Suspa MOVOTEC User manual

MOVOTEC®
Dual-Drive “Bolt-On”
Lift System Manual
by
Copyright © 2013 by
Suspa®Incorporated
All rights reserved. No part of this manual may be reproduced or transmitted
in any form or by any means, electronic or mechanical, including photocopying,
recording, or by any information storage and retrieval system
without permission in writing from Suspa®Incorporated.

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1.0 Table of Contents
2.0 Introduction................................................................................................................. 2
3.0 Safety Instructions...................................................................................................... 3
4.0 How it Works............................................................................................................... 6
4.1 Extension Cycle:........................................................................................................ 6
4.2 Retraction Cycle:....................................................................................................... 7
5.0 Unpacking Instructions.............................................................................................. 7
6.0 Lift System Specifications .......................................................................................... 9
6.1 Lift Cylinder Specifications..................................................................................... 10
6.2 Motorized Pump Specifications............................................................................... 10
6.3 Motor Controller Specifications.............................................................................. 11
7.1 System Component Placement................................................................................ 13
7.2 Motorized Pump Installation................................................................................... 14
7.3 Motor Controller Installation................................................................................... 15
7.4 Low Profile Switch Installation............................................................................... 16
7.5 Motor Controller Cable Connections ...................................................................... 16
7.6 Lift Cylinder Installation......................................................................................... 18
7.7 Hydraulic Tubing and Cable Management.............................................................. 22
7.8 Workstation Leveling.............................................................................................. 22
8.0 Operation Instructions ............................................................................................. 24
8.1 Before Connecting to Power.................................................................................... 24
8.3 First Operation......................................................................................................... 25
8.4 System Extension Cycle.......................................................................................... 26
8.5 System Retraction Cycle ......................................................................................... 27
8.6 Duty Cycle Monitoring............................................................................................ 27
8.7 Deceleration Zone.................................................................................................... 27
8.8 System Reset Procedure .......................................................................................... 28
9.0 Troubleshooting ........................................................................................................ 29
10.0 Inspection and Maintenance.................................................................................. 31
10.1 Changing Load Conditions.................................................................................... 31
10.2 Motor and Load Alignment................................................................................... 31
10.3 Contamination ....................................................................................................... 31
10.4 Power Cord and Hydraulic Tubing Damage ......................................................... 31
11.0 Warranty ................................................................................................................. 32
12.0 Replacement Parts.................................................................................................. 33
13.0 Optional Accessories and Enhanced Capabilities................................................ 33
14.0 Disposal.................................................................................................................... 33
15.0 Contact Information............................................................................................... 33

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2.0 Introduction
Thank you for purchasing the Movotec®Dual-Drive “Bolt-On” Lift System.
The Movotec®Dual-Drive “Bolt-On” Lift System is a motor driven single-acting fluid
displacement lift system. The “Dual-Drive” was designed specifically to raise and lower
large workstations and machine bases. It includes two of our standard motorized
Movotec®E-Drive “Bolt-On” lift systems. Both lift systems are actuated simultaneously
by linking the motor control boxes. The motor controllers keep the workstation level
during extension and retraction cycles even under unbalanced load conditions. The
Movotec®Dual-Drive lift system can be configured to drive up to eight lift cylinders and
is capable of lifting up to 2000 lbs. (907 kg).
Movotec®lift systems are subjected to life cycle testing on a regular basis. The tests are
performed in a temperature and humidity controlled environment under full system load
conditions. Movotec®lift systems perform consistently well in this controlled test
environment. However, due to the wide variety of possible lift system applications and
operating conditions, Suspa®does not warrant that any particular lift system is suitable
for any specific application. It is the responsibility of the person who specified the
system to determine its “fitness for use”in the application, through testing and analysis,
to ensure safe and reliable performance. A complete statement including the terms and
limitations of the Movotec® Dual-Drive “Bolt-On” Lift System warranty can be found in
Section 11.0 of this manual.
Movotec®lift systems are assembled and subjected to a full function quality test before
they leave our manufacturing facility. Suspa guarantees products are free from material
and manufacturing defects, but cannot support the warranty for our products if they are
altered, misused, misapplied, or abused in any way. It is the responsibility of system
installers, users, and service technicians to read and carry out the instructions in this
manual correctly to prevent these potentially unsafe and unwarranted occurrences from
happening.
Thank you again for purchasing the Movotec®Dual-Drive “Bolt-On” Lift System.
Suspa®Incorporated

