Acorn 80 Manual

Acorn 80
Maintenance & Service Manual

2ACORN 80 Maintenance & Service Manual
1 Introduction 4
1.1 Conventions 5
1.2 Safety 5
1.3 Manufacturer 5
1.4 Copyright 5
1.5 Lift Identification & CE Marking 5
1.6 Designed Usage 6
1.7 Standard Acorn 80 Specification 6
1.7.1 Rail Options 6
1.7.2 Lift Options 7
1.7.3 Seat Options 7
2 Description Of Operation 8
2.1 General Arrangement 8
2.2 Carriage Operation 9
2.2.1 Vertical Bends 10
2.2.2 Horizontal Bends 10
2.3 Safety Features 11
3 Operating Instructions 12
3.1 Carriage Hand Winding 12
4 Installation & De-Installation 12
5 Servicing 13
5.1 Training 13
5.2 Safety Procedures 13
5.3 Service Checklist 13
6 Testing & Setting 14
6.1 Diagnostic Display 14
6.1.1 Normal Operation 14
6.1.2 Programming Modes 15
6.1.3 Fault Conditions 15
6.1.4 Information Labels 15
6.2 Levelling Potentionmeter 16
6.3 Programming 16
6.3.1 Programming Summary 16
6.3.2 Pre-power Up Checks 17
6.3.3 Power Up Sequence 17
6.3.4 Calibrating The Levelling 17
6.3.5 Programming The Top Terminal limit 17
6.3.6 Programming The Rail 18
6.3.7 Programming The Bottom Terminal limit 18
6.3.8 Setting Up 19
6.3.9 Setting Lift Speeds 20
6.3.10 Bottom Parking 21
6.3.11 Hinge Zone 21
6.3.12 Intermediate/Park Charge Point 22
6.3.13 Intermediate/Landing Charge Point 22
6.3.14 Checking The Program 22
6.3.15 Amending The Program 23
6.3.16 Programming The Hinge Zone 23
6.3.17 Programming Do’s & Don’ts 23
6.4 Over-speed Governor (OSG) 24
6.4.1 Testing The OSG 24
6.4.2 Re-setting The OSG 24
6.5 Testing Batteries 27
7 Dismantling Components 28
7.1 Covers 28
7.1.1 Front Cover 28
7.1.2 Carriage Covers 28
7.2 Seat 29
7.2.1 Removal 29
7.2.2 Refitting A Seat 29
7.3 Footrest 30
7.3.1 Removal 30

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ACORN 80 Maintenance & Service Manual
7.3 Footrest 30
7.3.2 Replacement 30
7.3.3 Footrest PSE Board Replacement 30
7.4 Batteries 31
7.4.1 Removal & Fitting 31
7.5 Printed Circuit Board (PCB) 32
7.5.1 Removal & Fitting 32
7.5.2 Supercharger Systems 33
7.5.3 PCB Connections 35
7.6 Carriage 36
7.6.1 Transfer Rails 36
7.6.2 Carriage Removal 36
7.6.3 Carriage Dismantling 37
7.6.4 Removing Power & Levelling Bogies 38
7.6.5 Refitting Power & Levelling Bogies 38
7.6.6 Carriage PSE Switches 38
7.6.7 Refitting Carriage To Rail 39
7.7 Power Bogie 41
7.7.1 Main Components 41
7.7.2 Dismantling Rollers & Pinion 42
7.7.3 Reassembling Rollers & Pinion 42
7.7.4 Drive Motor Removal / Replacement 43
7.8 OSG Instructions 44
7.8.1 OSG Exploded Diagram 44
7.8.2 Checking The OSG 44
7.8.3 OSG Re-setting Procedure 45
7.8.4 OSG Removal & Refitting Procedure 47
7.8.5 Main Components 52
7.8.6 Levelling Drive Unit 54
7.8.7 Levelling Guide Rails 55
7.8.8 Rollers 55
8 Spares 56
Appendices 57
Appendix 1 - Service Checklist 57
Appendix 2 - Recommended Tool List 58
Appendix 3 - Recommended Torque Settings 59
Appendix 4 - Recommended Lubricants 60
Appendix 5 - Diagnostic Display 61
Appendix 6 - Remote Control Radio Channels 62
Appendix 7 - Levelling and Main Drive Encoder Testing 63
Appendix 8 - Charge System 66
Appendix 9 - Wiring Diagrams 67
Appendix 10 - Rationalisation Procedures 68
10.1 Changing Hand Of Seat 68
10.2 Replacing Seat Spacer On-site 70
10.3 Assembly Of Powered Swivel On-site 73
10.4 Connecting Supercharger Link 78
10.5 Replacing Seat Adapter Plate On-site 80
10.6 Replacing Carriage Front Cover / Arm Harness 84
10.7 Replacing On / Off Switch With Blanking Plate 88
10.8 Replacing Back Cover On / Off Switch With Blanking Plate 92
10.9 Technical Drawings 95
10.9.1 530 Powered Swivel Seat Spacer Complete 95
10.9.2 550 Powered Swivel Seat Spacer Complete 96
10.9.3 580 Powered Swivel Seat Spacer Complete 97
10.9.4 530 Powered Swivel R/H Seat Spacer Complete 98
10.9.5 550 Powered Swivel R/H Seat Spacer Complete 99
10.9.6 580 Powered Swivel R/H Seat Spacer Complete 100
10.9.7 Carriage Front Cover Assembly 101
10.10 Seat Adaptor Plate Assembly Instructions 102
10.11 Seat Adaptor Plate Retro-fit Kit 104
Appendix 11 - Notes 106

