VERTICAL PLATFORM LIFT SB200 SB200 Assembly instruction (Translation from the Original Lithuanian manual)
Revision No. 2.0/16-02 Manual code 200-1-EN-2 Date 2013 07 01
BARDUVA Liepkalnio str. 61, LT-02120, Vilnius, Lithuania Tel.: +370 5 2310770 Fax: +370 5 2310773 Email: firstname.lastname@example.org www.barduva.eu
1.1 Possible hazard situations
1.2 Electrical hazard
1.3 Personal safety equipment
3.1 Device installation
3.2 Tools for installation
4.2 Bottom frame assembly
4.3 Assembly of the guide rails
4.3.1 Guide rails fixing to the bottom frame
4.3.2 Extension of the guide rails
4.3.3 Top crossbar installation and leveling of the guide rails
4.3.4 Set assembly of the emergency lowering hand crank and stop button
4.3.5 Pit prop assembly
8.1 Structure of floor control system
8.2 Door control board V3.21 and higher version
8.3 Setting the door control board
8.3.1 Combinations of the door control board for the floor
8.3.2 Setting the door opening zone switch combination
8.4 Description and location of components on the platform
8.5 Description of the main control board on the platform
8.6 Safety circuit operation
8.7 Description of the distribution unit for 3 phase power supply
8.7.1 Description of terminal blocks 8.8 Description of the distribution unit for single phase power supply
15.1 Functional check
15.2 Plates under and over the doors
Prior starting the assembly of the platform lift and during installation, it must be taken all necessary actions to avoid dangerous and hazardous situations to the persons or the environment. The platform lift installation must perform skilled personnel. This personnel have to be informed of the instructions given in this manual and also have to be familiar with national statutory regulations for safety and general prevention of accidents at each country by domestic laws.
Work at height: corresponding safety measures have to be taken to guarantee the safe work at height. Depending on the domestic laws use appropriate hoisting equipment, etc. ladders, scaffolds, scissor lift or other;
Heavy parts: some of the platform lift parts are heavy, so it is important to lift it up by two persons or in some cases use hoisting equipment;
Danger zones: secure the assembly area and area near it with signs and / or other warning signs, restriction materials;
Falling things: never work under the platform, if there is a person already working on it. Before entering the shaft make sure that shaft components are fixed properly;
The electrical shock possibility in the machine room and / or near the lift parts having electrical components!
All the electrical instalation work have to be carried out by skilled personnel, as stated in the domestic laws in each country in order to avoid the accidents. Machine room cover have to be closed and locked all the time, when the work in the machine room is finished and / or technicians are not near the machine room.
Personal safety equipment: safety shoes, gloves, helmet, safety glasses, and earplugs, clothes.
It is very important to use personal safety equipment during the instalation and also using the instalation tools and machines to avoid or at least reduce personal injuries.
Storage of the material should not take place in high humidity environments. Doors should be stored within temperature -25 to 55Â° C. The storage area should be dry and free of dust. The periodical checks of the packed components, for possible existence of condensed water or damaged packaking can help to protect the material.
Before mounting the platform please check the mounting place for quality. Measure hight and width of lifting platform mounting place and check if the level of walls does not have inclination into the shaft. Also measure the horizontality of mounting ground and dimensions of pit (if intended) for lifting platform lower case.
Automatic or self-raiser for moving the lift platform. Weights (475 kg) for testing static and dinamic load of platform.
Perforator Electrical drill Drill kit for metal construction Drill kit for concrete construction Level Electrical cable extender Multimeter Accumulator drill with adjustable tightening torque Head kit for electrical drill Electrical disc saw with disc kit Laser distance meter (15 m) Plumb-line (plumb-line length depends on lift hight shaft) Nylon rope Knife Hammer Pencil Tape-measure 5 m Screwdriver kit Adjustable torque wrench (20 Nm to 200 Nm) Head kit for torque wrench. Device for rivet Wrench kit Flat file Oval file Two pieces of clamps
Carefully unpack all the components. In order not to scratch the painted surfaces work carefully in pairs. Thoroughly check the consignment for any possible damages or missing parts right after reception. If there are any problems regarding the consignment notify the manufacturer in written about it. Complaints received long time after the reception of the consignment will not be accepted.