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3.0 Safety Instructions
READ THE INSTRUCTIONS IN THIS MANUAL BEFORE ATTEMPTING TO
INSTALL, OPERATE, OR SERVICE THIS PRODUCT. FOLLOW THESE
SAFETY INSTRUCTIONS AT ALL TIMES.
This manual contains safety, installation, operation, maintenance, and user service
instructions for the Movotec®Dual-Drive “Bolt-On” Lift System. Suspa®Incorporated is
not responsible for any alteration, misuse, misapplication, or abuse of this product
resulting in property damage, personal injury or death.
FAILURE TO FOLLOW THE INSTRUCTIONS IN THIS
MANUAL COULD RESULT IN FIRE, PROPERTY
DAMAGE, ELECTRIC SHOCK, PERSONAL INJURY
OR DEATH.
If you have any questions about the use of this product, the safety practices outlined in
this manual or would like a print copy of this manual, please contact:
SUSPA®Incorporated
3970 Roger B. Chaffee Drive SE
Grand Rapids, MI 49548-3497
Phone: [phone]
Fax: [phone]
www.suspa.com
VERIFY SYSTEM SELECTION. Before the installing or operating the system,
please review the application to confirm that the correct Movotec®Lift System has been
selected. Pay particular attention to the load capacity and adjustment range ratings listed
on the orange pump warning label.
HANDLE COMPONENTS WITH CARE. Do not handle system by the motor cables,
power cords, or hydraulic tubing. Keep motor cables, power cords, and hydraulic tubing
far from heat, sharp edges, and moisture. If motor cables, power cords, or hydraulic
tubing are damaged, discontinue use and have the suspect component replaced
immediately. Do not ever attempt to repair a damaged motor cable, power cord or
hydraulic tubing line.
VISUALLY INSPECT COMPONENTS. Before installing and operating the system,
inspect all components for any damage that may have occurred during shipping and
installation. Do not attempt to disassemble system or system components for any reason.
If a defective component is found, contact Suspa®Incorporated for repair or replacement.

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USE OF TRAINED AND QUALIFIED PERSONNEL System installation, operation,
and repair should only be done by persons having sufficient knowledge of the lift system
and the contents of this manual. In addition, they must have an understanding of all
warnings and precautionary measures noted in these safety instructions. Furthermore,
these individuals must be trained, instructed, and qualified to switch electrical circuits
and equipment on and off in accordance with applicable technical safety regulations.
AVOID HAZARDOUS ENVIRONMENT. Do not operate the system outside. Do not
expose the system to damp or wet conditions. Avoid any chemical or corrosive
environments. Do not operate the system in the presence of flammable solvents,
propellants, and/or explosive materials (i.e. gas, vapor, dust, etc.) Avoid temperatures
outside of the system rated operating temperature range 41°to 113°F (5°to 45°C). Do
not subject lift system components to vibration and/or impact load conditions.
INSTALLATION SAFEGUARDS. Do not use the system for any purpose other than
its intended function. Before operating system, make sure that the workstation has a
minimum clearance of 2 in. (51mm) from any other object or structure to prevent
pinching or crushing hazards. Do not allow wall, cabinet, electrical lines, hydraulic or
pneumatic lines, or any other fixed structures to obstruct the movement of the
workstation during operation.
KEEP CHILDREN AWAY. It is not recommended that children operate this
electrically powered lift device. If this device is used by or near children, close
supervision is absolutely necessary.
OBSERVE DUTY CYCLE. The term duty cycle refers to the amount of time that a
motor or system is in motion versus the amount of time that it is resting. The Movotec®
Dual-Drive “Bolt-On” Lift System is not designed to operate continuously without rest.
It is designed for intermittent use only and is rated for a 10% duty cycle. This means that
if the lift system is in motion for 1 minute, it must be at rest for at least 9 minutes before
the next operation. It is also important to note that the maximum system on-time is 1
minute. To avoid damaging the system, the duty cycle must not be exceeded. Motor
surfaces can become warm after extended operation that exceeds the duty cycle. Provide
adequate ventilation to allow heat dissipation from within and around lift system
components.
USE OF ACCESSORIES. Use caution when routing extension cords. Do not allow
cords to become pinched or stretched. Avoid positioning cords where they can become a
trip hazard. Use only spare parts and accessories authorized or supplied by Suspa®
Incorporated. Do not replace or replenish lift system hydraulic fluid unless the fluid is
supplied by Suspa®Incorporated.
DO NOT INSERT OBJECTS. To reduce the risk of fire or electrical shock, do not
insert any objects into the system when powered.

