Lehner Lifttechnik OMEGA-F User manual

Lehner Lifttechnik GmbH Austria – 4724 Neukirchen am Walde, Salling 8
Tel: [phone] Email: offic[email protected]
OMEGA-F
Installation Manual

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2020
Omega platform lift page 2 of 52
CONTENTS
OBSERVE THE FOLLOWING POINTS BEFORE INSTALLATION! .................................... 4
STEP 1. – INSTALLATION OF THE GUIDE RAILS .............................................................. 5
STEP 2. INSTALLATION OF THE DRIVE BOX .................................................................... 7
STEP 3. INSTALLATION OF THE TENSION AND SUPPORT ROPE SYSTEM .................. 7
Installing the tension rope ................................................................................................................... 9
Installing the support rope ................................................................................................................ 12
STEP 4. INSTALLATION OF THE PLATFORM ONTO THE RAIL/ROPE SYSTEM .......... 16
STEP 5. TIGHTENING AND CONNECTION THE ROPES ................................................. 17
STEP 6: ELECTRICAL CONNECTIONS ............................................................................. 17
STEP 7. MOUNTING THE MECHANICAL STOP STATION ASSEMBLY .......................... 19
STEP 8: ADJUSTMENT OF THE LOADING RAMPS ......................................................... 21
STEP 9: PROGRAMMING THE UNIT ................................................................................. 22
Programming the drive speeds - Teach-in mode ............................................................................. 28
ERROR LIST AND EXPLANATION .................................................................................... 31
FINAL CHECKS ................................................................................................................... 37
EMERGENCY OPERATION ................................................................................................ 38
EXPLANATION OF THE ELECTRICAL CONCEPT ........................................................... 39
DRIVE UNIT ......................................................................................................................... 40
Drive unit control board .................................................................................................................... 40
Buttons and Jumpers ......................................................................................................................... 43
Main contactor control board (MCCB) ........................................................................................... 44

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PLATFORM CONTROL ....................................................................................................... 44
Platform control board overview ...................................................................................................... 45
Switch positions in the platform ........................................................................................................ 45
CONFIGURATION OF THE REMOTE RADIO CONTROLS ............................................... 50
ADJUSTMENTS ON THE PLATFORM MECHANICS ........................................................ 51
Overview of the platform mechanics ................................................................................................ 51
Adjustment of the platform inclination ............................................................................................ 52
Dismantle the platform floor ............................................................................................................. 53

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Observe the following points before installation!
Installation teams must have a general knowledge in
 basic mechanical engineering and providing adequate fixation of the rails and pillars
 reading and understanding circuit diagrams and wiring schematics.
In order to save time and energy, it is wise to be properly prepared before installing the
OMEGA-platform lift. The following points will assist in completing the installation efficiently
and on schedule:
 Have a complete electrical and mechanical tool kit on hand.
 Check beforehand what fixing materials (screws, anchor bolts, adhesives) are
required for the proper fixing of the rails to the wall or the pillars to the floor. These
materials are not included in the delivery! The installation company is responsible for
the fixing of the rail to the wall or the pillars to the floor/steps!
 Have the correct on-site power supply set up using the correct fuses. The power
supply has to be connected to the motor box at the upper end of the rail.
 Assemble a team of 2 technicians to mount the plant.
 Check the packages for shipping damage and missing parts before bringing the lift
to the site.
 Open the installation package (which is in the box of the OMEGA lift). Review the
enclosed Installation notes, if supplied. In some cases, additional components must
be brought to the site.
 Refer to the tube layout drawing and familiarise yourself with the tube configuration.
The following tools will be required to finish the installation successfully:
 A complete toolset for
mechanical and electrical works
 Voltmeter
 Drilling machines
 Drills, thread cutter
 Fixing material
 Water lever with angle indication

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Step 1. – Installation of the guide rails
 The rail can either be fixed directly to the wall or to free standing pillars that are fixed
either to the steps, the side of the staircase or the ground floor. Generally the
following important measures are given to start the installation at the lower landing:
 In case of support pillars, these have the serial letters
indicated in the drawing that are also stamped on the
pillar base plate in order to identify the correct pillar.
To facilitate fixing of pillars it helps to provisionally fix
the pillars with rope clams.
W – perpendicular distance step nose to underside of lower rail
X – floor to lower end of rail connection bracket (of center of rail)
Y – first step to side of rail connection bracket
Z
–
floor to underside of lower rail

