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Acorn 80
Installation Manual

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Summary of Contents for Acorn 80

  • Page 1 Acorn 80 Installation Manual...
  • Page 2 10.9.4 530 Powered Swivel R/H Seat Spacer Complete 10.9.5 550 Powered Swivel R/H Seat Spacer Complete 10.9.6 580 Powered Swivel R/H Seat Spacer Complete 10.9.7 Carriage Front Cover Assembly 10.10 Seat Adaptor Plate Assembly Instructions 10.11 Seat Adaptor Plate Retro-fit Kit ACORN 80 Installation Manual...
  • Page 3 SECTION 1 Introduction INTRODUCTION This manual contains installation (and de-installation) instructions for the Acorn 80 Stairlift. Other documents available include: Survey Manual Servicing & Maintenance Manual User Manual Product Price Guide Parts Price Guide ACORN 80 Installation Manual...
  • Page 4: Installation Training

    THIS STAIRLIFT MUST ONLY BE INSTALLED BY TRAINED PERSONNEL. TRAINING CAN USUALLY BE ARRANGED FREE OF CHARGE VIA YOUR LOCAL AREA REPRESENTATIVE OR THROUGH ACORN TECHNICAL SERVICES DEPARTMENT. A VIDEO COMPACT DISK (VCD), SHOWING INSTALLATION PROCEDURES, IS ALSO AVAILABLE AS A TRAINING AID FOR TRAINED PERSONNEL.
  • Page 5: Installation Flowchart

    SECTION 2 Installation Flow Chart INSTALLATION FLOW CHART ONLY ACORN TRAINED ENGINEERS SHOULD CARRY OUT STAIRLIFT INSTALLATIONS. ALL STATUTORY RULES AND REGULATIONS CONCERNING SAFETY, ELECTRICAL WORK OR ENVIRONMENTAL PROTECTION MUST BE OBSERVED. Before Starting An Installation Ensure that you have the correct installation drawing.
  • Page 6: Rail Installation

    Check correct number of legs are supplied. Tighten the rail fixings to the recommended Torque settings - see Appendix 2. Rail Sections (viewed from wall side of lift) Rail Section Top Joint Box Bottom Fixing Plate Pull Plate Countersink Screws Grub Screws ACORN 80 Installation Manual...
  • Page 7 See sample drawing. WHEN INSTALLING, INTERNAL OR EXTERNAL, 90˚ OR 180˚ WRAP ROUND SYSTEMS, IT IS IMPORTANT TO ENSURE THAT ALL THE RAIL ANGLES AND SECTIONS ARE CORRECT. ACORN 80 Installation Manual...
  • Page 8 ENSURE THAT THERE IS AT LEAST 180MM CLEARANCE BETWEEN THE WALL STRINGERS (S) AND THE FRONT OF THE RAILS (R) OR ANY OBSTRUCTION. Remove screws from protruding sections of top joints. Push the rail sections together. ACORN 80 Installation Manual...
  • Page 9 Note: If rail support kit needed see Section 5 (page 12). HORIZONTAL SECTIONS MUST NEVER BE LESS THAN LEVEL. NO NEGATIVE DECLINE. 12 Lubricate the rack throughout using Interflon Fin Grease (902231) or equivalent. ACORN 80 Installation Manual...
  • Page 10 Fit one screw to pull plate. YOU MAY NEED TO REMOVE RAIL SECTIONS TO ACHIEVE A 90° CUT FACE FOR T TRANSFER RAIL TO MEET. ACORN 80 Installation Manual...
  • Page 11 (T) onto the fitted rail. Remove transfer rail. Where necessary, fit the last section of rail. Level the carriage as required, using the winding handle (W) on the levelling motor. Check the carriage is level with a spirit level on the footrest. ACORN 80 Installation Manual...
  • Page 12 RAIL SUPPORT KIT In order to improve the stability of the Acorn 80 rail, a top bracket has been designed to secure the rail to the wall. The inclusion of this part will be determined by the Drawing Office as part of the feasibility, but can also be purchased when circumstances of the end user changes.
  • Page 13: Fitting Instructions