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MAINTENANCE SAFEGUARDS. Prior to performing any maintenance or service on
the device, remove the load from all lift cylinders and unplug the motor controller from
power source. The workstation or structure that the lift system is attached to should be
stabilized to prevent personal injury or property damage during maintenance or service
procedures.
RETRACT SYSTEM BEFORE MOVING. To reduce the risk of property damage and
personal injury, always retract the lift system fully before moving the equipment.
UNPLUG BEFORE CLEANING. Retract the lift system, unplug the motor controller
from power source, and allow the system to cool before cleaning components. Clean
system components with a mild soap and water-damped cloth. Do not use corrosive
cleaning agents or high pressure wash systems to clean lift system components. Make
sure system is clean and dry before plugging into power source and operating the system.
SAVE THIS MANUAL FOR FUTURE REFERENCE.

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4.0 How it Works
Movotec®Dual-Drive “Bolt-On” Lift Systems are comprised of three major component
subsystems; the motor drive, the pumps, and the lift cylinders. This section will explain
how each subsystem works together to make the lift system extend and retract.
Movotec®Dual-Drive Schematic
4.1 Extension Cycle:
The motor drive consists of two motor controllers, two 24 VDC gear motors, and motor
switch. The motor controllers convert AC line voltage to DC voltage to operate both
24 VDC gear motors. They control gear motor speed, direction of rotation, and
synchronization between both gear motors to keep the lift system level during extension
and retraction cycles. The motor controllers are also programmed to operate within
specific pump upper and lower limits. The motor switch is used to activate both 24VDC
gear motors simultaneously through the motor controller.
When the motor switch “UP” arrow button is depressed, each 24 VDC gear motor shafts
begin to rotate in a (CCW) counter-clockwise direction. As the gear motors continue to
rotate in a (CCW) direction, the threaded pusherblocks are driven up the leadscrew in the
direction of arrow “A”. This action drives fluid from the pressure elements, through the

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hydraulic tubing, and into the lift cylinders causing them to extend. The gear motors
automatically shut off once the programmed pump upper limit is reached.
4.2 Retraction Cycle: (Refer to Movotec®Dual-Drive Schematic on page 7)
When the motor switch “DN” arrow button is depressed, the 24VDC gear motor shafts
begin to rotate in a (CW) clockwise direction. As the gear motors continue to rotate in a
(CW) direction, the threaded pusherblocks are driven down the leadscrew in the direction
of arrow “B”. As long as there is sufficient load on the lift cylinder piston rods, the fluid
in the lift cylinders flows back through the hydraulic tubing and into the pressure
elements. The gear motors automatically shut off once the programmed pump lower
limit is reached.
5.0 Unpacking Instructions
The system comes packaged in a cardboard carton. To unpack the system:
Check the carton label to confirm that you have received the correct system; open
the carton and remove packaging material.
Carefully remove the system from the carton, and verify all components are
present (reference chart below), and that the correct lift system was received.
Do not handle the lift cylinders and motorized pumps by the hydraulic tubing. Incorrect
handling of hydraulic tubing could weaken the tubing material and system tubing
connections.
DAMAGE TO TUBING OR TUBING CONNECTIONS
COULD CAUSE FLUID LOSS AND UNCONTROLLED
DESCENT OF THE WORK-SURFACE RESULTING IN
PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH.