First of all, check the travel distance and dimensions of the shaft or the ventage in the floors. Make sure if it is solid material under the floors to fix the platform in stable possition. If the platform lift will be installed in the shaft, check if the walls of the shaft have not the inclination into the shaft. 1 2 3 4 5 6
Check on which side have to be the guide rails; Put the bottom frame into the pit; Plumb from the top landing and check that the plumb does not run into the shaft; With spirit level check the horizontality of the bottom frame, if necessary level the frame; Drill holes of Ă˜12 and depth of 130 mm in the concrete floor for anchors (expansion bolts); Fit the expansion bolts and fix the bottom frame to the floor. Plumb
Spirit level Bottom frame
Pos. 1 2
Guide rail side of the bottom frame
Job description Put the guide rails in the bottom frame corner where are predrilled holes to fix it; Screw the guide rail to the bottom frame using the bolts (ST6.3x13);
Guide rails could be heavy depending on lift height so we suggest carrying the guide rails by two persons!
Bolts (ST6.3x13) Anchor Ă˜12/100
1 2 3
ATTENTION: In pursuance with guide rails extensioning be careful of the falling parts!
Depending on the guide rail which is already installed in place, choose another part of the guide rail. The left side guide rails are marked L0; L1; L2; etc. respectively from bottom to top. The right side guide rails marked R0; R1; R2; etc. respectively from bottom to top; Fit next guide rail piece on the one which is below, make sure that the fixers fitted in place; Hammer in the lock pins, screw in and tighten the bolts;
Place the crossbar in position on middle bolts; Put the top crossbar in place screw in and tighten 4 bolts;
Fixing points for top crossbar Top crossbar
Job description Fit the angle bracket on top of the crossbar on both sides of the guide rails, as shown in the picture below; Mark and drill holes of Ø12 and depth of 130 mm for expansion bolts; Fix the angle bracket and tighten it to the wall; Drop the plumb lines down and check if the guide rails are in level, if not adjust it; When the guide rails are in level drill and fix it with 3.2x8 rivets in 4 places (as shown in the picture)
1 2 3 4 5
3 4 5 a) b) 6
When guide rails and the top crossbar are in level and fixed. Check the position of the guide rails below, if necessary level it; Depending on the installation place the middle connection plate of the guide rails can be situated from the inside of the shaft and from the outside of the shaft; Middle connection plate from outside of the platform lift shaft: a) Fit the middle connection plate in place tighten the screws; b) Bend the tongue into the shaft; Middle connection plate from inside of the platform lift shaft: a) Fit the middle connection plate in place and tighten two screws; b) Drill Ø3.2 four holes and rivet with 3.2x8 rivets; c) Remove two screws placed at the beginning;
Middle connection plate from outside shaft
Middle connection plate from inside shaft
Middle connection plate
Tongue Rivets Ø3.2x8
Bolts should be removed, after fixing with rivets
1 2 3 4
1 2 3 4 5
Fix the angle bracket to the wall, over the assembled middle connection plate,using the Ø12 anchors; Check, if the guide rails are in level with the plumb; Drill Ø3.2 holes and rivet with 3.2x8 rivets the angle bracket to the middle connection plate; The angle brackets have to be fixed to the wall and after that revited over each middle connection plate.
Fit the angle bracket with bearing on the side of the bottom floor door’s; Screw this angle bracket with two screws; Unbend the angle plate, which purpose is to fix the stop button in the shaft; Fit in the hand crank set delivered in one piece; Screw in and tighten four screws;
Angle bracket with bearing
Hand crank set
AFTER the bottom door assembly insert the hand crank, as shown in picture below;
Fit in the screw through the already predrilled hole and using the nut tighten it; Push the limit ring as close to the angle bracket with bearing and tighten with allan key the limit ring;
Angle bracket with bearing
Pit prop activating handle
Fix the stop button on the steel plate, on the side of emergency hand crank, at the bottom of the shaft;
Angle bracket plate
STOP button in the shaft
Fit the pit prop tube so, that the tube would cover the pit prop holding finger; Open the pit prop and rivet the angle bracket plate with 3.2x8
Electrical safety switch
Pit prop tube
Pit prop holding finger Pit prop tube covers the holding finger
Mechanical STOP mechanism (shown above) is always mounted on the left guide rail (looking from inside the platform)
1 2 3
Prepare a stable supports for horizontal part to protect safety switches underneath the platform; Put the horizontal part of the platform on the ground in the shaft; Cover the horizontal part of the platform in order not to damage the surface;
Platformâ€™s horizontal part
4 5 6
Put the vertical part of the platform between guiderails; Insert the guide slides and screw the bolts in; Lock it with lock pin and tighten the bolts;
ATTENTION! Screw the bolts tight but not overtighten.