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2020
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 Drill the mounting holes, starting at the bottom with
Pillar A and working up the system. In concrete, use
a 10 mm diameter masonry bit. Otherwise use a
dowel and drill a 12 mm hole!. When mounting in
wood, use a standard 6 mm wood drill. Pass the lag
bolt (screw materials like lag bolts, nuts, washers,
etc., are not included in Lehner-Lifttechnik delivery-
specification) through a washer, and screw it into the
end of a plug anchor. The anchor can then be
tapped into position using a small hammer. Avoid
spilling dust into the hole.
 Check each connection for damage and lightly
grease both ends before joining the tube sections.
Fasten the connection with the splice bolts and nuts
provided.
 Check the clearance dimensions. Ensure that the
actual measurements correspond with the clearance
dimensions on the layout drawing.
 Remember: Vertical clearances are measured from
the centreline of the tube (this is also the lower point
of the bracket on the railway) to the stair nose or to
the floor.
 With the tubes in position, check all splice
connections for alignment. Note that the proper fit of
the splices is critical to ensure smooth lift operation.
When fixing the lift in place, smooth out any
misalignment using shims behind the mounting
struts.
 On longer lifts some discrepancies may occur. Try to
average them out while making a final check for
landing clearances, splice alignment and fit.
 With the system in place, check that all struts and
support pillars are plumb. Use a water level for this
work!
 Clean any debris from the inside of the tubes.

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Step 2. Installation of the drive box
When the tube system is anchored in place you can mount the drive box on the upper rail
end. Dismantle the cover as shown on the pictures below.
It is important to add washer and spring washer to the fixing screws, otherwise the screws
will hit the drive gear tooth wheel in the back of the drive unit.
Drive wheel
Drive unit control board
Frequency
inverter
Current donator
Mains filter
Main power
switch
Main contactor
control board
Transformer
Emergency
hand wheel
Moto
r
Gear box
Upper ultimate
limit switch
Connect tube wire
Connect tension cable wire
Connect earth wire
Fix with these screws to rail – do not
forget washer and spring washer!!!!!
Connection for
power supply

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2020
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Tension rope
Support rope
Step 3. Installation of the tension and support rope system
 Dismantle the mains filter form the drive wheel cover and also the complete drive
wheel cover from the drive wheel
 Remove the over speed governor tube section at the bottom of the system and put
the complete rope on the bottom close to the upper motor and make sure it does not
get dirty.

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2020
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Installing the tension rope
 Start feeding the tension rope into the upper tube of the guide rail. Put as much
tension rope in the tube until the cable sticks out around 500mm on the lower rail end
of the upper tube.
 The put the fixing bracket for the tension rope on the end of the tensions rope. See
the following page for detailed description.
 Put the tension rope support connection onto the end of the tension rope.

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 Pull back the tension rope inside the upper tube so that it stops where you want to put
the platform onto the rail. The fixing bracket must be a minimum of 810mm above
ground floor level.
 Add the current collector into the upper tube next to the fixing bracket. Make sure the
spring between the current collector and the upper fixing bracket is securely attached
to the current collector. This spring is responsible to make the electrical contact
between the tension cable and the platform control board.
Fix spring with
screwdriver on
p
in
Sliding contacts
connect rail with
control board
(electrical mass)
Pull
back
Hole in upper fixing bracket should be located
minimum 810mm above lower floor level

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 Please note that there is only 1 spring installed between the tension rope and
the current collector! There is not spring between the collector and the support
rope!!!
Fixing bracket
Current collector
Spring

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2020
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Installing the support rope
 Feed the support rope into the lower tube and make sure the tension rope engages
well into the motor drive wheel. Make sure you put some cover on the lower floor so
the support rope does not get dirty when it gets out on the lower tube end.
 Enter the lower rope into the over speed governor tube section. It might be necessary
to release the tension spring in order to facilitate entry of the rope into the safety gear
tube section. This spring later should be set to the same tension again after the rope
is installed!

The teeth of the wheel
have to engage into
the metal elements of
the support rope
Tension spring

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2020
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 Loosen this spring –
move the safety nut to
the end of the screw.
After tensioning the
cable put the safety nut
back into its original
position.
 Now you need to define the right length of the support rope. Approach the over speed
governor tube to the lower rail end to measure necessary support rope element
length. Check how many support elements of the tension rope have to be removed
so that the there is still enough space for the fixing bracket of the support rope.
Overspeed
govener tube
Fixing bracket
for support rope
Measure
amount of
elements
Approach tube
to connection
Move nut