    Drill the hole out to 13mm diameter to allow the threaded studding to pass through. Place one washer and M12 slim nut on one end of the M12 studding and screw the studding into the wall plate as shown. ACORN 80 Installation Manual...
  • Page 14 Rail Support Kit Cut the M12 studding to the correct length to fit from the wall to the inside of the Acorn 80 rail section, allowing enough length to fit a M12 nyloc nut on the inside of the rail section. Fit a M12 slim plain nut and plain washer as shown.
  • Page 15 Take care when tightening the wall support nuts not to pull the rail out of line and therefore too close to the wall. 5.3 Wall Support Fixing Position Dimensions ACORN 80 Installation Manual...
  • Page 16 Hold paddle arms down and push the seat fully down into the frame (F). Check the seat swivel locking mechanism operates correctly, using the swivel paddles (SP). Connect the seat wiring (W) to the PCB connector. ACORN 80 Installation Manual...
  • Page 17 Fit the top & bottom limit switch striker plates onto the back of the charge points. THE NEXT STEP IS AN IMPORTANT SAFETY REQUIREMENT. Fit the top & bottom mechanical stops to the rail rack. Fit the end cap to the final section of rail. ACORN 80 Installation Manual...
  • Page 18: Programming Instructions

    Switch off the lift at the on/off switch. Put a call in using rocker in switch in required direction. Switch the on lift with the on/off switch whilst holding the call in on the rocker switch. The lift will now drive. ACORN 80 Installation Manual...
  • Page 19: Pre-Power Up Checks

    The carriage is now ready for programming down the full length of the rail. ACORN 80 Installation Manual...
  • Page 20 On all bends (except external horizontal bends) when the portcullis (P) is above the first bend joint line switch FULL SPEED to OFF - this reverts the lift to BEND SPEED (B) (if applicable). Repeat this procedure for all vertical, inside horizontal and helical bends on the installation. ACORN 80 Installation Manual...
  • Page 21 Switch PROGRAM MODE to OFF (into run mode). The standby symbol will be displayed. PROGRAMMING IS NOW COMPLETE. THE LIFT MUST NOW BE TESTED TO ENSURE THAT IT IS OPERATING CORRECTLY. THE ELECTRICAL AND MECHANICAL INSTALLATION MUST BE TESTED IN ACCORDANCE WITH LOCAL SPECIFICATIONS AND STANDARDS. ACORN 80 Installation Manual...
  • Page 22: Checking The Program

    Note: Creep speed is overridden at this point and the lift runs in bend speed. Drive the lift down the rail checking the levelling and speeds are satisfactory and the approach to the bottom terminal limit is okay, and the lift stops where it should. ACORN 80 Installation Manual...
  • Page 23 6 Do reprogram the final limit if you have reprogrammed within 150mm of the terminal limit DO NOT 1 Do not move the top charge point after datum has been set 2 Do not alter the level calibration potentiometer before or after programming ACORN 80 Installation Manual...
  • Page 24: Over-Speed Governor

    Cam gear tooth and the OSG wedges will be up against the rail. OSG NOT TRIGGERED OSG TRIGGERED OSG Regulator weight in level position OSG Regulator weight in upright position ACORN 80 Installation Manual...
  • Page 25 Whilst keeping the reset lever held hand wind the stair lift in an upwards direction until OSG wedges release and the regulator weight is in a horizontal position (normal operating position) ensuring the teeth of the regulator are clear of the Cam gear. Once set, release the reset lever. ACORN 80 Installation Manual...
  • Page 26 Re-fit the Power Bogie outers back onto the carriage. Switch on the lift using the holding switch located on the seat arm/ back of the seat cover. Run the lift an upward direction using the direction controller. ACORN 80 Installation Manual...
  • Page 27: Final Checks