Bolts and washers
Match the holes of the vertical part of the platform with the horizontal part of the platform which is laying on the ground and screw the bolts and tighten;
Put the corner profile to the guide rail, so that the widest side of the corner profile would be on the widest side of the guide rail
Aluminium corner profile
Aluminium corner profile fitted in place
Drill Ă˜4 holes and rivet with 4x10 rivets in two/three places the corner profile to the guide rail
50 mm height aluminium profile
2 3 4
Put the door close to the widest side of the guide rail; Check, if the gap in the door frame is in level with the aluminium corner profile; Push or pull the door’s to the side where gap of the door frame is, until it would fit with corner profile;
Aliuminium corner profile Gap in door frame Door’s fitted in place Door frame
5 6 7
Adjust the doors in level Drill Ø5 mm holes from outside of the shaft through the guide rail in the prepared places on the door‘s; Recommendation: drill for one hole in top and bottom positions and tighten it. Check the level of doors and drill and tighten the rest of the holes. Fix the threshold of the doors to the floor at each floor.
Insert drive screw through the hole in the top crossbar plate; Insert the plastic washer till the plate; Put on the top nut; Note: there are point markings on nut and screw top to match assembly correctly. Recommendation: hammer the pin into the nut first on solid ground. Hammer the pin through nut and screw till itâ€™s final position. Fit the screw into the drive nut on the platform and start to turn the screw; NOTE! Be carefull then mounting the screw into the drive nut not to damage it as depending on screw length it could be very heavy. Lift up the safety nut till its position as shown in the picture below; Continue to turn the screw till itâ€™s final position;
3 4 5 6 7
Safety nut electrical switch
Safety nut correct position marker
Turn the screw until the holes in the screw and the oblong hole in the bottom pipe matches; Put the pininto the nut and tighten it
Drive screw Lock pin Bottom pipe
Hole in the screw
Drive screw Plastic washer Lock pin
Top crossbar plate
10 11 12
If the screw is devided in several pieces put one in each other; Connect the screw pieces with double lock pins; MAKE SURE, that thread is correctly joint and pins are not left out of the holes
Outter lock pin
Inner lock pin
On detail B it is shown the correct pins positioning (gaps of pins should be in oposite directions)
The machine room in standard situated at the bottom floor doorâ€˜s on the side of the guide rails. The machine room is closed with the cover and locked with two locks.
Components of floor control system are located in top part of door frame. Each floor has its own control system located in same area.
Description of connections on door controller board v3.21
Connection for the grey cable going to the upper floor door‘s control board;
Power & Safety out
Power & Safety in
Dip switch for setting the door opening zone combination;
Connection for automatic door opener control; For opening door’s the signal from the system is empty NC contact;
Additional 24 V dc power supply input for lock;
Additional 24 V dc power supply output for lock (to upper floor);
D9; D10; D11
24V; 3.3V; 5V
Indication of the power on the board. When all three LEDs light it means that the power is coming to the board;
Connection for the bus cable coming from the main controller or from the lower floor door‘s control board;
Connection for the grey cable coming from the main controller or from the lower floor door‘s control board;
Dip switch for setting the door control board for the corresponding floor;
Bridge connection for the CAN cable connection;
Bridge connection for door contact in safety circuit;
Call button connection; Connection for the lock and door contact;
Each door control board with version V3.1 or higher can be setted up by DIP switches SW1 and SW2. DIP switch SW1 sets up the door control board for which floor it will be used. DIP switch SW2 sets up the door opening zone switches combinations, according to which the doors will be opened on appropriate floor.