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Verify that all of the listed components are present.
The carton should contain:
System Component
Quantity
(A) Pump
2
(B) Gear Motor (attached to pump)
2
(C) 120V Motor Controller
1
(D) Lift Cylinders (connected to pump)
8
(E) Surface Mount Switch
1
(F) Drill Templates
8
(G) Cable Ties
16
(H) Mounting Clips
16
(I) Power Cord
1
(J) Motor Cable (connected to motor)
2
(K) Controller Linking Cable
1
If the lift system is damaged or any component is missing, please contact
Suspa®Incorporated to resolve the issue.
Dispose of the all packaging materials in an ecologically sound manner.

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6.0 Lift System Specifications
The “A”, “B”, and “Z” dimensions shown in the table and drawings below vary
depending on the system lift capacity and the adjustment range of the selected system.
US System Part Numbers
Lift System
Adjustment
System Lift
CB "Bolt-On" Cylinder
Motorized
Pump
Part
Range
Capacity
"A"
"B"
"Z"
Number
(in/mm)
(lb/kg)
(in/mm)
(in/mm)
(in/mm)
MLS-00020
5.9 / 149
1500 / 680
10.2 / 258.5
6.49 / 165
12.99 / 330
MLS-00021
7.4 / 189
1500 / 680
13.1 / 333.5
9.45 / 240
15.35 / 390
MLS-00022
11.6 / 294
1500 / 680
18.3 / 463.5
13.39 / 340
20.08 / 510
MLS-00023
15.5 / 394
1500 / 680
22.0 / 558.5
13.39 / 340
24.88 / 632
MLS-00024
5.9 / 149
2000 / 907
10.2 / 258.5
6.49 / 165
15.35 / 390
MLS-00025
7.4 / 189
2000 / 907
18.3 / 463.5
13.39 / 340
17.72 / 450
MLS-00026
11.6 / 294
2000 / 907
18.3 / 463.5
13.39 / 340
24.88 / 632
MLS-00027
15.5 / 394
2000 / 907
18.3 / 463.5
13.39 / 340
29.92 / 760
European System Part Numbers
Lift System
Adjustment
System Lift
CB "Bolt-On" Cylinder
Motorized
Pump
Part
Range
Capacity
"A"
"B"
"Z"
Number
(in/mm)
(lb/kg)
(in/mm)
(in/mm)
(in/mm)
MLS-00028
5.9 / 149
1500 / 680
10.2 / 258.5
6.49 / 165
12.99 / 330
MLS-00029
7.4 / 189
1500 / 680
13.1 / 333.5
9.45 / 240
15.35 / 390
MLS-00030
11.6 / 294
1500 / 680
18.3 / 463.5
13.39 / 340
20.08 / 510
MLS-00031
15.5 / 394
1500 / 680
22.0 / 558.5
13.39 / 340
24.88 / 632
MLS-00032
5.9 / 149
2000 / 907
10.2 / 258.5
6.49 / 165
15.35 / 390
MLS-00033
7.4 / 189
2000 / 907
18.3 / 463.5
13.39 / 340
17.72 / 450
MLS-00034
11.6 / 294
2000 / 907
18.3 / 463.5
13.39 / 340
24.88 / 632
MLS-00035
15.5 / 394
2000 / 907
18.3 / 463.5
13.39 / 340
29.92 / 760

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6.1 Lift Cylinder Specifications
6.2 Motorized Pump Specifications (Refer to Chart on Page 11 for “Z” dimension)
The Movotec®gear motor used with the motorized pump shown below is rated for
24 volts DC. The no-load speed of the gear motor is 160 rpm. The no-load current is 3A.
The maximum rated operating torque is 62 lb-in (7N-m).