4ACORN 80 Maintenance & Service Manual
SECTION 1
Introduction
INTRODUCTION
This manual contains instructions for servicing and
maintenance of the Acorn 80 Stairlift.
It should be used in conjunction with these documents:
Acorn 80 Survey Manual
Acorn 80 Installation Manual
Acorn 80 User Manual
Product Price Guide
Parts Price Guide

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ACORN 80 Maintenance & Service Manual
1.3 Manufacturer
Acorn Mobility Services Limited
Telecom House, Millennium Business Park, Station Road, Steeton, West Yorkshire, BD20 6RB.
www.acornstairlifts.co.uk
Contact Technical Support on [phone]
SECTION 1
Introduction
Throughout the manual comments may be inserted as follows:
Note - Supplementary information.
1.1 Conventions
INFORMATION TO PREVENT A DANGER
TO YOURSELF OR OTHER PEOPLE AND/OR DAMAGE TO EQUIPMENT.
1.2 Safety
Only Acorn trained engineers should carry out work on the Stairlift. All national rules and regulations concerning
safety, electrical work or environmental protection should supplement, and may supersede, this document.
Only Acorn parts should be fitted to the Stairlift.
1.4 Copyright
Acorn Mobility Services Ltd has the copyright of this document. Nothing from this publication must be duplicated,
stored in any automated database or published in any form or manner either electronically, mechanically, by
photocopying, exposures, or any other method, without prior written consent of Acorn Mobility Services Ltd.
1.5 Lift Identification & CE Marking
An identification plate is attached to the Lift. The Lift has been given a
CE mark, declaring its conformity with the fundamental health and safety
requirements of the European Community, subject to it being correctly
installed and tested as detailed in Acorn 80 Installation manual.

6 ACORN 80 Maintenance & Service Manual
SECTION 1
Introduction
1.7 Standard Acorn 80 Specification
LIFTS ARE DESIGNATED LEFT HAND OR RIGHT HAND AS VIEWED UP THE STAIRS.
OTHER ITEMS AND FUNCTIONS ARE DESIGNATED LEFT HAND OR RIGHT HAND AS VIEWED
WHEN SITTING IN THE LIFT.
1.6 Designed Usage
The lift is designed to safely transport the client up and down stairs. It should not be used by more than one
person or to transport other items. It has a maximum safe load of 120 kilograms (265 pounds or 19 stone). It is
the responsibility of the person installing the lift to:
Fully test it in accordance with the Acorn 80 Installation Manual and any local statutory requirements.
Maximum load 120 Kilograms 265 pounds - 19 stone
Maximum Speed 120mm per second 4.8 inches per second
Weight of Carriage (without seat) 39 Kilograms 86 pounds
Weight of Carriage (with transfer rail) 43.4 Kilograms 96 pounds
Operating Voltage 24 Volt DC (from Nickel Cadmium batteries)
Maximum Operational Noise level Less than 70 decibels
1.7.1 Rail Options
Vertical Inside & Outside Bends
Horizontal Inside & Outside Bends
Helical Inside & Outside Bends
Hinged Bottom Section
Intermediate Charge Point

7
ACORN 80 Maintenance & Service Manual
SECTION 1
Introduction
1.7.2 Lift Options
1.7.3 Seat Options
Left Hand or Right Hand fitting
Key switch
Remote Controls
No start up Delay
Powered Footrest
Non-padded Seat or Arms
Powered Seat Swivel
Space Saver Seat
Quick Release Clasp Seatbelt
Reel Seatbelt
Double Reel Seatbelt
Alternative seat heights (using seat spacers)
Fixed seat
Barrier arm
Seat adapter plate

8 ACORN 80 Maintenance & Service Manual
SECTION 2
Description Of Operation
The Acorn 80 Stairlift comprises a seat (1) and
footrest (6), mounted on a motor driven carriage (9).
All Stairlifts are provided with a Seatbelt (11)
The Stairlift is operated with a Holding Switch
(3) and a Direction Controller (12). Pressure Sensitive
Edges (5 & 6) stop the Stairlift if they strike
an obstruction.
Seat Swivel Release Paddles (10) allow the
User to swivel the seat around when alighting
and dismounting.
The arms (2), seat and footrest can be folded up when
the lift is not in use to give access past the Stairlift.
The carriage runs on a support rail (8) fitted to one
side of the staircase. Charging Plates (7) automatically
re-charge the internal batteries when the Stairlift
is parked.
Rechargeable batteries, located inside the carriage,
power the 24 volt direct-current (DC) motors. Internal
motors include the main drive motor, levelling
mechanism motor and optional powered items.
A hinged rail section may be fitted to allow access past
the lift at the bottom of the stairs.
A Diagnostic Display (4) provides information during
normal operation and programming, together with a
comprehensive list of codes should a fault occur.
DESCRIPTION OF OPERATION
2.1 General Arrangement
1
3
4
2
6
5
7
8
9
11
10
12
5