Setting up wrong combination of the DIP switches (SW1 or SW2) will affect the opening of the lock!
Depending on the type of DIP switch used, can be such combinations for setting up the door control board:
The most important is to set up the pins of DIP switch, that correspond with the lines of the table
It is very important to set up the correct combination on the door control board (SW2) for door opening zone:
(1) – Over travel, reference point and door zone opening switches
(4) – Platform’s keyboard
(2) – Screw (3) – Solenoids
(6) – Drive nut (5) – Main contactor
(11) – Terminal blocks
(8) – Main control board (7) – Safety nut (9) – Travelling cabel fixing place
(12) – Relay
(15) – DC voltage power supply unit
(13) – Freguency converter
(10) – Travelling cabel in plastic chain
(14) – Safety nut electrical switch
(19) – Safety brakes test button
(16) – Loudspeaker
(18) – Safety edge electrical swithces
(17) – Battery
Power supply voltage.....................................................................................+22..+28 V Current consumption in idle mode with closed lock and lighting....................less than 0.5 A Maximum current consumption of external devices connected to the board.....less than 9 A Operating temperature....................................................................................-20..+60 ºС
When the voltage supply is below the +22 V the movement of the platform is being blocked
View of main control board
Safety circuit in platform lift SB200 is a protection system of unauthorized platform movement for end users and service personal as well. It is a requirement in industry standarts of safety system availability. The principle of safety system protection is related with disconnection of any switch in entire safety circuit (STOP button, switch connected to perimeter of the platform, lower and upper emergency limit switchs and etc.) therefore movement of platform (frequency inverter) will be stoped immediately.
Safety circuit interruption is fully independent from control system status. It is connected on independent electrical circuit. Control system is not able to prevent safety circuit interruption.
Positive pole in safety circuit comes from contact 2 on X29 connector through F12 fuse in main controller board SB200. Further safety circuit goes through: 1. STOP button in platform
2. Obstacles switch 1 under platform perimeter
3. Obstacles switch 2 under platform perimeter
4. Obstacles switch 3 and 4 under platform perimeter
5. Platform front cover switch
6. Overload switch
7. Upper over travel limit switch
8. Lower over travel limit switch
9. Transition to distribution unit with X37 connector 9.1 Transition out of distribution unit terminal K14 to door controller 9.1.1
Input to door controller connector X21
Transition through connector X20 of door controller
Transition through closed doors relay contacts
Output of X22 connector to upper floor door controller
Circuit return to distribution unit terminal K15 out of top floor door controller
9.2 Activation switch of platform mechanical stop inside the shaft 9.3 STOP button inside the shaft 9.4 Transition of terminal K16 to contact 8 in X37 connector 10. Transition to relay RL3 on main controller board SB200. In occasion of safety circuit interruption relay R3 breaks the starter KN1 as a result disconnecting the frequency inverter from power supply. 11. Controlled transitor key Q21 on board SB200 bypassing J3 jumper.
In process of servicing or repair of platform lift SB200 safety circuit may be temporarily bridged up to relay RL3 with jumper on main controller board contact J2.
Diagnostics of safety circuit breaking problems could be performed with help of measuring voltages in safety circuit points and connectors located above. Diagnostics could be also performed with special diagnostics module or using computer through diagnostic connector on board SB200.
The distribution unit, in standard, is always in the bottom door frame. The position of the distribution unit do not depend on the power supply, if it is single or three phase. The place for electrical supply cable is at the bottom landing on guide rail side, that it would be convenient and safe to enter into the door frame and connect to distribution unit‘s terminals. -Terminal blocks
Distribution unit fixing points
-3 poles main switch – A1
-Shaft light relay – RL4 -RCB unit for shaft light – A2
Distribution unit fixing points
3 poles main switch
K1; K2; K3;
Bottom terminal blocks
RCB unit for shaft light
Shaft light relay
To connect input power supply phases (lines) Ground and neutral terminals for input power supply To connect the travelling cable To connect cable of the shaft light To connect control signal for shaft light
Terminal blocks are used to make an easier connection of the cables at the distribution unit. Below are the descriptions of terminal block contacts. Explanation of terminal blocks below is for six stop platform lift. The terminal block contacts from K17 to K22 can be taken out depending on the number of stops, etc. two stops platform lift will have only K17 and K18 terminal block contacts and K19â€ŚK22 will be taken out.
