TERRY Melody 1 User manual

Installation Manual
Melody 1 Platform Lift
Ref. ED01050g Date: 03/04/2012
Original instructions

Terry Melody 1 - Installation Instructions - ED01050g
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CONTENTS
THE MELODY 1 PLATFORM LIFT 3
MELODY 1 INSTALLATION INSTRUCTIONS 4
MELODY 1 BASE FRAMEAND SCISSOR ASSEMBLY 10
MELODY 1 SCHEMATIC CABLE RUN 11
MELODY 1 DUCT POSITIONS 11
MELODY 1 TECHNICAL SPECIFICATION 12
MELODY 1 HEIGHT ADJUSTMENT 13
MELODY 1 GENERAL FAULT FINDING 14
MELODY 1 INSTALLATION TEST CERTIFICATE (PAGE 1 OF 3) 15
MELODY 1 INSTALLATION TEST CERTIFICATE (PAGE2 OF 3) 16
MELODY 1 INSTALLATION TEST CERTIFICATE (PAGE 3 OF 3) 17
TRADE CUSTOMER FEEDBACK QUESTIONNAIRE 19
MELODY 1 SERVICE & MAINTENANCE 23
MELODY 1 SERVICE POINTS 23
MELODY 1 BASIC SAFETY SYSTEM CHECKS 24
MELODY 1 DEFINITION OF BASIC SAFETY ITEMS 25
MELODY 1 WIRING DIAGRAM 27
MELODY 1 CIRCUIT BOARD LAYOUT 29
MELODY 1 CONTROL BOARD WIRING 30
MELODY 1 LIFT GATE CONTROL CIRCUIT 31
MELODY 1APPENDIX-REMOTE CONTROL ENABLER SYSTEM 32
MELODY 1 MEGGER TESTING 33
MELODY 1 CHARGER BOX TEMPLATE 35
BULLETINS 37
MELODY 1 CABLE TIE FIXING 38
MELODY 1 UPPER LEVEL GATE FITTING INSTRUCTIONS (XB00223) 39
MELODY 1 RAMP CALL POST INSTRUCTIONS (XB00198B) 53
TRIPLE BRIDGING STEP HEIGHT ADJUSTMENT (XB00218) 58
BRIDGING STEP PICK-UP BRACKET INSTALL INSTRUCTIONS (XB00217) 59
MELODY 1 CLIENT CHECK LIST 65

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01051b, dated: 10/01/2012
THE MELODY 1 PLATFORM LIFT
The Melody 1 is a hydraulically operated scissor platform lift capable of lifting
loads of 280Kg up to 1.0m between fixed levels.
Designed and manufactured in accordance with BS 6440, the Melody 1 is
suitable for use by persons with impaired mobility in either public buildings or
private dwellings. The Melody 1 standard features include an integral platform
gate and a low closed height eliminating the need for a pit. An interlocked
gate is installed on the carriage as standard. An upper level gate option is
also available or an interlock unit can be supplied to fit the client’s own door.
Special consideration has also been given to the location and dimensions of
controls allowing safe and unaided use by person(s) with impaired mobility
whether standing or with a wheelchair. An isolation switch is supplied as
standard on the charger box and control stations are provided on the platform
handrail and the upper and/or lower levels. A radio remote control lift enabler
option to limit the lift to authorised use only is also available.
The lift is suitable for internal and external locations and a major feature
of the design is that the platform is free standing, eliminating the need for
column supports and thus minimising aesthetic intrusion into the environment.
Standard finish is stainless steel and other finishes can be supplied to special
order.
NOTES

