AAT Vario-max User manual

Translation of the original user’s manual
Stair climbing system Vario-max
GB

CE declaration of conformity
AAT Alber Antriebstechnik herewith declares that the products of the stair
climbing system Vario-max have been designed and manufactured accor-
ding to the current regulations of the guidelines 200/747/EG and
2006/42/EG of the European Union.
This declaration becomes void, if any changes or alterations of any sort are
being made at the above described devices without the consent of Alber An-
triebstechnik.
Signature of the manufacturer:
Markus Alber
Managing shareholder
AAT Alber Antriebstechnik GmbH
Vario-max
2
vario_max_gb_10_2010
AAT Alber Antriebstechnik GmbH
Postfach 10 05 60 · D-72426 Albstadt
Tel. +49.74 31.12 95-0 · Fax +49.74 31.12 95-35
[email protected] · www.aat-online.de

3
Table of contents
CE declaration of conformity . . . . . . . . . . . . 2
Table of contents . . . . . . . . . . . . . . . . . 3
1 General information . . . . . . . . . . . . . . . . . . . . . 5
1.1 How to use this user’s manual . . . . . . . . . . . 5
1.2 Instruction . . . . . . . . . . . . . . . . . . . . 5
1.3 Care and maintenance . . . . . . . . . . . . . . . 5
1.4 Warranty and liability. . . . . . . . . . . . . . . . 5
2 Description of the product. . . . . . . . . . . . . . . . . . 6
2.1 Adequate use . . . . . . . . . . . . . . . . . . . 6
2.2 Features of the Vario-max . . . . . . . . . . . . . 7
2.3 Technical data . . . . . . . . . . . . . . . . . . . 8
2.4 Dimensioned sketch . . . . . . . . . . . . . . . . 9
2.5 Standard scope of delivery . . . . . . . . . . . . . 10
2.6 Optional accessories . . . . . . . . . . . . . . . . 11
3 Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Model for the transportation of people . . . . . . . . 12
3.2 Disassembly . . . . . . . . . . . . . . . . . . . . 13
3.3 Connector with helix cable . . . . . . . . . . . . . 13
3.4 Attach the battery pack. . . . . . . . . . . . . . . 13
3.5 Detach the battery pack . . . . . . . . . . . . . . 13
3.6 Adjust the handles . . . . . . . . . . . . . . . . . 14
3.7 Functional check. . . . . . . . . . . . . . . . . . 14
4 Safety instructions . . . . . . . . . . . . . . . . . . . . . 15
4.1 Special information concerning the operation . . . . 15
4.2 Instruction . . . . . . . . . . . . . . . . . . . . 15
4.3 Safety brakes . . . . . . . . . . . . . . . . . . . 15
4.4 Lining of climbing foot . . . . . . . . . . . . . . . 16
4.5 Lifting capacity . . . . . . . . . . . . . . . . . . 16
4.6 Care and maintenance . . . . . . . . . . . . . . . 16
4.7 Conditions of paths, walkways etc. . . . . . . . . . 16
4.8 Charge of the batteries . . . . . . . . . . . . . . . 16
4.9 Climbing mechansim . . . . . . . . . . . . . . . . 16
4.10 Transport . . . . . . . . . . . . . . . . . . . . . 16
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.1 Maximum lifting capacity . . . . . . . . . . . . . 17
5.2 Control light . . . . . . . . . . . . . . . . . . . . 17
5.3 Helix cable connector . . . . . . . . . . . . . . . 17
5.4 Battery pack . . . . . . . . . . . . . . . . . . . . 17
5.5 Safety brakes . . . . . . . . . . . . . . . . . . . 17
5.6 Lining of the climbing foot . . . . . . . . . . . . . 17
Vario-max