(7) (8) (9)
+ 24 V dc power supply to the lowest door controler connection X17 and diagnostic module HMI from main board on platform.
Ground for door controlersâ€˜ connection X17 and diagnostic module HMI from main board on platform.
RS232 communication cable between main board on platform and diagnostic module HMI.
CAN communication cable between main board on platform and the door controlers. Safety circuit coming from platform and going to the door controlers Safety circuit coming from door controlers and going to pit
Safety circuit coming from pit and going to the platform
K17 ... K22
LAND1IN ... LAND6IN Signals from door opening zone switches.
Ground for the lowest door controler connection X21 + 24 V dc power supply to the lowest door controler connection X21 Not used
Connection for power supply ground wire
Connection for power supply neutral wire
3 poles main switch to connect power supply phases (lines). Rating - C25
RCB unit for connection shaft light. Rating â€“ C6, 30 mA.
To connect control signal from main board on platform to control shaft light
The distribution unit in case of single power supply is also at the bottom landing door frame. The marking and meaning of the terminal block contacts from K4 to K25 are not changed and are the same as described in section 7.5.1. The place of diagnostic module HMI also is the same. The differences between the distribution unit of 3 phases and single phase power supply are described below: (1) – Terminal blocks
(2) – Relay
(3) – Terminal blocks
(4) – RCB unit (5) – Terminal contact K1
The purpose of each terminal block is the same as described in section 7.4.1
K4 ... K25
To connect control signal from main board on platform to control shaft light To connect shaft light cable. N – neutral; L – Line; Main switch for power supply. RCB unit with ratings – C25, 30 mA. 1 contact – L (line); 2 contact – N (neutral) To connect ground wire of main power supply cable
1 2 3
Put in 50 mm height aluminium profile; Fit in the side wall panels; If it is a glass panel make distances even from both sides;
Aluminium profile 50 mm height
Check the distance from the safety edge of the platform till the corner profile of the shaft, it should be not less than 8 mm;
Steel panel or glass panel Aliuminium corner profile
Distance from corner profile to the safety edge of the platform from 8 – 10 mm
Safety edge of the platfrom Distance from corner profile to the safety edge of the platform from 9 – 11 mm
5 6 7 8 9
Drill the with Ø 3.3 ÷ 3.5 drills and rivet with Ø 3.2x8 rivets the panels; Drill with Ø 4 drill and rivet with Ø 4x12 rivets on the guide rail side; Drill with Ø 3.3 or 3.5 drills and rivet with Ø 3.2x8 rivets on the opposite side of the guide rails; Each side of the panel have to be rivetted not less than 4 rivets, totally not less 8 rivets for each panel; Continue with the assembly and fixing of the side walls of the shaft;
Recommended amount of rivets on one side of the panel – 6 rivets
Before starting the ceiling assembly fix the „U“ form profile 20 x 20 on the last panel; Fit the ceiling holding „U“ form profile 20 x 20 on the long side of the shaft and rivet it with Ø 3.2x8 rivets; Make the same on the opposite side; Fit in the ceiling parts;
1 2 3 4
Last panel of the shaft
“U” form profile 20 x 20 to cover the top of the last panel Ceiling’s part Ceiling’s “U” form profile 20 x 20
Check that the ceiling parts with pre-fitted lamps would be at the center of the shaft; the configuration of ceiling parts for the standard platform dimensions should be: - 3 blind parts; - 1 part with spot lights; - 3 blind parts; - 1 part with spot lights; - 3 blind parts; The distance between the ceiling parts should be about 13 mm, for standard platform dimensions; Rivet the ceiling’s parts at the middle on each side with one rivet of Ø 3.2x8;
Distance between the ceilingâ€™s parts about 12 mm (with standard platform)
The bottom over travel and reference point (bottom floor stop position) activation ramps are on the same fixing tube; Fit in on side of the tube, after that fit in other end of the tube by pressing downwards between the guide railâ€™s edge closest to the back wall;
When the platform is at the bottom floor the over travel and reference point activation ramps should be adjusted;
Bolts for fixing and adjustment of activation ramps
Bottom door opening zone ramp Reference point activation ramp (bottom floor position ) Bottom over travel activation ramp
(1) – Bottom over travel switch LS8 (2) – Top over travel switch LS1
(3) – Reference point switch LS2
(4) – First floor door opening zone switch LS9
(5) – Second floor door opening zone switch LS10
Depending on the number of the floors, all other activation ramps should be placed and adjusted; The top over travel activation ramp should be placed and adjusted about 3 cm above the top stop position.
