CO 2.30 / 2.35 / 2.

40 E 3
Two Post Lift

Technical Handbook
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nicht definiert.
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Contents
1 Installation ...............................................................................................................5
1.1 Standard Delivery ................................................................................................................................. 5
1.1.1 CO 2.30 E 3 .......................................................................................................................................... 5
1.1.2 CO 2.35 E 3 .......................................................................................................................................... 5
1.1.3 CO 2.40 E 3 .......................................................................................................................................... 5
1.2 Installation Checklist ............................................................................................................................. 6
1.3 Location ................................................................................................................................................ 6
1.4 Foundation Thickness .......................................................................................................................... 6
1.5 Positioning the Columns....................................................................................................................... 7
1.6 Shimming the Baseplates..................................................................................................................... 8
1.6.1 Standard ............................................................................................................................................... 8
1.6.2 With Adapter Plate................................................................................................................................ 8
1.7 Aligning the Columns............................................................................................................................ 9
1.8 Anchoring the Columns ...................................................................................................................... 10
1.8.1 Anchor Installation .............................................................................................................................. 10
1.8.2 Anchor Dimensions............................................................................................................................. 11
1.8.3 Curing Time ........................................................................................................................................ 11
1.8.4 Anchor Installation .............................................................................................................................. 12
1.9 Electrical Connection .......................................................................................................................... 13
1.9.1 Overhead Cable Installation ............................................................................................................... 13
1.9.2 Inground Cable Installation................................................................................................................. 13
1.10 Potential Equalization ......................................................................................................................... 14
1.11 Installing the Control PCB .................................................................................................................. 14
1.12 Installing Strain Relief Clips................................................................................................................ 15
1.13 Connector Pin Assignment and Contactors ....................................................................................... 16
1.14 Connecting the Power Supply Cord ................................................................................................... 18
1.15 Installing the Cable Guide and the Motor Covers............................................................................... 19
1.16 Installing the Support Arms ................................................................................................................ 20
1.17 Installing and Checking the Arm Restraints ....................................................................................... 20
1.18 Installing the Door Protection Strips ................................................................................................... 22
1.19 Initial Operation................................................................................................................................... 22
1.19.1 Yellow LED flashing............................................................................................................................ 23
1.19.2 Yellow LED not flashing...................................................................................................................... 23
1.19.3 Floor Contact ...................................................................................................................................... 24
1.19.4 Namur LEDs on Controller Board....................................................................................................... 24
1.20 Operational Check .............................................................................................................................. 24
2 Service Information...............................................................................................25
2.1 Controller Board.................................................................................................................................. 25
2.1.1 LED Display Unit................................................................................................................................. 25
2.1.2 Connector Pin Assignment ................................................................................................................. 25
2.1.3 Connector Types ................................................................................................................................ 25

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2.1.4 Extensions .......................................................................................................................................... 25

2.1.5 Serial Interface.................................................................................................................................... 26
2.1.6 EEPROM-Variables ............................................................................................................................ 27
2.2 Behavior of Lift Control System .......................................................................................................... 29
2.2.1 Emergency-Down (previously "Trial Run") ......................................................................................... 29
2.2.2 Performing the Emergency-Down ...................................................................................................... 29
2.2.3 Load Nut Failure ................................................................................................................................. 30
2.2.4 Floor Contact of Support Arms ........................................................................................................... 31
2.2.5 Contact with an Obstruction during Lowering Cycles......................................................................... 32
2.2.6 Motor Speed Error during Raising Cycles .......................................................................................... 32
2.2.7 Level Difference between Carriages .................................................................................................. 32
2.2.8 Upper End Position............................................................................................................................. 32
2.2.9 Bottom Position................................................................................................................................... 33
2.2.10 LED Display Unit................................................................................................................................. 33
2.3 Upper and Lower Proximity Switches................................................................................................. 35
2.3.1 Adjusting the Upper Proximity Switches (Pulse Generators) ............................................................. 35
2.3.2 Adjusting the Lower Proximity Switches (Limit Switches) .................................................................. 36
2.4 Motor Plate ......................................................................................................................................... 36
2.5 Support Bearings for Lifting Screw ..................................................................................................... 37
2.5.1 Upper Bearing..................................................................................................................................... 37
2.5.2 Lower Bearing..................................................................................................................................... 38
2.6 Drive Motor ......................................................................................................................................... 39
2.7 Manual Lowering ................................................................................................................................ 40
2.8 Aligning the Pulleys ............................................................................................................................ 41
2.9 Maintenance Schedule ....................................................................................................................... 41
2.9.1 Checking the Load Nut for Wear ........................................................................................................ 42
2.9.2 Greasing the Load Nut ....................................................................................................................... 43
2.9.3 Greasing the Slide Tracks .................................................................................................................. 44
2.9.4 Greasing the Arm Extensions............................................................................................................. 44
2.9.5 Greasing the Disk Adapter Threads ................................................................................................... 45
2.9.6 Operational and Wear Checks ........................................................................................................... 45
2.9.7 Checking the Lift Stability ................................................................................................................... 48
3 Company Information ...........................................................................................49

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This Technical Handbook is to be used exclusively by trained service personnel. Regulations

and guidelines in the Operating Manual listed under section "Safety" apply in all cases!

1 Installation

Lift installation and commissioning only by manufacturer authorized service personnel.