base
frame
platform
Fixing
holes
1345mm
440mm
Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01052c, dated: 10/01/2012
MELODY 1 INSTALLATION INSTRUCTIONS
1. Manually raise platform / scissor arms and insert safety scotch through
holes in base frame (see diagram page 10).
2. Slide platform onto scissor arm
blocks (tall side up) and secure
in place with 6 X M6 counter-
sunk screw.
Note :These fasteners will be
located in the top of the scissor
arms when the lift is supplied
without the platform already
fitted.
3. Level platform using levelling bolts on base frame ensuring moving ramp
aligns flush with fixed ramp.
4. Remove the 4 X M6 CSK, 2 X M6 HEX/Washers located on the top face
of platform.
5. Position power pack assembly on platform, pump to ramp and secure
into place using bolts previously removed.
6. Feed the Hydraulic hose/ 6 Way connector and attached wiring for
charger box / 3 way connector and attached wiring for lower wall station
/ Bowden cable through the round hole in the base of the platform that is
located near the pump reservoir tank.
7. Engage end of Bowden cable through slot in control mechanism.
8. If necessary re-engage spring hook end onto control mechanism roll pin.
NOTES
This side must be either 150mm
away from any wall / obstruction
or less than 10mm
Must be at
least 150mm
away from
any wall
obstruction
Allow 10mm
(max) between
lift and rise

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01052c, dated: 10/01/2012
9. Connect the 8 core cable from charger and cable from lower wall station
as per diagram below.
Note: Ensure anti-creep (purple wire to mech wheel) is disconnected.
Wire must only be reconnected after all height settings are complete.
10. Secure wiring in place with tie wraps.
11. Connect up hydraulic hose to pump.
12. Remove 8 sets of barrel nuts/dome head screws /washers /lockwashers
from platform uprights (4 off).
13. Gate & lock fitting;
• Take note of the gate handing on the lift
paperwork. The handing refers to the side of
the gate hinge when viewing the lift from the
lower level. The diagram shows a left hand
gate.
• Fit the gate by sliding the required handrail
through the hinge tubes on the gate and
positioning the gate handrail in place along with appropriate kick plate
and refit both sets of barrel bolts/nuts.
• Lift the gate upwards to reveal the holes in the
handrail.
• Fit the gate hinge pin, spacer tube, 2 circlips
and domed star washer in the order shown.
Ensure pin is inserted in the correct hole! As the
gate is opened it will rise if the correct hole has
been used.
NOTES
8 core for charger
Power Pack wiring
Carriage Gate Lower Call Station

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01052c, dated: 10/01/2012
• Offer the lock assembly to the gate. Note:
orientate the lock assembly so that the lock is
located on the outer side of the gate.
• Run the gate wire neatly from the gate outlet,
through the holes in the lock mounting plates
and into the lock through the appropriate side.
• Fix the lock assembly in place using the 4
bolts, washers and nuts from the fixing kit.
14. Position opposite hand rail and kick strip
and refit the dome head screws/washers/
lockwashers at the two non-ramp and top ramp end fixing positions.
15. Lock fitting continued:
•Fit the lock beak bracket mounting plate
together with the lock beak and spacer plate
onto the appropriate handrail. The lock beak
mounting plate is secured using the pre-fitted
handrail cross tube bolts. Unscrew the bolts,
insert the mounting plate and re-fit bolts in
correct locations. DO NOT TIGHTEN.
•Close the gate and align the lock and lock
beak with each other using the adjustment
slots on each assembly. When alignment is
satisfactory, tighten all bolts.
• Wire the lock, matching the wire numbers with the terminal identifiers:
wire No. Terminal
1 21
2 22
3 Earth
4 M
• Fit the back cover using the 4 screws from the fixing kit.
• Fit the lock cover and secure with the screw
from the fixing kit. Insert the blanking bung into
the lock cover.
NOTES

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01052b, dated: 10/01/2012
• Cut off the 4 pin connector from the other
end of the gate cable, ensuring numbers are
present on the cable stubs for reference later.
• Insert the sleeved grommet from the fixing
kit into the hole on the hinge side in the
barley seed floor.
• Thread the cable through the grommet,
underneath the platform and up thorugh the
large hole in the platform which leads into
the powerpack housing. Ensure the pre-
fitted cable spring sleeve remains in place
on the cable. Reconnect the 4 pin connector,
following the stub wire numbering.
• Plug the connector into the designated
sockets in the main powerpack wiring loom - see wiring diagram for
reference.
16. Connect connector block from car station to 16 way connector block and
carriage gate latch as per page 25
NOTES