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2020
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 It is important that there are not too many support elements on the support rope as
then it is not possible to tension the cable. A gap between the last support element
and the fixing bracket of the support rope is ideal. This gap depends on the length of
the rail and number of curves and is later reduced when the rope is tensioned! Below
a table that shows approximate gap length based on rail length.
 Below it can be seen how the rope system should look before
putting the platform onto the rail.
 Add the drive wheel cover and the mains filter again onto the drive wheel. This cover
must be fixed before the rope is tensioned!
Makes sure
elements are
pressed
together
Gap of X mm
before
tensioning the
cable
Fixing bracket of
support rope
Length Gap
3-6m 80mm
8m 85mm
10m 90mm
12m 95mm
14m 100mm
16m 105mm
18m 110mm
20m 115mm
22m 120mm
24m 125mm

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Detailed diagram of the rope fixing assembly to the platform sidewall
Please note that there is only 1 spring installed between the tension rope and the current
collector! There is not spring between the collector and the support rope!!!
Tension rope Support rope
Connect wire for
support rope on
cable clamp –
blue cable
Connect wire for
tension rope –
brown cable
Connect wire for
rail/tube – green-
yellow cable
Spring
connection
Make sure
plastic cap and
support rope is
placed as shown
here
Current
collector
Fixing
bracket
Upper fixing bracket

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Remove
conic
rollers
Step 4. Installation of the platform onto the rail/rope system
When the rope system is securely in place,
begin mounting the carriage. Complete the
following steps:
 Bring the carriage to the bottom of the
tube system and unwrap it.
 Remove the conical rollers from the
lower carriage.
 Carefully lift the carriage into position,
guiding the upper carriage rollers onto
the upper tube. Ensure that the rope
fixing brackets fit between the bosses
of the upper carriage. Be careful not to
scratch the paint on the tubes.
Note: The carriage weighs about 90
kg, so two people should install it to
ensure safety and avoid damage.
 Tighten the screws that fix the carriage
to the fixing brackets of the tension and
support rope.
 Install the conical rollers again on the
lower carriage.

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Connect to rail
1. Put in the plastic isolation parts around rope
2. Add metal parts
without tightening!
3. Add tensioning device
4. Tension
the rope
by around
40mm
5. Tighten these bolts
after the ro
p
e is tensioned
6. Add 2 rope
clam
p
s to fix ro
p
e
10. Connect
su
p
p
ort ro
p
e
9. Connect
tension
11. Put cover
12. Attach remaining rope in this
7. Add
plastic
tube
8. Connect to rail
Step 5. Tightening and connection the ropes
Note: Make sure you reinstalled the cover of the drive box before tightening the rope!

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2020
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Tube and
earth wire
Tension
rope wire
Current
Donator
Ultimate upper
limit switch
Main power
switch
Step 6: Electrical connections
 Connection the tension rope and the rail from the current collector, and the support
rope to the platform control board as described on the previous page.
 Connect the tension rope wire from the drive
unit control board to the current donator on
the drive wheel and also connect the earth
and the tube wire to the rail next to the
current donator.
 Connect the upper ultimate
limit switch to the drive unit
control board – connector
name “NESO”.
 Connect the on-site main
power supply to the main
power switch on the drive
unit.

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2020
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Step 7. Mounting the mechanical stop station assembly
 Adjust the position of the control cam in reference to the limit switch device on the
rail. The bypass switch has to be activated before the levers for unblocking of the
barrier arms touch the control cams on the rail.
Levers for
unblocking of the
barrier arms at
the upper and
lower control cam
Bypass switch
S16 and lever
Landing stop
switches

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2020
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 The bypass switch S 16 makes an
electrical bridge on the barrier arms
safety switches S14 and S15 and
therefore allows that the lift remains
in function although the barrier
arms are mechanically unblocked
and electrical safety circuit is
interrupted. S16 has to be activated
before the control cams start to
unblock the barrier arms in each
landing station. Otherwise the lift
will stop when the barrier arms are
unblocked, as thus the barrier arm
safety switches S14 and/or S15 are
pushed and the safety circuit is
interrupted!
 In the upper stop position (and also
intermediate stop positions) the
platform floor should be at the same
level as the landings.
 On the lower landing the carriage
should touch down slightly on the
bottom with both buffers located on
the lower end of the backside of the
carriage.
 Run the carriage out of the landings
and back again. If the lift does not
stop in the correct position, adjust it
as necessary.
 Adjust the ultimate limit
switch so that it is
properly aligned with the
activation pin on the
cover of the upper
carriage. The pin should
reach the switch in case
the normal limit switch
does not work.
Adjust the ultimate
limit switch and the
activation pins!
Activates
by-pass
Activates
limit switch
Deactivates
by-pass
Cam for
unblocking
of barrier
Mechanical
stop assembly
Ultimate
limit switch