1.1 Standard Delivery

1.1.1 CO 2.30 E 3
• 2 columns with 1 control unit
• 2 support arms, long
• 2 support arms, short
• Overhead cable guide (with overhead cable installation) or
extended connecting cables (with inground cable installation)
• Operating manual
• Packaging

1.1.2 CO 2.35 E 3
• 2 columns with 1 control unit
• 2 support arms, long
• 2 support arms, double telescopic
• Plug-in disk adapter system
• Overhead cable guide (with overhead cable installation) or
extended connecting cables (with inground cable installation)
• Operating manual
• Packaging

1.1.3 CO 2.40 E 3
• 2 columns with 1 control unit
• 2 support arms, single telescopic, extra long
• 2 support arms, double telescopic
• Plug-in disk adapter system
• Overhead cable guide (with overhead cable installation) or
extended connecting cables (with inground cable installation)
• Operating manual
• Packaging

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1.2 Installation Checklist

During installation thoroughly check the following items:
• Shimming and alignment of lift with slight inclination to the outside
• Electrical connection of lift
• Potential equalization between the columns
• Upper and lower proximity switches
• Fastening of load nut
• Clearance (2 mm) between wear check screw and safety nut
• Adequate lubrication of lifting screw
• Tight fit of anchors in the concrete foundation
• Installation torque of fastening nuts
• Securing of support arm pins and disk adapters
• Smooth engagement of arm restraints
• Synchronization of carriages
• Smooth operation of lift in loaded and unloaded condition

1.3 Location
• Choice of a suitable lift location is the owner's responsibility.
• The lift may not be installed outdoors, in moist rooms or in the vicinity of explosives or
flammable liquids.

1.4 Foundation Thickness

• Proof of safe floor load capacity is the owner's responsibility.
• Always use the current foundation plans.

Standard with Adapter Plate with Baseframe

CO 2.30 E 3 175 mm 175 mm 130 mm
CO 2.35 E 3 175 mm 175 mm ---
CO 2.40 E 3 220 mm 175 mm ---

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1.5 Positioning the Columns

For details and dimensions see applicable data sheet.

1 Transport the lift to its final location and remove the packaging material.
2 Position the columns using the dimensions indicated in the applicable data sheet. Place the
operating column (3) on the right side as seen from approach direction (2).
The clearance between the columns can be determined e.g. by using dimension BG
(Outside baseplates).
3 Check the column positions using a levelling board (1), correct as required.

With inground wiring, ensure that the cutout provided in each baseplate exactly lines up with the
opening of the inground cable conduit.

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1.6 Shimming the Baseplates

After shimming the baseplates make sure the lift has a slight V shape (see also section
"Aligning the Columns").

1.6.1 Standard

• Shim the baseplate close to the anchor points and along the column profile.
With inground wiring, ensure that the cutout in each baseplate remains unobstructed.

To prevent the columns from tilting under load, carefully shim

• the corners of the column profile and
• the baseplate side which is not anchored.

1.6.2 With Adapter Plate

• Shim the adapter plate close to the anchor points and along the baseplate profile.

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1.7 Aligning the Columns

CO 2.30 E 3 CO 2.35 E 3 CO 2.40 E 3

Inside columns BL 2600 mm 2700 mm 2730 mm

1 Align the columns in a slightly V-shaped position (see also section "Shimming the Base-
plates"). The clearance between the upper column ends should be 15 mm larger than the
clearance between the lower column ends.
2 Check the alignment using a contractor's level.

Rule of thumb:
The column inclination has been adjusted properly if the
horizontal bubble level touches the inner mark.

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1.8 Anchoring the Columns

1.8.1 Anchor Installation

Detailed installation instructions come with the product. For further information go to the anchor
manufacturer's website: http://www.mkt-duebel.de/mkt-home_eng.htm

1 2

3 4

5 6

7 8

1 Drill holes with a hammer drill.

CO 2.xx E 3 w. Adapter Pl.

2 Clean thoroughly with steel brush and blow-out pump.

CO 2.30 E 3 / 2.35 E 3

3 Remove caps from cartridge and thread the mixing nozzle onto it.
4 Remove first two strokes of resin mixture coming out of the nozzle.
5 Fill cleaned drill hole with resin mixture.
CO 2.40 E 3

CO 2.50 E 3

CHO 2.40 E

6 Apply conical rod by hand.

7 Observe curing time.
8 Apply installation torque.

Part № Description Quantity

23000241 Cartridge VMZ 2 3 3 2 3
23000242 Anchor VMZ-A 145 M16-30/200 (Standard) 10 – – – –
23000255 Anchor VMZ-A 145 M16-80/250 (Option) 10 – – – –
23000240 Anchor VMZ-A 170 M20-25/230 – 10 12 – 12
23000256 Anchor VMZ-A 100 M12-25/145 – – – 12 –

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1.8.2 Anchor Dimensions

VMZ-A 100 M12 145 M16 170 M20
Drill hole diameter d0 [mm] 14 18 24
Diameter of clearance hole in
df [mm] 14 18 24
the fixture
Depth of drill hole h0 [mm] 105 153 180
Depth of anchorage hef [mm] 100 145 170
Fixture thickness tfix [mm] 25 30; 80 (Option) 25
Installation torque Tinst [Nm] 40 60 80
Width across nut [mm] 19 24 30
Mortar quantity per drill hole [ml] 9.2 15.8 30.1

1.8.3 Curing Time

Temperature of Gel Time Curing Time in Dry Curing Time in Wet
Base Material [° C] [min] Concrete [min] Concrete [min]
+40 1.4 15 30
+35 2 20 40
+30 4 25 50
+20 6 45 90
+10 12 80 160
+5 20 120 240
0 45 180 360
–5 90 330 660

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1.8.4 Anchor Installation

Applies to CO 2.30 E 3 with baseframe only.