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01052c, dated: 19/08/2011
17. Fit 5 Amp fuse for battery.
18. Fit 30 Amp isolation fuse.Secure
powerpack cover in place using
No.8 x 1/2” Stainless steel Pozi-
head screws.
19. Put lift in position referring to
Diagram on page 4 and secure
upper level gate (if supplied) in
desired location
20. The upper call station is mounted in the gate post. Run a 7 core cable
from the upper level gate call station to the charger box. Run the 8 core
cable from the lift, the 4 core cable to the gate lock, and the 7 core from
upper level gate call station along the most appropriate route to the
charger box location and connect as per diagram below. Refer to page 8
for schematic cable run (note all cables to be put in conduit or similar)
Charger Box
Gate Post
Call Station
.
NOTES
Charging
indication light
Charger box dimensions
223mm
92mm
206mm
Cable exit point
Isolating Switch

Terry Melody 1 - Installation Instructions - ED01050g
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NOTES
ref: ED01052c, dated: 19/08/2011
21. Fix charger box to wall. Plug in charger and replace cover
22. Bleed hydraulic system.
• Ensure the hydrualic hose is plugged into pump connector.
• SAFETY: cover the hydraulic fittings to avoid injury from high
pressure hydraulic fluid!
• Loosen the 1/4” BSP female Q-release carrier - 1/4” BSP male
female compact elbow joint.
• Operate pump and bleed from the loosened joint.
• Retighten loosened joint after bleeding.
23. Make suitable holes in the base of the bellows and secure to the front of
the base frame and ramp support plate with tie wraps. Note: On outside
installations before securing the bellows liberally spray all lift parts
enclosed by the bellows e.g base frame and scissor arms with the wax
oil provided.
24. Rivet the ‘serial number plate’ to the RH side of the power pack cover
using the existing holes.
25. Carry out final adjustment and test as per pages 13, 15, 16, 17 and 29

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01054a, dated: 07/06/2006
MELODY 1 BASE FRAME AND SCISSOR ASSEMBLY
To gain access under the platform :
• Send lift up.
• Remove tie wraps securing base of
bellows to front of base frame and
ramp support plate.
• Fold bellows and hook up to base
of platform using beaded tie
wraps.
• Ensure that base of bellows is re-
secured to front of base frame and
ramp support plate after all work is
completed.
Please note that safety scotch must be inserted in chassis holes when
scissors are up BEFORE any work is carried out under the platform.
Adjustable foot
Adjustable foot
Insert safety scotch here
NOTES

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01055c, dated: 28/01/2010
MELODY 1 SCHEMATIC CABLE RUN
MELODY 1 DUCT POSITIONS
1 x 40mm duct from either side of the lift, in the base or the lift face at ground
level. This duct goes to the charger box.
1 x 40mm duct from lower call station to the front corner of the platform /
ramp
1 x 40mm duct from upper call station to the power pack.
1 x 40mm duct from the centre of the lift face, 100mm up from the base going
back to the charger box or join this one in with the lift cable duct.
If the call stations are to be flush mounted then a 50mm deep double socket
back box needs fitting vertically at each landing.
Note: All ducts to have swept elbows and a substantial draw cord fitted
NOTES
This component must
be located internally
240 V AC
Charger
Box
Single or double mains socket
or 13 Amp –switched spur
with front outlet.
Lower Call
Station post mounted
(7 Core X 0.75 used)
8 Core Cable 8 core cable External Wall
Upper Level Gate with Upper
Call Station incorporated.
Melody 1

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01056b, dated: 10/01/2012
MELODY 1 TECHNICAL SPECIFICATION
Application Range Ambulant and Wheelchair users only
Internal and external locations
Safe working load 280Kg
Closed height 75mm
Maximum travel 1 metre (1000mm)
Upper level protection requirements Domestic rise exceeding 290mm
Public Access rise exceeding 260mm
Rated speed 0.07 – 0.08 metres per sec.
Power supply
Electrical requirements
The lift does not require a dedicated
power supply or RCD protection
Low voltage operating system
Optional remote control enabler
220/240V AC~ 50/60 Hz
current 680 mA (max)
24 V DC
The lift has full battery back-up
and the lift should never be left
disconnected from the mains supply
for long periods.
12V Key fob non-rechargeable
alkaline battery.
Duty Cycle
Normal cycling (maximum) 10 cycles per hour or
40 cycles in any 24 hour period
Safety features Full platform and ramp safe edge
Lifting Mechanism Bellows enclosed hydraulic scissor
arms
Hydraulic oil grade T22
Temperature Range -5oC to +40oC
Designed and manufacturing
standard BS 6440 & CE Mark
Terry Lifts’ policy is one of continuous product development and the company
reserves the right to change specifications without notice.
NOTES