    4 When required by local regulations, complete appropriate installation test & examination certificate. 5 Remove all debris and packaging from the work area. 6 Ensure that the lift, rail and work areas are left in a clean condition. 7 Ensure that the client has contact details for assistance. ACORN 80 Installation Manual...
  • Page 28: De-Installation

    9.1 Disposal Local legislation regarding environmental pollution must be observed. POTENTIALLY TOXIC ITEMS INCLUDE ALL PLASTIC COMPONENTS, SEAT UPHOLSTERY, BATTERIES, PRINTED CIRCUIT BOARDS AND ELECTRICAL WIRING. THESE MUST BE SAFELY DISPOSED OF IN AN APPROVED MANNER. ACORN 80 Installation Manual...
  • Page 29: Installation Checklist

    D.C. charge current satisfactory and record mA = GENERAL Check all warning and information labels are fitted where necessary. Check operation of arm control device. Check operation of call and sends. Lift Serial Number Other Work Required or Completed ACORN 80 Installation Manual...
  • Page 30: Recommended Tool List

    1/2 inch Drive ratchet 19mm x 1/2 inch drive socket Digital Angle Finder 10 Digital Multi-meter 11 5m Steel Measuring Tape 12 1/2 inch drive Torque Wrench with suitable scale setting 13 Rack Meshing Tool 14 Crimping Tool ACORN 80 Installation Manual...
  • Page 31: Recommended Torque Settings

    Recommended Torque Settings Recommended Torque Settings Torque settings Component Newton metres (Nm) Foot Pounds M12 Leg clamp fixing bolt 66.4 M10 Top joint box grub screw M8 Pull plate countersink fixing screws M8 Bottom Joint fixing screws ACORN 80 Installation Manual...
  • Page 32: Recommended Lubricants

    APPENDIX 4 Recommended Lubricants Recommended Lubricants Component Lubricant Seat swivel pin Rail Rack Interflon Fin Grease Levelling Vee Wheel Rails (Acorn part number 902231) Power Bogie Gear Wheel Thrust Washers Silicon Grease Levelling Ball Screw ACORN 80 Installation Manual...
  • Page 33 APPENDIX 5 Wiring Diagrams Charge System ACORN 80 Installation Manual...
  • Page 34 APPENDIX 5 Wiring Diagrams ACORN 80 Installation Manual...
  • Page 35 APPENDIX 6 Example Installation Drawing ACORN 80 Installation Manual...
  • Page 36 Acorn 80 installation manual. Position the Acorn 80 rail system in place on the staircase as indicated on the installation drawing. The hinge interlock switch is located on the underside of the hinge section, therefore care must be taken not to damage the switch or the associated wiring whilst handling the hinge.
  • Page 37 The hinge folded interlock switch wiring that is in the same cable as the motor wiring, is connected to the terminal block marked ‘hinge folded limit switch’. The hinge limit switch, which is also the same cable connected to the terminal block marked ‘hinge interlock safety switch’. ACORN 80 Installation Manual...
  • Page 38: Lift Operation

    Pressing the red button on the remote handset will automatically run the lift to the next charge point, either an intermediate charge point if fitted or the top charge point. When the lift leaves the programmed hinge zone the powered hinge will be automatically raised (folded). ACORN 80 Installation Manual...
  • Page 39 APPENDIX 7 Installation & Programming The Powered Hinge Powered Hinge Diagram ACORN 80 Installation Manual...
  • Page 40: Diagnostic Display

    The Stairlift has overrun the normal parking position and Programming mode is on Main Drive Over Speed activated the Final Limit Switch. Programming the terminal Over-speed Governor has Levelling Over Speed limits (charge point positions) been activated ACORN 80 Installation Manual...
  • Page 41: Channel Selection