1 Drill a hole as per anchor manufacturer's recommendations.

2 Blow the anchor hole clean of dust.
3 Position the washer on the anchor and thread on the nut.
4 Drive the anchor through the fixture into the anchor hole until the nut and washer are firmly
seated against the fixture. Note the required embedment depth!
5 Tighten the fastening nut to the prescribed torque.

Drill hole diameter 12 mm Depth of anchorage 65 mm

Depth of drill hole 90 mm Installation torque 50 Nm

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1.9 Electrical Connection

Remove the mains fuse before installing or servicing the electrical equipment.
Do not carry out any changes on the prewired control system.

1.9.1 Overhead Cable Installation

Run the power supply cords and air hoses through the channels provided inside the columns.
Be sure to run the cords and hoses in such a way that they do not contact the carriage. Verify
again after connecting the motor and control wires.

• Use the overhead cable guide to interconnect both columns (see section "Installing the
Cable Guide and the Cover Hoods").

If the vertical channels have been shortened to suit the ceiling height, make sure the vehicle
does not contact the overhead cable guide. A safety light barrier is optionally available.

1.9.2 Inground Cable Installation

• Ensure that the cutout exactly lines up with the opening of the inground cable conduit used
for the power supply cord, and for the motor and control wires of the second column.

If the lift is ordered with inground cable installation, the standard delivery includes extended
connecting cables instead of an overhead cable guide.

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1.10 Potential Equalization

• Run a potential equalization cable (wire size 4 mm²) from each column to the control unit.
The connecting points are marked with the PE symbol.

1.11 Installing the Control PCB

Sensitive electronic components! Risk of damage!
The controller board may be damaged or destroyed by electrostatic diskharge.
Before installing the controller board assembly touch a grounded metal object.
During installation hold the controller board on the edge and avoid contact with any
components.

1 Install the mounting bracket with the 2 Connect the motor and control wires
PCB to the operating column. (see section "Connector Pin Assignment
and Contactors").

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Risk of damage!
Make sure the motor and control wires do not contact the pulley.

1.12 Installing Strain Relief Clips

1 The strain relief clips at the cable exit from 2 After connecting the cables install a strain
the column (A) and at the motor (B) are relief clip (C) beneath the controller board.
preinstalled at the factory. Check if they are
present and complete them if necessary.

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1.13 Connector Pin Assignment and Contactors

X1 Mains Connector
Pin Description Remarks
X1.1 L1
X1.2 L2
X1.3 L3
X1.4 N
X1.5 PE

X2 Namur Switches, Operating Column

Pin Description Remarks
X2.1 Lower Namur Switch – (Limit Switch) Blue
X2.2 Lower Namur Switch + (Limit Switch) Brown

X3 Namur Switches, Operating Column (X3 marked with white dot on PCB)
Pin Description Remarks
X3.1 Upper Namur Switch – (Pulse Generator) Blue
X3.2 Upper Namur Switch + (Pulse Generator) Brown

X4 Namur Switches, Second Column

Pin Description Remarks
X4.1 Lower Namur Switch – (Limit Switch) Blue White
X4.2 Lower Namur Switch + (Limit Switch) Brown Brown
X4.3 Upper Namur Switch – (Pulse Generator) Blue Green
X4.4 Upper Namur Switch + (Pulse Generator) Brown Yellow

X5 Serial Interface
Pin Description Remarks
X5.1 +5 V
X5.2 RXD TTL Level
X5.3 TXD TTL Level
X5.4 GND

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X6 Motor Connector, Operating Column

Pin Description Remarks
X6.1 L1
X6.2 L2
X6.3 L3
X6.4 PE

X7 Motor Connector, Second Column

Pin Description Remarks
X7.1 L1
X7.2 L2
X7.3 L3
X7.4 PE

X8 Ceiling Light Barrier

Pin Description Remarks
X8.1 +24 V
X8.2 24 V Input DC-decoupled N/O contact against 24 V
required

X9, X10 Control Panel Connectors, Operating Column / Second Column

Pin Description Remarks
X9.1 / X10.1 +24 V
X9.2 / X10.2 24 V Button Input, Down N/O contact against 24 V, 200 mA max.
X9.3 / X10.3 24 V Button Input, Up N/O contact against 24 V, 200 mA max.
X9.4 / X10.4 LED Green + Dropping Resistor
X9.5 / X10.5 LED Yellow + Dropping Resistor
X9.6 / X10.6 LED Red + Dropping Resistor
X9.7 / X10.7 GND
X9.8 / X10.8 Potentiometer Input (Maximum Lifting Height) 0…24 V, 0 V = Maximum Lifting Height

K1A, K1B, K3, K4 Contactors

Contactor Description Remarks
K1A Up
K1B Down
K3 Motor, Operating Column
K4 Motor, Second Column

Risk of damage!
Do not manually actuate the contactors.