6 Instructions for operation . . . . . . . . . . . . . . . . . . 18
6.1 Control unit . . . . . . . . . . . . . . . . . . . . 18
6.2 Single step control . . . . . . . . . . . . . . . . . 19
6.3 Climbers . . . . . . . . . . . . . . . . . . . . . 19
6.4 Safety brakes . . . . . . . . . . . . . . . . . . . 20
6.5 Transportation of a person with the Vario-max . . . 21
6.6 Transportation of loads with the Vario-max . . . . . 22
6.7 Operation on level ground . . . . . . . . . . . . . 22
6.8 Adjust the handles . . . . . . . . . . . . . . . . . 22
6.9 Tilting the stair climbing system . . . . . . . . . . 23
6.10 Operation on slopes . . . . . . . . . . . . . . . . 23
6.11 Climbing upstairs . . . . . . . . . . . . . . . . . 24
6.12 Climbing downstairs . . . . . . . . . . . . . . . . 27
6.13 Laying the Vario-max on the stairs ........... 29
6.14 Transport ......................... 30
6.15 Trouble shooting ..................... 30
7 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1 Battery pack . . . . . . . . . . . . . . . . . . . . 31
7.2 Charging cable for your vehicle . . . . . . . . . . . 31
8 Care, maintenance and recycling. . . . . . . . . . . . . . . 32
8.1 Charger . . . . . . . . . . . . . . . . . . . . . . 32
8.2 Battery pack . . . . . . . . . . . . . . . . . . . . 32
8.3 Fuses . . . . . . . . . . . . . . . . . . . . . . . 33
8.4 Check brake lining . . . . . . . . . . . . . . . . . 35
8.5 Check the lining of the climbing foot . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.6 Cleaning. . . . . . . . . . . . . . . . . . . . . . 36
8.7 Recycling . . . . . . . . . . . . . . . . . . . . . 37
9 Warranty and liability . . . . . . . . . . . . . . . . . . . . 38
9.1 Warranty . . . . . . . . . . . . . . . . . . . . . 38
9.2 Liability . . . . . . . . . . . . . . . . . . . . . . 38
4
Vario-max

1 General information
Congratulations for acquiring the Vario-max.
With this device you may transport a person with a walking disability or heavy
loads effortlessly upstairs and downstairs. Even winding stairs or inclines are
no problem. The safety brakes on both sides assure the necessary safety. Für
die Beförderung auf Ebenen ist der Vario-max ebenfalls sehr gut geeignet;
er ist raumsparend, leicht und wendig. Naturally the Vario-max is also suit-
able to drive on level ground. The device is lightweight, flexible and does not
take up much space.
The Vario-max is capable of climbing stairs up to a step heigth of 21 cm.
The minimum depth of the step’s surface must be 14 cm, regardless of the
type of stairs (regular straight stairs or winding stairs).
The necessary step width concerning straight stairs is the width of the Va-
rio-max plus an extra 10 cm for manoeuvring.
The minimum platform size for u-shaped stairs depends on factors such as
the attendant’s height, etc. AAT Alber Antriebstechnik GmbH or one of its re-
presentatives are happy to advice you personally.
The sticker with the device’s serial number is located on the left side of the
housing. Read the number here.
1.1 How to use this user's manual
The user’s manual is part of the delivery package and instruct you step by
step about the safe and adequate use of the Vario-max. Operating the Va-
rio-max takes a certain skill.
Please read this user’s manual carefully and particularly take note of the sa-
fety instructions before you use the Vario-max for the first time.
After reading, please store this user’s manual at an appropriate place for
further reference.
1.2 Instruction
In the interest of your safety the Vario-max may only be operated by trained
personnel.
Instruction on how to operate the device is part of the delivery package and
takes place with an AAT representative.
FPlease read this user’s manual carefully and particularly take note of
the safety instructions before you use the Vario-max for the first
time.
1.3 Care and maintenance
One of the most important aspects concerning the maintenance of the Va-
rio-max is charging the sealed lead acid batteries. They are part of the batte-
ry pack and must be charged every time after using the device.
Other than that your Vario-max does not need much care or maintenance.
More extensive instructions you find in chapter 8.
1.4 Garantie und Haftung
For damage that was caused by inadequate use disregarding this manual we
assume no liability whatsoever. (Please read chapter 9 for more detailed in-
formation concerning warranty and liability).
5
Vario-max

