must be determined in consultation with the customer. The call and park units must be mounted on the wall, in a location from where the complete rail system is visible. If this is not possible, a round mirror can be mounted.

1. Take the batteries out of the unit

2. Remove the call and park unit from its housing

3. Mount the call and park unit mountings on the wall. a. Mark the holes where the unit will be positioned. b. Drill holes and mount the call and park unit cases with the right mounting materials (plugs, screws and washers).

4. Assemble the batteries.

5. Click the call and park unit into their cases.

6. In public buildings: screw the battery cover closed with the M3 bolt and nut supplied.

7. Place the call and park stickers at the right places.

8. Place the logo stickers on the battery cover of the call and park unit



Repeater

1. Mount the repeater housing on a wall level with the middle of the rail, at least 0.4 m by 0.4 m from the corner of the wall.

2. Connect the adapter

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