    Dip switches (S) on the transceiver board (T) are set to ON or OFF. Set the dip switches (S) to the positions indicated below. Channel Selection Channel Green Loop Yellow Loop Switch 1 Switch 2 Uncut Uncut Uncut Uncut ACORN 80 Installation Manual...
  • Page 42 SWIVEL PIN In order to change the hand of the seat the below changes must be implemented. Remove the grub screw securing the Swivel Pin in position and remove the shaft one loosened. GRUB SCREW 104CSB33 ACORN 80 Installation Manual...
  • Page 43 IF PATCHED BOLT IS NOT PRESENT, USE LOCTITE 243 AND SECURE IN POSITION The lift has now been changed to a Left Handed seat. Place seat on carriage and check to see if the swivel release operates freely and locks correctly. ACORN 80 Installation Manual...
  • Page 44 4 x M8 x 20 (901200) screws as shown in Option 2A/2B. OPTION 1A OPTION 2A REMOVE 2 x M8 REMOVE DOME CSK SCREW HEAD SCREWS 901045 1040250 OPTION 1B OPTION 2B REMOVE 4 x M8 REMOVE 4 x M8 NUTS x 20 SCREWS 900009 901200 ACORN 80 Installation Manual...
  • Page 45 Position the new Seat spacer assembly onto the mainframe ensuring the hole for the Seat swivel pin is correctly aligned with the hole on the mainframe casting and that the Seat interlock harness is fed through the casting correctly. ACORN 80 Installation Manual...
  • Page 46 TO MAIN PCB SECURE WITH 4x TIE WRAPS Secure front cover back onto the mainframe. 10 Reposition the seat onto the carriage, Reconnect carriage harness and secure Lower back cover and back pad back onto the seat. ACORN 80 Installation Manual...
  • Page 47 M8 x 20 (901200) screws as shown in Option 2A/2B. OPTION 1A OPTION 2A REMOVE 2 x M8 REMOVE DOME CSK SCREW HEAD SCREWS 901045 1040250 OPTION 1B OPTION 2B REMOVE 4 x M8 REMOVE 4 x M8 NUTS x 20 SCREWS 900009 901200 ACORN 80 Installation Manual...
  • Page 48 1243017 – 580 Powered Swivel Seat Spacer complete R/H Remove Swivel pin thrust washer (112CSB22) from the Powered swivel spacer assembly and position onto the swivel pin on the bottom of the new powered swivel seat. SWIVEL PIN THRUST WASHER 112CSB22 ACORN 80 Installation Manual...
  • Page 49 Assemble seat spacer assembly to the mainframe and secure in position with 4 x PATCHED M8 x 20mm Socket Cap Head screws (902100) and connect the seat interlock harness to the main PCB board as shown below. 4 x PATCHED M8 x 20mm SOCKET CAP HEAD SCREWS 902100 REMOVE SEAT INTERLOCK HARNESS ACORN 80 Installation Manual...
  • Page 50 Once released pull down on the seat ensuring that the gear teeth are aligned to the motor quadrant positioned on the base of the seat. ACORN 80 Installation Manual...
  • Page 51 MUST NOT BE BELOW WITH THE SEAT BASE EDGE OF SEAT BASE OR SLIGHTLY ABOVE WHEN FULLY CLOSED 14 Connect the options and seat harnesses from the seat to the harnesses from the carriage. OPTIONS HARNESS ARM HARNESS ACORN 80 Installation Manual...
  • Page 52 10.4 Connecting Supercharger Link IN ORDER FOR THE SUPERCHARGER LINK WIRE TO WORK, THE MAIN PCB MUST ALSO HAVE A LINK WIRE ON THE BACK OF THE BOARD AS SHOWN BELOW LINK WIRE ON THE BACK OF THE BOARD ACORN 80 Installation Manual...
  • Page 53 PCB as shown. SUPERCHARGER LINK WIRE 1021542 Connect the charge harness to the supercharger link wire. Neatly secure cable with cable ties and re-assemble front cover to carriage. SUPERCHARGER LINK WIRE CHARGE HARNESS ACORN 80 Installation Manual...