Bottom over travel electrical switch
Top over travel electrical switch. This switch contains two groups of electrical contacts used for double action of the switch. If platofrm over travels and activates upper limit switch the platform stops and it can move ONLY downwards. If activated the upper emerg. limit switch the platform can be moved only in manual mode.
Reference point switch. To set up the bottom stop position of the platform.
First floor door opening zone electrical switch.
Second floor door opening zone electrical switch.
Third floor door opening zone electrical switch.
Fourth floor door opening zone electrical switch.
Fifth floor door opening zone electrical switch.
Sixth floor door opening zone electrical switch.
1 2 3 4 5 6 7 8 9 10 11
Change the paltform lift working mode from „Normal“ to „Maintenance“ – by taking out the jumper X13 on the main control board situated on the platform; The bottom stop position is adjusted by reference point switch and have to be adjusted prior programming the floors; Step on the platform; Drive up till nearest floor level; Stop the platform at the floor level; Make sure that the platform is at the correct floor level; Press STOP button on the platform; Press the corresponding floor button on platform’s keyboard and hold it for 30 seconds or until the indication LED of this pressed button changes the lighting color; Repeat the steps from 3 to 5 untill all the floor levels are programmed; When the programming is finished switch to „Normal“ mode; Check the functions of the platform lift;
Put profile corner on the shaft frame as shown in ( pictures 1a and 1b)
Picture no. 1a
Picture no. 1b (view from top of platform)
Drill with Ø 4 drill and rivet with Ø 4x12 rivets to conect over corners sides (picture 2);
Drill with Ø 4 drill and rivet with Ø 4x12 rivets on the guide rail side to fix top profile (pictures 3a and 3b)
Put in 50 mm height aluminium profile on the frame of lift and start to mounting panels (picture 4); Fix the panels with the aliuminium profiles (picture No. 5)
First panel is always with the hole for STOP button in the pit ( see picture No. 5)
1 2 3 4
The platform’s front cover consists of four independent pieces and only the middle cover is supplied with locks. This middle part cover done for maintenance purpose; Assemble the platforms front cover; Recommendation: start fit and tighten cover parts from the left and right hand sides, after that the top part of the cover and finally, the middle part of the cover. Fit the handrail and fix it with two screws;
Cover’s top part
Handrail fixing bolts
Cover’s right hand side part
Cover’s left hand side part
Cover’s middle part
5 6 7
Make sure that the trailling cable and cables between the doors are properly tightened to prevent them from getting jammed or hook on to moving platform; Check that all emergency stop buttons are working; Run the platform lift to all landings and check that the platform stops at correct position and if the doors opens / closes; If the doors are supplied with automatic door opener, check itâ€™s operation; Press down the safety edge at different points during movement of the platform. The platform lift have to stop immediately; Check the operation of the locks; Check the overtravel swiches; Check the pit prop;
Fit the cover plate under and over the doors and rivet it with Ă˜3.2x8 rivets in three places;
1 2 3 4
Cover plate under or over the doors
Safety nut distance
Functioning of motor brake
Functioning of motor
Sensitive safety edge (control panel)
Sensitive safety edges (platform floor)
Functioning of door opening zone devices
Means of attachment
Over travel limit switch positions (adjusted)
Door opening zone plates
Emergency stop at shaft bottom
Dynamic test (maximum load + 10% kg.)
Static test (maximum load + 25% kg.)
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