2 Description of the product
2.1 Adequate use
Please use the Vario-max exclusively for the transportation of a physically
disabled person or heavy loads.
For the transportation of persons you must secure him or her with the availa-
ble belt harness plus lap belt. Also make sure that the transported person’s
arms do not protrude over the arm rests to avoid potential injuries.
Loads must always be secured by the safty belt.
FIn the interest of your safety you may not use the stair climbing devi-
ce Vario-max on escalators or moving belts!
FOnly authorized operators may use the Vario-max.Therefore never
leave the Vario-max unattended.
FPlease do not use the Vario-max in rain, slippery and wet conditions,
snow or ice due to the following potential safety hazards, e.g. danger
of slipping restricted braking effect etc.
FDue to safety reasons the Vario-max may only be operated by trained
personnel who are physically and intellectually capable to handle the
device in all situations of operation.
6
Vario-max

2.2 Features of the Vario-max
Model to transport loads (power unit)
1 = Handles
2 = Up/Down switch
3 = Speed control
4 = On/Off switch
5 = clamp plus locking screw
6 = Helix cable
7 = safty belt
8 = Single step switch
9 = Toe plate
10 = Main wheel
11 = Climbers
12 = Safety brackes
13 = Battery pack
Model to transport persons (seat)
1 = Back rest
2 = C-part with integrated seat
3 = Foot rest
4 = Seat belt system including hip belt
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Vario-max

2.3 Technical data
8
Vario-max
Measurements
Height = 1060 - 1400mm
Width, model for loads = 450 mm
Width with seat = 450 mm
Depth, model for loads = 550 mm
Depth with seat = 815 mm
Weight Power unit = 22,5 kg, seat = 8,2 kg, battery pack = 4,3 kg,
Total weight = 35 kg
Max. lifting capacity (model for
loads) 170 kg
Max. lifting capacity (model to
transport persons) 160 kg
Batteries 2 x 12 V / 5 Ah (sealed lead acid)
Direct current motor 24 V / 275 W
Climbing speed 8 - 23 steps / minute, continually adjustable
Capacity with one battery charge 10 - 25 floors, depending on the load
Max. height of step 21 cm
Noise level The device’s A weighted noise level lies typically below 70 dB (A)
Storing/operating temperature,
device 0° C up to + 60° C / - 30° C up to + 50° C
Storing/operating temperature,
batteries 0° C up to + 60° C / - 30° C up to + 50° C
Vibrations The weighted RMS value of acceleration the upper body is exposed to lies
typically below 2,5m/s²

2.4 Dimensioned sketch
9
Vario-max

2.5 Standard scope of delivery
1 = Power unit
2 = C-part with integrated seat
3 = Back rest
4 = Seat belt system including hip belt
5 = Battery pack
6 = Charger
plus the user's manual
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Vario-max

2.6 Optional accessories
1 = Increase of climbing height
2 = Extra battery pack
3 = Charging cable for the car
4 = Extended handles
Accessories to transport loads
5 = Support for round containers
6 = Hook for crates
7 = Holding device for grocery boxes
8 = Back wall
9 = Special plate to transport laundry
10 = Special plate to hinge on
11 = Auxiliary stairs
Accessories to transport persons
12 = Foot rest, adjustable in height
13 = Extended/shortened foot rest
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Vario-max