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1.14 Connecting the Power Supply Cord

Supply voltage........................... 3~ 400 V + N + PE

Motor Power Fuse (time delay) Rated Current

in kW in A in A
CO 2.30 E 3 2 x 2.4 16 14
CO 2.35 E 3 2 x 2.4 16 14

CO 2.40 E 3 2 x 3.0 16 14

The wire size must be selected depending on lift model and cord length.

Wire designation / Wire color Terminal of control unit

of power supply cord
(L1) Black L1

(L2) Brown L2
(L3) Grey L3
(N) Blue N

(PE) Green-Yellow PE

Risk of damage!
If any phase is connected to the zero terminal, a controller board component may be destroyed.

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1.15 Installing the Cable Guide and the Motor Covers

1 2 5

3 4

1 Bend the vertical cable channels in such a way that the connecting links are on top.
2 Fasten the links using two self-tapping screws.
3 Install the cable channels to the columns (2x M6 or M8).

Fold the link (A) at the bottom end of the cable channel to the inside so that it rests on the stop
pin (B). In this way the cables are protected from making contact with the pulley.

4 Install the cross member on one side (2x M6 or M8). Do not fasten the other end!
5 At completion of cable laying insert the channel covers into the side parts and install the
motor covers on both columns. Secure with supplied cable clips as required.

Run excess cable lengths inside the cable channel or under the motor covers.

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1.16 Installing the Support Arms

1 Insert the support arms into the carriages and fasten them using the arm pins.
2 Secure the arm pins at the top and the bottom using snap rings.

1.17 Installing and Checking the Arm Restraints

1 Pre-install the gear segments using three fastening screws M10 (A) on each support arm. Do
not tighten screws yet.
2 Slightly raise the carriage.
⇒ Arm restraints are in engaged position.
3 Check the contact points of the gear segments (B) for smooth engagement. If necessary, fix
the jam by moving the gears and slightly grease the contact points.
4 Torque the fastening screws. The tightening torque depends on the type of screw used (see
table).
CO 2.30 E 3 CO 2.35 E 3 CO 2.40 E 3
M10x25 / 8.8 42 Nm 42 Nm 42 Nm
M10x30 / 12.9 --- 64 Nm 64 Nm

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If the arm restraints are jammed when reaching the lower end position, this may result in invalid
error messages.

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1.18 Installing the Door Protection Strips

Install the door protection strips to the support arms:

1 To the inner edges of the long support arms (2 pcs).
2 To the inner and outer edges of the short support arms (4 pcs).

Position the door protection strips as required by the vehicle type to be lifted.

1.19 Initial Operation

During initial operation the pulse generators will not be monitored.
This means the following functions are disabled:
• Detection of sluggish operation
• Detection of obstructions
• Detection of motor defects
• Detection of belt failure or belt slipping
• Correction of level difference between carriages
Switchoff when level difference between carriages is too big

At initial operation check the rotary field for correct phase sequence:

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1.19.1 Yellow LED flashing

⇒ The yellow LED is flashing. (Otherwise see section "Yellow LED not flashing").
1 Push and hold the LOWER button for 10 seconds.
⇒ Lift lowers.

Risk of damage!
If lift raises, release button immediately. To rectify the phase sequence two phases must be
interchanged.

2 Lower lift to bottom position.

⇒ All LEDs are lighting. Lift is ready for operation.

1.19.2 Yellow LED not flashing

• If the yellow LED is not flashing, push and hold the LOWER and
RAISE buttons simultaneously for 10 seconds. Then proceed as
explained under section "Yellow LED Flashing".
+

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1.19.3 Floor Contact

Once a carriage contacts the floor, stop the lift immediately and correct the error
(no response from proximity switches).
After the error has been remedied repeat the initial operation procedure.
If the error cannot be remedied, check wiring, adjustment and function of all proximity switches
(limit switches and pulse generators).

1.19.4 Namur LEDs on Controller Board

Display
Namur LED flashes cycli-
cally 3x and extinguishes.
Description Remarks
LEDs are positioned according
Interruption of Namur switch. to the corresponding Namur
switch connections.

LEDs are positioned according

Namur LED flashes cycli-
cally 3x and lights.
Namur LED on / off.
Namur LED (pulse
generator) lights faintly.
Short circuit of Namur switch. to the corresponding Namur
switch connections.
On = Namur switch covered
Off = Namur switch uncovered
Lift running. Display of LEDs
changes quickly.

1.20 Operational Check

During commissioning once again thoroughly check the following items:
• Shimming and alignment of lift with slight inclination to the outside
• Electrical connection of lift
• Potential equalization between the columns
• Upper and lower proximity switches
• Fastening of load nut
• Clearance (2 mm) between wear check screw and safety nut
• Adequate lubrication of lifting screw
• Tight fit of anchors in the concrete foundation
• Installation torque of fastening nuts
• Securing of support arm pins and disk adapters
• Smooth engagement of arm restraints
• Synchronization of carriages
• Smooth operation of lift in loaded and unloaded condition

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2 Service Information

2.1 Controller Board

2.1.1 LED Display Unit

LEDs VD1 (red) , VD2 (yellow) and VD3 (green) indicate operating states and errors.

2.1.2 Connector Pin Assignment

See section "Installation / Connector Pin Assignment and Contactors".