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01057a, dated: 07/06/2006
MELODY 1 HEIGHT ADJUSTMENT
IMPORTANT:
Before adjusting the mechanism ensure anti-creep switch is disconnected
(refer to page 19)
The control mechanism will be pre-set to a platform height of 1000mm
With lift at ground level disconnect the spring
Stop lift at required height. Slacken bolts. Rotate adjustment disc (larger
diameter) until face A is in contact with roller of top limit switch (brown wires).
Re-tighten bolt
Lower lift to ground level and re-connect the spring. The spring must be
wound around 1 full turn before hooking onto tab on rear of disc. Check top
level height
BOWDEN CABLE ADJUSTMENT
Before setting the height the bowden cable must be adjusted to set the
position of the switch on the wheel that releases the lower gate. The lower
gate should only release when the lift is around 100mm off lower level
(usually nuts are to very end of thread closest to wheel).
Spring
Top Limit Switch (Brown wires)
Final Limit Switch Latch
Platform Gate
Enabler Switch Face A Inner Wheel
Final Limit
Switch Adjustment disc
NOT TO BE USED IN
SETTING TOP HEIGHT
Fixing Bolt
Upper Gate
Enable Switch
Anti Creep Switch
(Purple wires)
Cable Failure Switch
NOTES
Used to set gate
release for lower
level. Wind nut to
the end of the thread
on every install

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01058a, dated: 07/06/2006
MELODY 1 GENERAL FAULT FINDING
FAULT CHECK
Lift will not go up Check that when the up button is pressed, is L1 (green
LED) lit ?
If not :-
1. Check platform gate
2. Check F1 fuse (25A)
3. Check isolate switch on charger box is in.
4. Check remote control enabler operation.(if fitted).
If above is OK, check wiring.
Lift will not go
down Check when the down button is pressed, is L2 (yellow LED) lit ?
If not :-
1. Check final limit switch
2. Check F2 fuse (5 A)
If above is OK, check wiring
3. Check isolate switch on charger box is in.
4. Check remote control enabler operation (if fitted).
If above is OK, check wiring .
Lift will not go up
or down
(L1 and L2 not lit)
1. Check F3 (1A) is OK
2. Check lift isolate fuse (30A) is OK
3. Check battery voltage - should be in the range 27.5
– 29.5V(from charger) – if not -
4. Check 5A fuse to charger – if OK change charger
5. Check for bowden cable failure
6. Check that upper level gate (if fitted) is closed.
Upper level gate
will not open 1. Check that lift is at the top.
Note: Gate will only be opened within the first five-ten
seconds of the lift reaching the top level. If timer has
expired the gate can be released by pressing and re-
leasing gate release switch, unless on the lift in which
case the lift will have to be sent down and brought back
up to the top to open the gate.
Lower level gate will
not open 2. Check that lift is at the bottom.
Note: Gate will only be opened within the first five-ten
seconds of the lift reaching the bottom level. If timer has
expired the gate can be released by pressing and releasing
the carriage or lower post gate release switch, unless on
the lift in which case the lift will have to be sent down and
brought back up to the top to open the gate.
Reprogramming
the remote control
enabler key fob
It maybe necessary to reprogram the key fobs if the
lift has been disconnected from the mains or been in
storage for a long time. Full instructions to reprogram
the key fob including the 3 minute timer feature are at-
tached. See page 22
NOTES

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01059c, dated: 28/01/2010
MELODY 1 INSTALLATION TEST CERTIFICATE
(PAGE 1 OF 3)
B.1. Description of installation:
Lift reference:-
Location:-
Manufacturer:- Terry Group Ltd, Longridge Trading Estate, Knutsford,
Cheshire. WA16 8PR
Lift Description:
Date of Manufacture
Length of travel: m Lift serial No.
Other
identification:
Safe working
load
Rated speed:
Description of lift:
Maximum working pressure:
Pressure relief valve setting:
Electrical supply: a)contract 13A
240V
1 Phase 50Hz
NOTES