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6.3 Motor Controller Specifications
Motor Controller Parameter
Specification
Supply Voltage / Frequency
120V / 50-60Hz (US)
230V / 50-60HZ (Europe)
Standby Power Consumption
<0.7W
Switch Operating Voltage / Current
5VDC / 150mA
Hall Sensor Operating Voltage / Current
5VDC / 150mA
Operating Temperature Range
32º to 86ºF (0º to 30ºC)
Operating Humidity Range
5% to 85% (non-condensing)
Storage Temperature Range
-40º to 185ºF (-40º to 85ºC)
Storage Humidity Range
5% to 90% (non-condensing)
Protection Class
I
Motor Controller Dimensions
10.4in x 4.1in x 1.5in
(264mm x 103mm x 37mm)
Weight
1.1 lb (0.5kg)
Each controller comes complete with power cable, 3000mm (120 in.) in length. US-
based systems use a 3-prong, NEMA 5-15P type plug. European-based systems use a
“Schuko” style, CEE 7/7 type plug.

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6.4 Surface Mount Switch Specifications
The operating voltage and current of the surface mount switch when attached to the
motor controller is 5VDC and 150mA, respectively.

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7.0 Installation Instructions
FOLLOW ALL SAFETY INSTRUCTIONS CONTAINED
IN SECTION 3.0 OF THIS MANUAL BEFORE
INSTALLING THIS PRODUCT. FAILURE TO
FOLLOW THE INSTRUCTIONS IN THIS MANUAL
COULD RESULT IN FIRE, PROPERTY DAMAGE,
ELECTRIC SHOCK, PERSONAL INJURY OR DEATH.
7.1 System Component Placement
There are many system components in a Movotec®Dual-Drive “Bolt-On” Lift System.
Since all of these components are physically linked together with hydraulic tubing and
electrical cables, it is very important to make sure that the components are located on the
workstation so that everything can be connected safely and correctly.
7.1.1 Motorized Pump Placement - The motorized pumps can be mounted in
any orientation, however it is recommend to be mounted horizontally. The
motorized pumps should be mounted so that there is enough hydraulic tubing to
reach each lift cylinder and enough clearance for the minimum hydraulic tubing
bend radius of 2 in. (51mm) to be maintained. Suspa®Incorporated offers a black
thermoformed plastic motor cover to further protect the gear motors and cable
connections from possible damage. The motor cover can be purchased on our
website at http://shop.suspa.com.
7.1.2 Motor Controller Placement - There should be enough power cord length
to facilitate movement of the workstation without the power cord connector
becoming separated from the motor controller during operation. To accomplish
this and to ensure that there is enough power cord length to reach a power
receptacle, the motor controller should be placed toward the center and backside
of the workstation. In addition, the motor controller should be placed so that it is
in relatively close proximity to the gear motors. If this is not possible, Suspa®
Incorporated offers motor extension cables to make up the difference. These
cables can be purchased on our website at http://shop.suspa.com.
7.1.3 Switch Placement - The switch should be mounted on the side of the
workstation where it is most accessible to the user and so that there is enough
switch cable to reach the motor controller. The low-profile switch is one of many
motor switch options offered by Suspa® Incorporated. Alternate motor switches
can be purchased on our website at http://shop.suspa.com.
7.1.4 Lift Cylinder Placement –The lift cylinders should be located on the
workstation so that the load on the system is balanced. Lift cylinders must also be
oriented vertically and parallel to one another to prevent cylinder binding during
extension and retraction cycles. Suspa®Incorporated offers an assortment of
brackets to reduce the number of holes to be drilled for lift cylinder mounting and