2.1.3 Connector Types

Connector Circuit Card Number of Poles Type of Contact Type of Opposite Connector
X1 AMP MATE N LOK 5 Socket
X2 AMPMODU 2 Pin
X3 AMPMODU 2 Pin
X4 AMPMODU 4 Pin
X5 JST XHS 4 Pin
X6 AMP MATE N LOK 4 Socket
X7 Molex 5566 4 Pin Molex 5557
X8 Phoenix MCV 2 Pin
X9 RJ 45 8
X10 RJ 45 8

2.1.4 Extensions
Namur Switch Extension
Pin Description Remarks
1 Lower Namur Switch – (Limit Switch) Wired 1:1
2 Lower Namur Switch + (Limit Switch) Wired 1:1
3 Upper Namur Switch – (Pulse Generator) Wired 1:1 (marking)
4 Upper Namur Switch + (Pulse Generator) Wired 1:1 (marking)

Motor Extension
Pin Description Remarks
1 L1 Wired 1:1
2 L2 Wired 1:1
3 L3 Wired 1:1
4 PE Wired 1:1

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2.1.5 Serial Interface

Interface with 5 V level, adapter required.

Interface Settings
Baud rate.............. 38400 Baud
Data bits ............... 8
Stop bit ................. 1
Parity .................... none

ECON Manager (KE Tool) Settings

In menu <Options / Set File Paths and Names> make the settings for the MOT file (software
update for control unit), and for the EEPROM texts.txt.
In menu <Options / RS232 Settings> make the settings for the serial interface (see above).

Software Update
Perform the software update using the ECON Manager.
1 Connect the PC with the control unit using the RS232 box.
2 In menu <Test Functions / Test RS232 Connection> test the connection.
3 Start the bootloader using key <F5>.
4 Start the software update using key <F2>.
5 Start the application using key <F4>.

If the power supply is interrupted during the update, the bootloader can no longer be started
fron the ECON monitor. In this case proceed as follows:
1 Switch off the power supply.
2 Set the bootjumper (J1) on the control unit.
3 Switch on the power supply.
⇒ Bootloader is started automatically (red and green LEDs lighting up).
4 Repeat the update.
5 Remove the jumper from the control unit.

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2.1.6 EEPROM-Variables
№ Description Default

0
1 Not blank Pattern – Do not change!
2 EEPROM version 1

3 Position 1 [Digit]
4 Position 2 [Digit]
5 Check sum of positions (XOR)

6 Maximum lifting height [Digit] 2236

7 Pinch point position [Digit] 180
8 Control On-threshold [Digit] 30

9 Control Off-threshold [Digit] 3

10 Maximum difference [Digit] 100
11 Load nut failure detection, lower limit value [Digit] 14

12 Load nut failure detection, upper limit value [Digit] 30

13 Rated frequency [Hz] 60
14 Detection of sluggish operation Up [%] 50

15 Detection of sluggish operation Down [%] 50

16 Startup time Up [ms] 200
17 Startup time Down [ms] 200

18 Pause for change of direction [ms] 1000

19 Synchronization time after startup [ms] 500
20
21
22
23
24 Debug mode [0/1] 0
25 Reference flag (1 for Bootloader; 0 for Application)
26 Obstruction flag 1 [0/1] 0
27 Obstruction flag 2 [0/1] 0

28 Obstruction position 1 [Digit]

29 Obstruction position 2 [Digit]
30 Load nut failure flag [0/1] 0

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№ Description Default
31 Difference flag [0/1] 0

32 Flag for power failure during lowering [0/1] 0

33
34

35 Load nut failure counter 1

36 Load nut failure counter 2
37 Sluggish operation counter Up 1

38 Sluggish operation counter Up 2

39 Obstruction counter Down 1
40 Obstruction counter Down 2

41 Floor contact counter 1

42 Floor contact counter 2
43 Difference-too-big counter

44 Namur short-circuit counter ES 1

45 Namur interruption counter ES 1
46 Namur short-circuit counter IG 1

47 Namur interruption counter IG 1

48 Namur short-circuit counter ES 2
49 Namur interruption counter ES 2
50 Namur short-circuit counter IG 2
51 Namur interruption counter IG 2
52 Seconds counter (Low Word) [s]
53 Seconds counter (High Word) [s]

54 Number of lifting cycles (Low Word)

55 Number of lifting cycles (High Word)
56 Number of startups (Low Word)
57 Number of startups (High Word)
58 Counter for voltage drops

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2.2 Behavior of Lift Control System

2.2.1 Emergency-Down (previously "Trial Run")

During the emergency-down watch both carriages and the vehicle contiuously. If the vehicle is
in danger of getting off balance, stop the lift immediately.

During the emergency-down the pulse generators will not be monitored.

This means the following functions are disabled:
• Detection of sluggish operation
• Detection of obstructions
• Detection of motor defects
• Detection of belt failure or belt slipping
• Correction of level difference between carriages
• Switchoff when level difference between carriages is too big

2.2.2 Performing the Emergency-Down

⇒ The yellow LED is flashing. (Otherwise see section "Yellow LED not flashing").
1 Push and hold the LOWER button for 10 seconds.
⇒ Lift lowers.
2 Lower lift to bottom position.

⇒ All LEDs light up. Lift is ready for operation.

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• If the yellow LED is not flashing, push and hold the LOWER and
RAISE buttons simultaneously for 10 seconds. Then proceed as
explained under section "Yellow LED flashing".