3 Assembly
The Vario-max's serial model is the one to transport persons. All you have to
do is to plug in the helix cable at the device (see chapter 3.3) and to mount
the battery pack, as described in chapter 3.4. In addition, you need to adjust
the grips to the appropriate height (see chapter 3.6).
If you left the device in its variation to transport loads, you simply need to
unfold the toe plate and fasten the load with the safty belt.
The transformation from the model for loads to the one for persons is descri-
bed in chapter 3.1.
3.1 Model to transport persons
3.1.1 Attach the back rest
Hook the back part onto the upper horizontal bar and press it against the
power unit’s frame.
3.1.2 Attach the C-part plus seat to the climbing frame
Unfold the toe plate (if you haven’t already done so).
Now put the C-part plus seat onto the climbing frame; the locating bolts of
the C-part fit into the corresponding holes in the frame .
3.1.3 Mount the C-part
Please tighten the locking bolts tightly so that the C-part is securely
mounted on the frame.
FAlways make sure that the C-part plus seat is securely fastened to the
frame.
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Vario-max

3.2 Disassembly
To transport loads with the Vario-max again, you need to disassemble and
assemble the device in reverse order, (see chapter 3.1.)
3.3 Connector with helix cable
Put the connector of the helix cable into the socket on the power unit’s
housing .
FPlease make sure that neither the connector nor the socket get wet
e.g. by rain or snow. Moisture at the plug contact may lead to short
circuits and malfunction.
3.4 Attach the battery pack
Please place the battery pack on the locking bolts on top of the power unit’s
housing.
3.5 Dettach the battery pack
Press the locking bolt on the battery pack and simply lift it off the power
unit’s housing.
13
Vario-max

3.6 Adjust the handles
3.6.1 Adjust the height of the handle
Pull out the handle to the appropriate height – at most shoulder height—and
lock them with the locking bolts (see chapter 6.8).
FPlease always check whether the handles are securely locked.
3.6.2 Adjust the angle of the handle
Loosen the locking bolts and unscrew them about 6 mm. Then jiggle the
handle outward until it can be pushed forward. At the appropriate angle put
the locking bolt back into the drilling and retighten the locking bolt.
FPlease always check whether the handles are securely locked.
3.7 Functional check
FPlease check the safety brakes each time before using the device
(see chapter 6.4 and 8.4)!
FPlease also check the safety brakes’ braking effect as described in
chapter 6.4.1 and 6.4.2!
FPlease check the device’s electronic functions each time before
using it (see chapter 6.11 and 6.12)
FRegularly check whether the climbing feet’s linings are still suffi-
cient (see chapter 8.5)
FMake sure that the battery pack is charged before you use the device!
14
Vario-max

4Safety instructions
FFor a safe operation of the Vario-max it is important that you observe
and adhere to all warning signs and instructions in this user’s manual
as well as the warning signs and instructions on the device itself.
4.1 Special information concerning the operation:Due to safety rea-
sons the stair climber Vario-max may not be used on escalators and moving
walkways!
4.1.1 Environmental conditions, electro-magnetic compatibility:Elec-
tro-magnetic compatibility means that an electric device functions properly
in its electro-magnetic environment without influencing other devices in the
same environment.
FNevertheless, please check the device’s electronic functions before
each operation. This particularly applies if there are radio masts in
the close vicinity.
FPlease note that the Vario-max may interfere with the electromagne-
tic fields of other electronic devices (e.g. anti-theft systems in de-
partment stores). Other devices may also interfere with the
Vario-max.
FAlso make sure that you do not operate the Vario-max in close vicini-
ty to medical devices with a high potential of danger and/or life pre-
serving functions as well as diagnostic devices.
4.1.2 Climate:To ensure proper functioning it is not advisable to expose
the Vario-max to freezing conditions. Should this be unavoidable, always
put the device in a non-freezing environment for at least one hour before
using it.
4.2 Instructions: The Vario-max may only be operated by trained per-
sonnel. In addition, the operator should be capable of lifting 1/3 of his or her
own weight. Minors are not allowed to use the Vario-max exempt for the abo-
ve are adolescents over 16 years of age who have been trained under supervi-
sion to operate the Vario-max. While using the Vario-max you should always
wear good shoes that do not slip.
4.3 Safety brakes: Please check the safety brakes each time before
using the Vario-max (see also chapter 6.4 and 8.4). The safety brakes, parti-
cularly the knurled surface of the brake drums in the wheel rims, must be
cleaned weekly or after contamination with spirit to ensure the optimum bra-
king effect.
FNever smoke during the cleaning of the device as well as keep it away
from ignition source.
FPlease consider the danger warning of the manufacturer previous
cleaning the device with spirit.
FNever use suds or greasy cleaners.
After cleaning the safety brakes must be checked as described in chapter
6.4.
4.4 Lining of the climbing foot:Please check regularly whether the li-
ning of each climbing foot is still sufficient (see chapter 8.5).
15
Vario-max