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to facilitate system installation. These cylinder mounting brackets can be
purchased on our website at http://shop.suspa.com.
7.1.5 Tubing and Cable Placement –Hydraulic tubing and power cables must
be kept away from sharp edges and moving parts. Contact with moisture and heat
must also be avoided. Hydraulic tubing and power cables should fixed to the
workstation or structure using the cable ties and mounting clips provided.
Additional cable ties and mounting clips can be purchased on our website at
http://shop.suspa.com.
7.2 Motorized Pump Installation
If possible, orient workstation as shown for ease of component placement and
installation.
Place motorized pumps in the desired location. Ensure enough room exists for
both motor controllers. Keep in mind each pump and control box must be
mounted close together, in order to connect the control boxes.
Mark and prepare eight holes in the locations provided by the motor brackets and
rear pump support brackets.

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Mount the motorized pump assemblies to the surface. Please note that mounting
screws are not provided with system.
Check mounting screws to ensure that the units are tightly secured.
7.3 Motor Controller Installation
Place each motor controller in the desired location, ensuring that the motor cable
is long enough to reach the motor ports after installation is complete. Also,
position control boxes close enough to make the connection between the two.
Mark and prepare (2) mounting holes for each control box

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Install controller using mounting screws, and check to ensure that the unit is
secured.
7.4 Low Profile Switch Installation
Place the low-profile switch in the desired location on the underside of the work
surface.
Align the switch body with front edge of the work-surface. Mark and prepare two
holes in the locations provided in the switch enclosure.
Using the appropriate screws, mount the switch to the work-surface taking special
care not to over tighten the screws. While (2) mounting screws are included with
the switch, ensure they will work for the particular application before using to
mount switch.
Check mounting screws to ensure that the switch is secured.
7.5 Motor Controller Cable Connections
The motor controller ports are labeled on the top side of the control box.

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The switch plug is blue and corresponds with the round switch port shown
above. The motor cable plugs are marked “M1” and “M2” on the cable, and
correspond with the (M1) and (M2) motor ports shown above (white, rectangular
plugs).
The switch plug has an arrow to indicate proper connection alignment. This
arrow must face away from the work-surface and toward their corresponding
connection port.
To make the connections:
Connect the black motor cable plugs in to their respective (M1) and (M2) motor
ports on each control box. Firmly press the plug into the port until the plastic
hook “clicks” in place.
It is important to install both motor cables in to the control
box! Ensure both connections are secure and in the correct
ports on the controller.
If not already installed, connect the blue switch cable plug to the (HS) switch port
on the master control box. Firmly press the plug into the port to ensure that a
complete connection has been made.
Note: When the dual-drive systems leave the factory, one control box is assigned
as the ‘master’ control box, indicated on the control box with a white label
reading “SYSTEM SWITCH PORT.”The switch will also ship installed into this
control box. The switch must be plugged in to this control box for the system to
function! The second control box will not accept up/down input from the switch.
Connect power cord to motor controller IEC power port. Firmly press power cord
plug into the IEC receptacle to ensure that a complete connection has been made.
NOTICE

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Once each individual motor/controller assembly is connected independently,
connect the Mating Cable in each controller to join the two together.
Check all connections to ensure that they have been made correctly and
completely.
7.6 Lift Cylinder Installation
Unwrap lift cylinders and drilling templates from bubble wrapping. Dispose of
bubble wrapping material in an ecologically sound manner.

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Thoroughly clean all workstation leg surfaces to ensure the cylinder drilling
templates will adhere. Apply the drilling templates parallel to the workstation leg
surfaces, making sure that the templates are oriented correctly. Please note that
the drilling templates are shown upside down due to the orientation of the
workstation.
Lift cylinder mounting hole locations vary depending
upon the lift cylinder model number. The lift cylinder
model number can be found on the product label.
“Bolt-On” lift cylinder model numbers begin with “CB”
(i.e. CB415).
Lift cylinder mounting instructions can also be found
printed on the drilling templates provided with the system.
Drill (4) - 6mm holes in the appropriate locations indicated on each drill
templates.
NOTICE