2.2.3 Load Nut Failure

Load nut failure is stored in the control system by setting the "load nut failure flag" and is
indicated by the red LED lighting up and the yellow LED flashing at the same time.

For ease of verification the relevant portion of the load nut has been marked with red paint
during final assembly.
In case of load nut failure the red paint will be covered completely by the broken load nut.

Check surface A: Anchor plate of load nut Simulated load nut failure
Check surface B: Top edge of safety nut

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1 Raise or lower the lift until the inspection
windows in the carriages line up with the
windows in the screw drive covers.
2 Check the clearance between load nut (A)
and safety nut (B). With an undamaged
load nut, the clearance is 21…24 mm. With
a broken load nut, the clearance and the
red paint are no longer detectable.

Shut down and lock the lift until the broken load nut has been replaced.
After replacement perform an emergency-down to reinitialize the control system.

2.2.4 Floor Contact of Support Arms

Floor contact of support arms is detected by the lift control if the upper pulse generators
transmit too few or no pulses at a lifting height of less than 30 mm. This status is detected and
stored by the lift control and indicated by the yellow LED.
Once the main switch is actuated again, the lift can only be raised. At the same time the flag is
reset.

After the support arms have contacted the floor, check the following components:
• Ribbed V-belt for condition, tight fit and correct tension.
• Proximity switches (limit switches) for correct operation and adjustmen.

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2.2.5 Contact with an Obstruction during Lowering Cycles

If one of the support arms contacts an obstacle, the lift movement stops. This status is detected
and stored by the lift control and indicated by the yellow LED.
Once the main switch is actuated again, the lift can only be raised. Raise 10 cm at least to reset
the flag.

After the support arms have contacted an obstruction, check the following components:
• Ribbed V-belt for condition, tight fit and correct tension.

2.2.6 Motor Speed Error during Raising Cycles

If the upper pulse generators transmit too few or no pulses, e.g. due to overload, belt slipping or
maladjustment of the proximity switches (pulse generators), this status is detected and stored
by the lift control and indicated by the yellow LED.
Once the main switch is actuated again, the lift can only be lowered. At the same time the flag is
reset.

In the event of frequent speed errors check the following components:

• Ribbed V-belt for condition, tight fit and correct tension.
• Proximity switches and pulse generator wheel for correct operation and adjustment.

2.2.7 Level Difference between Carriages

Level differences between the carriages (≥ 26 mm) are corrected automatically by the lift
control.
However, if the level difference exceeds 10 cm due to an error, the lift stops, the yellow LED
flashes and the control is disabled.
Lower the lift either manually or by performing an emergency-down.

Before lowering the lift by means of an emergency-down, mechanically equalize the carriages to
prevent the vehicle from getting off balance.

2.2.8 Upper End Position

The internal counters store the number of pulses transmitted from the upper proximity switches
(pulse generators). A distinction is made between "positive" (raising) and "negative" (lowering)
pulses.
The maximum permissible lifting height is defined by a preset number of pulses stored in the lift
control. Once this number is reached the lift movement stops.

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2.2.9 Bottom Position

Lowering of carriages to bottom position is monitored by the lower proximity switches (limit
switches).
Once both carriages have reached bottom position, the lift movement stops. When starting a
new raising cycle, the internal counters are reset to zero.

2.2.10 LED Display Unit

The display unit indicates different operating states and errors by means of coloured LEDs.

The LED display unit is enabled only while the main switch is in position 1.
With the control switched off the display will not register any status changes.

Signals during Regular Operation

Indication Description Remarks
Green LED lights up. Lift switched on, no errors.

Audible signal while lowering, lift
stops.
Audible signal while lowering.
Lift has reached pinch point
Release button, press again.
position.
Lift is lowering and below pinch
point position.

Audible signal while raising, lift Ceiling light barrier triggered.

Lift can only be lowered.
stops. Maximum lifting height reached.
Yellow LED lights up briefly while Lift is correcting level difference
lift is moving. between carriages.

Error Messages
Indication Diagnosis Remedy

Audible signal immediately after Button pushed inadvertently. Release button.

switch-on. Short circuit. Remove short circuit.

Lift stops during operation, green

In case of repetition have line
LED flashes while button is Voltage drop.
voltage checked.
pressed.

Lift has contacted obstruction or Raise lift until yellow LED

Lift stops while lowering, yellow
LED lights up.
floor. extinguishes.
Reinstall lifting screw. Check gear
Arm restraint jammed, lifting screw
segments for sharp edges, file
outside bearing, obstruction
smooth if necessary. Clean slide
detected.
tracks for gear segments.