4.5 Lifting capacity: The stated maximum lifting capacity of 170 kg for
the transportation of loads, and 160 kg for the transportation of people may
not be exceeded (see chapter 5.1).
4.6 Care and maintenance:Please make sure that you charge the bat-
tery pack after each use of the Vario-max.
If the Vario-max is not in operation, please turn off the device.
FRepairs may only be done by the manufacturer. Please use exclusive-
ly original AAT parts.
Please note the extensive care and maintenance instructions in chapter 8.
4.7 Condition of paths, walkways etc.: Please make sure that the paths
and walkways you use with the Vario-max are free of obstacles and not slip-
pery. Avoid operation on damaged stair linings, snow, ice, etc.
FThe Vario-max may not be used in wet and rainy conditions.
4.7.1 Environmental conditions:Although the Vario-max has been tes-
ted for its electro-magnetic compatibility, you should still check its electro-
nic functions before each use. This is particularly important if there is an
aerial mast nearby.
4.8 Charge of the batteries:You should only use the Vario-max with
fully charged batteries. In case the batteries run low on the stairs (a sequen-
ce of 2 flashes repeated every 2.5 seconds) the available charge of the batte-
ries is sufficient to transport the person or the load safely to the bottom of
the stairs. Driving downstairs the motor works as a generator, thus recharging
the batteries. The potential steps downward, therfore, are not limited.
4.9 Climbing mechanism: Please make sure that during the climbing
process your hands and feet are in no way close to the rotating area. Always
keep a safe distance.
4.10 Transport:
FMake sure you never lift the device at the frame!
FAlways turn off the Vario-max for transportation!
FWhen you transport the device in vehicles, please secure it according
to the relevant legal regulations in your country.
16
Vario-max

5 Operation
5.1 Maximum lifting capacity
Please make sure that the maximum lifting capacity of 170 kg for loads and
160 kg for persons is not exceeded.
5.2 Control light
After turning on the device, the control light should light up and stay on.
Flashing of the control light indicates malfunction.
Further information on malfunction you find in chapter 6.1.4
5.3 Helix cable connector
Check whether the connector of the helix cable is plugged into the hou-
sing of the power unit and locked each time before you use the Vario-max .
5.4 Battery pack
Please make sure that the sealed lead acid batteries are fully charged be-
fore you use the Vario-max for the first time.
Extensive instructions you find in chapter 8.3
5.5 Safety brakes
Before operating the Vario-max check the safety brakes every single time.
Extensive instructions you find in chapter 6.4
5.6 Lining of the climbing foot
Please check regularly whether the lining on each climbing foot is still suf-
ficient.
Further instructions you find in chapter 8.6
17
Vario-max