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01059c, dated: 29/01/2010
MELODY 1 INSTALLATION TEST CERTIFICATE
(PAGE2 OF 3)
B.2. Static Examination
a) Is all metalwork that encloses live conductors bonded to the main
earthing terminal by protective conductors?
b) Is the platform bonded to earth by a separate conductor?
c) Does the resistance of the earth protective path exceed .1 ohm?
d) Insulation resistance to earth. Power circ. safety circuits.
e) Full load control volts.
f ) Are the platform anti-trapping safety devices adequate?
By for example, an enclosure, guards, bellows, blinds, safety edges
or sensitive surfaces.
g) Do they operate correctly?
h) Does the platform level to within + or - 12mm on full load?
i ) Is adequate liftway protection provided?
By for example, short flights of steps, strong enclosure 1M
above upper level, interlocked + locked gate or barrier.
j ) Are the liftway clearances adequate? (As stated in Specifier’s Guide)
That is less than 10mm or greater than 150mm or protected by
sensitive edges.
k) Do the interlocks on any gates fitted operate correctly? Carriage
Upper level (optional)
l ) Does the manually operated scotching device operate correctly?
m) Does the manually lowering valve function correctly?
n) Does the final limit switch latch operate correctly ?
o) Does the upper limit switch stop the lift at the upper level?
p) Confirm that the on-site load test has been successful
List any points on which the installation fails to comply:-
NOTES

Terry Melody 1 - Installation Instructions - ED01050g
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ref: ED01059c, dated: 29/01/2010
MELODY 1 INSTALLATION TEST CERTIFICATE
(PAGE 3 OF 3)
B.3. BASIC SAFETY SYSTEM CHECKS
Hose condition and connectors
Check call station operation x3 - check all buttons work with key on and
stop works with ley off
Check carriage gate interlock operation - ensure the gate only releases
at correct level / check gate stays locked during travel / check no
operation with gate open / proximity switches x 1
Check upper level gate interlock operation if fitted - ensure the gate only
releases at correct level / check gate stays locked during travel / check
no operation with gate open / proximity switches x 1
Check gate beaks are secure - check tightness of beaks and brackets
Check main ram rollers
Check remote control enable operation (if fitted)
Check S/Edges operation x 4 - check lift stops when obstructed (4
corners) / check lift rides away from obstruction / check no sticking
edges
B.4. DECLARATION A
I/We certify that on / / this Steplift was installed to the latest
installation instructions and thoroughly examined and found to be free from
obvious defects and to comply with the requirements of BS 6440 and that the
foregoing is a correct report of the examination.
Signed:- Qualifications:- Authorised
Installer
Address:- Date:-
CERTIFICATE OF ACCEPTANCE BY PURCHASER/USER
I/We being the purchaser/user of this Terry Melody 1 (serial No.
) have received, and fully understood, verbal and written
instructions, in association with a demonstration, from
on its correct and safe use.
Signed:- Date:-
NOTES

Terry Melody 1 - Installation Instructions - ED01050g
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TRADE CUSTOMER FEEDBACK QUESTIONNAIRE (Please Circle)
COMPANY NAME ..................................................
Lift Number ..................................................
1. Were any parts missing (If Yes please detail below) Y / N
2. Were any parts damaged (If Yes please detail below) Y / N
3. Were all parts packed as expected (If No please detail below) Y / N
4. Were parts incorrectly manufactured/wired (If Yes please detail below) Y / N
5. Was the paint quality acceptable (If No please detail below) Y / N
6. Was the specification of the lift as ordered (If not please detail below) Y / N
7. Was the end user satisfied with the product (If not please detail below) Y / N
8. Are there any recommendations or product improvement requests you would
like to make?
Y / N
Details:
Terry Group Limited
Head Office & Factory:
Unit 1, Longridge Trading Estate, Knutsford,
Cheshire, WA16 8PR
tel: [phone] fax: [phone]
email: [e-mail]
web: www.terrylifts.co.uk
London Office:
tel: [phone] fax: [phone]
Terry Melody 1 - Installation Instructions - ED01050g
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TRADE CUSTOMER FEEDBACK QUESTIONNAIRE

Terry Melody 1 - Installation Instructions - ED01050g
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