  • Page 54 4 x M8 x 20 (901200) screws as shown in Option 2A/2B. OPTION 1A OPTION 2A REMOVE 2 x M8 REMOVE DOME CSK SCREW HEAD SCREWS 901045 1040250 OPTION 1B OPTION 2B REMOVE 4 x M8 REMOVE 4 x M8 NUTS x 20 SCREWS 900009 901200 ACORN 80 Installation Manual...
  • Page 55 Secure the adaptor plate assembly to the carriage using the supplied 4 PATCHED M8 x 30MM CSK socket cap screws (901045) and 4 M8 nuts (900009). HARNESS WIRING FED CORRECTLY THROUGH THE MAINFRAME CASTING M8 x 30mm CSK 4 x M8 NUTS SOCKET CAP SCREWS 900009 901045 ACORN 80 Installation Manual...
  • Page 56 FROM EITHER SIDE OF THE SEAT BASE Reconnect the Seat interlock harness onto the board as shown and secure the harness in place with 4 x Tie wraps. RECONNECT HARNESS TO MAIN PCB SECURE WITH 4x TIE WRAPS ACORN 80 Installation Manual...
  • Page 57 10 Rotate the seat base and the following should be seen on the display whilst the call is activated. 11 If this does not happen then loosen and adjust the plastic cover until the position of the switch is correct. 12 Secure Front cover to carriage. ACORN 80 Installation Manual...
  • Page 58 Remove Front cover from the carriage. Disconnect Arm Harness from Main PCB and completely remove from carriage. Unpack carriage cover assembly kit, parts included are as shown below. B80 CARRIAGE FRONT COVER ASSEMBLY 1249000 ARM / SWITCH HARNESS 1021541 ACORN 80 Installation Manual...
  • Page 59 Feed Arm/Switch Harness (1021541) through the rear and centre of the mainframe as shown, and connect to the PCB as shown. HARNESS FED THROUGH THE REAR OF THE MAINFRAME CASTING CONNECT ARM FEED HARNESS HARNESS THROUGH THE CENTRE TO THE PCB OF THE MAINFRAME ACORN 80 Installation Manual...
  • Page 60 Harness to the ON/OFF switch connector Pin 3 as shown. Connect Keyswitch Male block connector to Female block connector on Arm harness. RED PLUG MALE BLOCK CONNECTOR TO CONNECTED TO FEMALE BLOCK CONNECTOR ON ARM HARNESS PIN 3 ACORN 80 Installation Manual...
  • Page 61 12 Secure Front cover assembly to the carriage using 2 m4x10 Pozi screws (902101). 13 Place new seat onto carriage and connect the seat harness to the carriage harness as shown. 14 Complete Seat and carriage with upgrade. ACORN 80 Installation Manual...
  • Page 62 BE LOCATED ON THE CARRIAGE AND A BLANKING PLATE WILL BE POSITIONED WHERE THE SWITCH PREVIOUSLY WAS. Push on the front of the seat arm pad to release, then slide and remove pad completely. Unscrew and remove the 3 screws indicated in the image below. ACORN 80 Installation Manual...
  • Page 63 Pull on the arm cover to release from the casting. Remove the cover. Disconnect Arm harness from the ON/OFF switch by disconnecting the block connectors as shown, and then remove the 4 screws securing the ON/OFF switch in position. REMOVE 4 POZI SCREWS DISCONNECT HARNESS FROM SWITCH ACORN 80 Installation Manual...
  • Page 64 4 No.8x1/2 Pozi pan screws (104CSA38). SECURE WITH 4 No.8 BLANK PLATE x ½ POZI PAN SCREWS 112CSA27 104CSA38 Reposition lower cover in place and secure with 3 M3x16 screws (104CSA46). M3 x 16 SCREWS 104CSA46 ACORN 80 Installation Manual...