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Indication
Lift stops while raising, yellow LED Sluggish operation. Possible
lights up.
Yellow LED flashes.
Red LED lights up + yellow LED
flashes.
Red LED flashes.
All three LEDs light up
permanently.
Bootloader Signals
Indication
Green and red LEDs light up.
Green LED lights up, red LED
flickers.
Button Combinations
Buttons
Press Service button for at least
1 s.
Press RAISE and LOWER buttons
simultaneously for at least 10 s.
Press RAISE and LOWER buttons
simultaneously for at least 10 s
while switching on the lift.
TH362605-en
Diagnosis
Overloaded lift.
causes: Long standing under load, points.
insufficient lubrication, no pulses…
Difference between carriages too
big.
Load nut failure occurred.
Arm restraint jammed, lifting screw smooth if necessary. Clean slide
outside bearing, loss of pulses.
Namur switch error.
Error occurred (Watchdog).
Description
Control in bootloader.
Bootloader performing a software
update.
Function
Deletes load nut failure and
reference flags.
Deletes reference flag (enabling
emergency-down).
Deletes load nut failure flag.
Remedy
Release button, press again.
Reduce load, check greasing
See "Button Combinations".
Check load nut. If load nut failure
is found, shut down the lift and
replace load nut.
Reinstall lifting screw. Check gear
segments for sharp edges, file
tracks for gear segments
(Î section 2.17).
See "Button Combinations".
Correct error.
Turn off main switch and turn on
again after approx. 5 s.
Remarks
Start application using Windows
tool or by voltage cutoff.
Wait until red LED stops
flickering.
Remarks
Should be pressed at completion
of final assembly.
Then perform an emergency-
down to reinitialize the lift.
Buttons must be pressed
simultaneously within 100 ms.
Then perform an emergency-
down to reinitialize the lift.
After checking the load nut
perform an emergency-down to
reinitialize the lift.
 35

2.3 Upper and Lower Proximity Switches

2.3.1 Adjusting the Upper Proximity Switches (Pulse Generators)

The pulse generators are fastened to a holder under the motor plate by means of lock nuts.
1 Open the lock nuts (1.1).
2 Adjust the clearance between the pulse generators (1) and the teeth of the pulse generator
wheel (2) to 1…1.2 mm. Repeat procedure for both columns.

Inaccurate positioning of the upper proximity switches results in faulty speed measurement (Î
yellow LED) and fatal control errors including complete lift failure.
The pulses may be picked up only at the even surfaces of the pulse generator wheel, not at the
edge (see illustrations).

CORRECT WRONG

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2.3.2 Adjusting the Lower Proximity Switches (Limit Switches)

• The clearance between the upper edge of the limit switch and the upper edge of the
mounting bracket must be set to 10 mm.

2.4 Motor Plate

To install the motor plate on the column use 4 fastening bows M8-8.8 and 8 hex nuts M8-8
DIN EN ISO 10511.

Item. Description Installation torque

Hex Nut M8-8 DIN EN ISO
1 Torque to 22 Nm.
10511
2 Fastening Bow M8-8.8
3 Motor Plate

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2.5 Support Bearings for Lifting Screw

2.5.1 Upper Bearing

Sensitive components! Risk of damage!
Use caution when removing the flange bearing (item 8). The bearing may be easily damaged as
it absorbs forces in one direction only.

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Item. Description Installation torque

Glue in the nuts using screw locking glue (medium)
1 Hex Nut M24x2-8
and torque to 70 Nm.
2 Washer A25 DIN125

3 Ribbed Pulley (Large)

4 Shim Ring 28x40x2
5 Shim Ring 30x42x2,5

6 Shim Ring 30x42x2

7.1 Hex Screw M8x25-8.8 Torque to 24 Nm.
7.2 Hex Screw M8x45-8.8 Torque to 24 Nm.

8 Flange Bearing
9 Feather Key A8x7x30
10 Lifting Screw

2.5.2 Lower Bearing

Item. Description Installation torque

1 Lifting Screw
2 Hex Screw M6x20 Torque to 10.5 Nm.
3 Flange Bearing igubal EFOM
4 Baseplate

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2.6 Drive Motor

Item. Description Installation torque

1 Hex Screw M8x16-8.8
2 Hex Screw M8x30-8.8 Torque to 22 Nm.
3 Hex Nut M8-8 DIN EN ISO 10511

4 Hex Screw M8x35-8.8

5 Belt Tensioner (Long)
6 Belt Tensioner (Short)

7 Washer A8.4 DIN 7349

8 Ribbed Pulley (Small)
9 Threaded Pin M5x8 DIN 914-45H
10 Feather Key A8x7x50
11 Drive Motor

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2.7 Manual Lowering

Authorized personnel only! Do not restart the lift before the error has been remedied.

In case of motor defect or power failure the lift can be lowered manually. The lift may only be
lowered, not raised.

1 Open the fastening screws ; Do not remove the 2 Apply a wrench to the
(A) and (B) and remove the mounting brackets (C) of fastening nut (D) of the
motor covers from both the motor covers! pulley.
columns.
3 Lower both carriages in steps of 20 mm by intermittently turning the pulleys.
4 Reinstall the cover hood.
5 Once lift is in bottom position, swing arms to full drive-through position and drive the vehicle
off the lift.

After the error has been remedied, have the control system reinitialized by authorized service
personnel.

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2.8 Aligning the Pulleys

Make sure the pulleys of motor and lifting screw are in alignment. Misalignment exceeding
± 0.5 mm is not permissible.

The motor pulley (A) is fastened using a setscrew (B).

• Open the setscrew and adjust the motor pulley until it aligns with the lifting screw pulley.

2.9 Maintenance Schedule

Turn off and lock the main switch before servicing the lift.

Interval Maintenance on Description

1 week Support arms / Disk adapters • Check rubber pads for wear
• Check arm restraints for proper operation
6 months Greasing points of lift • Check and lubricate as required
• Load nuts
• Slide tracks
• Arm extensions
• Threads of disk adapters
Fastening nuts of anchor bolts • Check all nuts for correct torque and
retighten them as required.
12 months Load nuts • Check both load nuts for wear
Drive assembly • Check drive belts for wear, soiling and
correct tension

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2.9.1 Checking the Load Nut for Wear

Once a year check the load nuts for wear.