6Instructions for operation
Before we get to the actual instructions for operation, we would like to intro-
duce the Vario-max's most important components to you:
6.1 Handle for operation
In the standard version controls such as the On/Off switch , speed control
Up/Down switch are located on the right handle.
6.1.1 On/Off switch
If the Vario-max is not in operation, please turn the device off.
FThe Vario-max is equipped with a turn-off feature: if the device is on
and has not been used for 5 minutes, the turn off feature switches
the Vario-max off automatically. In such case you can only use the
Vario-max again by pressing the On/Off switch.
6.1.2 Up/Down switch
With the Up/Down switch you activate the climbing mechanism up- or
downstairs.
6.1.3 Speed control
The speed control enables you to adjust the speed continuously. When you
use the Vario-max for the first time, please choose the lowest speed.
6.1.4 Control light to indicate malfunction
After turning on the Vario-max the green control light (LED) lights up and
remains lit, which indicates that the stair climbing system is in order and
ready to use.
Potential malfunction is indicated by a light diode. After a period of 3 se-
conds each time a blinking signal is repeated.
In case of malfunction, turn the device first off and then on again. If there is
still an indication of malfunction, charge the batteries in case of low battery
charge. For all other cases of malfunction, please contact your manufacturer
AAT Alber Antriebstechnik GmbH or your AAT representative.
Vario-max
18
LED is blinking Identified malfunction
1 x overload of the device
2 x battery pack, undervoltage
3 x overvoltage
4 x up/down switch or its supply line is damaged
5 x defective electromagnetic brake
6 x malfunction of electronics

6.2 Single step control
The single step switch is located on the climbing frame .
If you activate the On/Off switch in that mode, the device will climb only one
step at a time. The climbing system stops in the correct position, even if you
press the On/Off switch continuously.
The climbing mechanism cannot unintentionally be activated. You can take
your time to move the main wheels to the next step’s edge.
To continue climbing you simply release the Up/Down switch and then press
it again.
The arrows with the dotted line symbolize the interruption of the climbing
process, i.e. the single step mode is activated. To do that you press the ro-
cker switch on I. By contrast, if you press the rocker switch on Oit signifies
the uninterrupted climbing process, i.e. the single step mode is OFF.
6.3 Climbers
The climbers (see picture) must be pulled in to topmost position by means of
the Up/Down switch if you want to:
•drive on level ground and on slopes
•check the safety brakes
•begin climbing upstairs and downstairs
However, you need to fold out the climbers by activating the Up/Down
switch, direction up, whenever a person takes a seat in the Vario-max ,so
the device is supported by the climbers (please also see chapter 6.5.1).
19
Vario-max

6.4 Safety brakes
There are safety brakes located on the climbing frame on both sides.
FPlease check the safety brakes each time before you use the Va-
rio-max.
You may check the brake effect either on top of the stairs or on level ground
as described in 6.4.1 and 6.4.2 .
6.4.1 Test the required brake effect
Pull in the climbers to their upmost position and tilt the Vario-max bac-
kwards until the back rest is in an almost horizontal position. If the Va-
rio-max cannot be pushed forward by the handles in said position, but mere-
ly rolls backwards, then the required brake effect for the safe operation of the
Vario-max is granted (see picture).
FImportant: If the required brake effect is not guaranteed, you may,
under no circumstances, use the Vario-max any more. Please con-
tact the manufacturer AAT Alber Antriebstechnik GmbH or your AAT
representative immediately.
FShould the brake not kick in, you may under no circumstances use
the device. Please contact the manufacturer AAT Alber Antriebstech-
nik GmbH or your AAT representative immediately.
6.4.2 Test the required brake effect at the top edge of the stairs
FPlease do not test the braking efficiency with a person sitting in the
chair or a load on the device.
Pull in the climbers to their upmost position and tilt the Vario-max bac-
kwards until the back rest is in an almost horizontal position. Drive the Va-
rio-max in this position (but without a load or person!) to the edge of the top
step. If the Vario-max cannot be pushed over the top step, the required safe
operation is granted.
FImportant:If the required brake effect is not guaranteed, you may,
under no circumstances, use the Vario-max any more. Please con-
tact the manufacturer AAT Alber Antriebstechnik GmbH or your AAT
representative immediately.
FShould the brake not kick in, you may under no circumstances use
the device. Please contact your the manufacturer AAT Alber An-
triebstechnik GmbH or your AAT representative immediately.
20
Vario-max