  • Page 65 APPENDIX 10 Rationalisation Procedures Line up groves of arm pad with cut-outs of the arm casting and push the arm pad into position, ensuring that it is fully secured. Complete seat to new revision. ACORN 80 Installation Manual...
  • Page 66 WHERE THE SWITCH PREVIOUSLY WAS. ON / OFF SWITCH LOCATED ON THE SEAT BACK COVER Remove padded seat insert, and lower back seat cover by unscrewing all 8 screws as indicated in the image below. UNSCREW 8 SCREWS ACORN 80 Installation Manual...
  • Page 67 BY PUSHING ON THE REAR OF THE SWITCH REMOVE ARM HARNESS FROM HERE Remove Yellow indication sticker (if present) from the back cover, and assemble hole plug by pressing in. ON / OFF SWITCH HOLE PLUG ACORN 80 Installation Manual...
  • Page 68 ARM HARNESS WILL ONLY SUPPLY ONE ARM (ROCKER SWITCH) Re-assemble back cover insert and lower back cover by securing in position with the 8 screws removed previously. SECURE IN POSITION WITH 8 SCREWS SEAT TO NEW REVISION ACORN 80 Installation Manual...
  • Page 69 APPENDIX 10 Rationalisation Procedures 10.9 Technical Drawings 10.9.1 530 Powered Swivel L/H Seat Spacer Complete ACORN 80 Installation Manual...
  • Page 70 APPENDIX 10 Rationalisation Procedures 10.9.2 550 Powered Swivel L/H Seat Spacer Complete ACORN 80 Installation Manual...
  • Page 71 APPENDIX 10 Rationalisation Procedures 10.9.3 580 Powered Swivel L/H Seat Spacer Complete ACORN 80 Installation Manual...
  • Page 72 APPENDIX 10 Rationalisation Procedures 10.9.4 530 Powered Swivel R/H Seat Spacer Complete ACORN 80 Installation Manual...
  • Page 73 APPENDIX 10 Rationalisation Procedures 10.9.5 550 Powered Swivel R/H Seat Spacer Complete ACORN 80 Installation Manual...
  • Page 74 APPENDIX 10 Rationalisation Procedures 10.9.6 580 Powered Swivel R/H Seat Spacer Complete ACORN 80 Installation Manual...
  • Page 75 APPENDIX 10 Rationalisation Procedures 10.9.1 Carriage Front Cover Assembly ACORN 80 Installation Manual...
  • Page 76 1121285 R/H), quadrant 105CT 09 and swivel switch harness 1020794 and secure with 2 x 1040250 and 2 x 104CT24 torqued to 22Nm using Loctite 270. 104CT24 TORQUE 22Nm AND APPLY LOCTITE 270 NOTE USE CABLE CLAMP TO SECURE THE WIRE ROUTING ACORN 80 Installation Manual...
  • Page 77 Rotate the seat base and the following should be seen on the display whilst the call is activated. If this does not happen then loosen and adjust the plastic cover until the position of the switch is correct. IF IN DOUBT, PLEASE ASK FOR ASSISTANCE ACORN 80 Installation Manual...
  • Page 78 1 off Seat Spacer RH 1121285 2 off M8 x 20 Soc CSK 104CT24 4 off M8 x 30 Soc CSK 901045 2 off M8 x 10 Soc Butt Hd 1040250 1 off Self Adhesive Cable Clamp 900030 ACORN 80 Installation Manual...
  • Page 79 Trim cover as shown - note this is for retro-fit kit only and not for normal production. TRIM AS SHOWN Assemble complete as shown - note swivel harness should already be present on-site. TORQUE BOLTS 104CT24 TO 22Nm AND SECURE USING LOCTITE 270 1040250 ASSEMBLE CABLE CLAMP 900030 901045 ACORN 80 Installation Manual...
  • Page 80 Thank you for choosing Acorn. You can rest assured that your stairlift will provide many years of reliable service and allow you to enjoy the full use of your home. Your stairlift is covered by a manufacturer’s warranty for 12 months that covers the cost of replacement parts.

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