Shut down and lock the lift until the worn-out load nut has been replaced.

1 Raise or lower the lift until the inspection
windows in the carriages line up with the
windows in the screw drive covers.
2 Check the clearance between between
check screw (A) and safety nut (B). A
clearance of 2 mm has been preset at the
factory.
If no clearance can be detected, have the
load nut replaced prior to further use.
3 At completion of wear check reinstall the
cap plugs.

The correct setting of the clearance between wear check screw and safety nut is imperative for
proper functionality and safety of the lifting screw and load nut system.
If the clearance is not set properly when installing the new load nut, the wear and tear on the
load nut can no longer be reliably checked. In this case, the safe operation of the lift can no
longer be guaranteed.

After servicing the carriage (e.g. load nut replacement) proceed as follows:
1 Raise the lift to upper end position.
2 Briefly unscrew the motor plate, centre it, fasten it again.
3 Lower the lift to bottom position.
4 Briefly unscrew the lower support bearing, fasten it again.
5 Recheck the clearance between check screw and safety nut.

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2.9.2 Greasing the Load Nut

Twice a year lubricate the load nuts using a grease gun.
Use the following type of lubricant:
• Kuwait Petroleum / Q8 Rembrandt Moly 36 20305 (400 g cartridge).
Ensure that ecologically harmful substances are disposed of only in accordance with the
appropiate regulations.

1 Raise or lower the lift until the inspection
windows in the carriages line up with the
windows in the screw drive covers.
2 Grease the load nut through the lubricator
nipple.
3 Fully raise and lower the lift to distribute the
grease evenly on the lifting screw.
4 Repeat this procedure two or three times.
5 Reinstall the cap plugs.

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2.9.3 Greasing the Slide Tracks

The slide tracks inside the columns should be greased every six months or more frequently if
required.

1 Fully lower the lift.
2 Open fastening screws (A)
and (B) and remove motor
covers from both columns.
3 Open upper fastening
screws (C) of screw drive
cover and remove cover.
4 Slightly grease the slide
tracks (D) over their whole
length using a brush.
5 Reinstall the covers to the
columns.

2.9.4 Greasing the Arm Extensions

1 Every six months check the support arm extensions for smooth operation.
2 Grease as required.

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2.9.5 Greasing the Disk Adapter Threads

1 Every six months check the threads of the disk adapters for smooth operation.
2 Grease as required.

2.9.6 Operational and Wear Checks

Rubber Pads of Disk Adapters
1 Weekly check the rubber pads for wear.
2 Replace defective pads.

Arm Restraints
1 Periodically check the restraint pin (A) for smooth and secure engagement.
2 If required, slightly grease the contact points of the gear segments (B).

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Ribbed V-Belts
Once a year check the ribbed V-belts for wear, soiling and correct tension. Worn-out belts have
to be replaced. Make sure the running surface is free of lubricants.

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Adjusting the Belt Tension

1 Open fastening screws (A) and (B) and ; Do not remove the mounting brackets
remove motor covers from both columns. (C) of the motor covers!
2 Slightly open the fastening screws (D) of the motor.
3 Slightly open the fastening screw (E) of the tensioning device.
4 Tension the belt using the tensioning screw and nut (F).
5 Torque fastening screws (D) and (E) to 23 Nm.
6 Reinstall the cover hood.

TH362605-en
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2.9.7 Checking the Lift Stability

1 Every six months check the nuts of all anchor bolts for correct installation torque Tinst using a
torque wrench.
2 Retighten the nuts as required.

Standard with Adapter Plate with Baseframe

CO 2.30 E 3 60 Nm 40 Nm 50 Nm

CO 2.35 E 3 60 Nm 40 Nm ---
CO 2.40 E 3 80 Nm 40 Nm ---

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 49

3 Company Information
© MAHA Maschinenbau Haldenwang GmbH & Co. KG
Legal notice based on ISO 16016:
The reproduction, distribution and utilization of this document as well as the communication of
its contents to others without explicit authorization is prohibited. Offenders will be held liable for
the payment of damages. All rights reserved in the event of the grant of a patent, utility model or
design.
The contents of this edition have been checked with great care. However, errors cannot be fully
excluded. Subject to technical change without notice.

Document
Document №: TH362605-en
Approval Date: 12.01.2011

Manufacturer
MAHA Maschinenbau Haldenwang GmbH & Co. KG
Hoyen 20
87490 Haldenwang
Germany
Phone: +49 (0) 8374 585 0
Fax: +49 (0) 8374 585 499
Fax Parts: +49 (0) 8374 585 565
Internet: http://www.slift.de
E-Mail: vertrieb@slift.de
Hotline: +49 (0) 180 56242 60 for Brake Testers and Test Lanes
+49 (0) 180 56242 80 for Automotive Lifts
+49 (0) 180 56242 90 for Dynamometers and Emission Testers

Service
AutomoTec GmbH
Maybachstraße 8
87437 Kempten
Germany
Phone: +49 (0) 180 56242 50
Fax: +49 (0) 180 56242 55
Internet: http://www.automo-tec.com
E-Mail: service@automo-tec.com

TH362605-en