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ACORN 80 Maintenance & Service Manual
SECTION 2
Description Of Operation
2.2 Carriage Operation
The carriage comprises a power bogie (PB) and a levelling bogie (LB) mounted on a common frame (F). The
carriage is held square on the rail by side rollers (S) on both power and levelling bogies.
The downward weight of the power bogie is taken on the support wheel (SW) running on the bottom of rail (R).
The support wheel may bear against underside of the rail when negotiating vertical bends.
The downward weight of the levelling bogie is taken on the top roller (TR) running on the rail (R).
The drive motor (DM) rotates a pinion (P) on a rack to drive the carriage along the rail.
The levelling motor (LM) adjusts the frame to maintain the seat upright when moving over vertical bends.
An over-speed governor (OSG) will activate and stop the carriage in the case of an uncontrolled descent.

10 ACORN 80 Maintenance & Service Manual
SECTION 2
Description Of Operation
2.2.1 Vertical Bends
2.2.2 Horizontal Bends
Vertical bends connect horizontal and sloping rails (R). When the carriage moves over vertical bends the levelling
motor (L) adjusts the frame to maintain the seat in an upright position. All side rollers (S) on both bogies are
mechanically adjusted to remain horizontal with the rail. An anti-tilt mechanism (A) prevents the carriage from
tipping excessively in the event of a levelling failure.
When the carriage moves around helical bends, both levelling and pivoting operations occur at the same time.
Carriage speed is decreased when traversing vertical bends, inside horizontal bends and helical bends. The speed
sequence is programmed during installation. If battery power is lost the datum setting must be re-programmed.
The carriage has a “soft” start and stop feature.
Horizontal bends connect horizontal rails (R) at
90˚ to each other. When the carriage moves
around horizontal bends the power bogie (PB)
and levelling bogie (LB) pivot in the frame as
the carriage moves around the bend.

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ACORN 80 Maintenance & Service Manual
SECTION 2
Description Of Operation
2.3 Safety Features
The Stairlift will not start unless there is sufficient power in the batteries to complete the journey The Stairlift will
be stopped by:
Mechanical End Stops on the drive rack - if lift final limit switches fail.
Drive Motor Brake applied - if the battery power supply is lost.
Over-speed Governor (OSG) - if lift exceeds a pre-set speed.
Anti-tilt mechanism to prevent the carriage from tipping excessively in the event of a levelling failure.
Any one of the five pressure-sensitive edges (PSEs) striking an obstruction. There are two either side of the
carriage (A), two either side of the footrest (B) and one under the footrest (C).

12 ACORN 80 Maintenance & Service Manual
SECTION 3
Operating Instructions
SECTION 4
Installation & De-Installation
IF THE OSG HAS DEPLOYED (THIS SYMBOL WILL BE DISPLAYED ON THE
DIAGNOSTIC DISPLAY*) DO NOT USE THE HAND WINDER IN THE DOWNWARD
DIRECTION. THIS COULD CAUSE DAMAGE TO THE DRIVE MECHANISM.
* ONLY WHEN A CALL HAS BEEN MADE.
OPERATING INSTRUCTIONS
3.1 Carriage Hand Winding
Specific Operating Instructions for the Stairlift User are described in the User Manual. The additional instructions
in this manual are for Servicing and Maintenance Engineers.
The carriage can be hand wound manually along the rail if the drive motor cannot be used.
ENSURE THAT POWER IS SWITCHED OFF ON THE ARM REST HOLDING SWITCH.*
* DEPENDANT ON MODEL.
Remove the Drive motor cover cap, insert the Hand Winding Wheel (W) and
rotate to move the carriage along the rail (R).
Refer to the Installation Manual for detailed instructions.
ON NO ACCOUNT MUST POWER TOOLS BE USED TO WIND THE CARRIAGE
ON OR OFF THE RAIL.

13
ACORN 80 Maintenance & Service Manual
SECTION 5
Servicing
5.1 Training
SERVICING
This Stairlift must only be serviced and maintained 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 servicing and maintenance procedures, is also
available as a training aid for trained personnel.
Contact Technical Support on [phone]
5.2 Safety Procedures
5.3 Service Checklist
See Appendix 1
BEFORE WORKING ON THE LIFT ENSURE THAT POWER IS SWITCHED OFF ON THE SEAT ARM
HOLDING SWITCH (CERTAIN FAULT CONDITIONS MAY NOT MAKE THIS POSSIBLE
– PROCEDURES FOR THESE WILL BE CONTAINED IN THE RELEVANT SECTIONS).

14 ACORN 80 Maintenance & Service Manual
SECTION 6
Testing & Setting
TESTING & SETTING
6.1 Diagnostic Display
The LED (Light Emitting Diode) on the PCB (Printed Circuit Board) is visible through a window in the lift Front Cover.
6.1.1 Normal Operation & Programming Modes
NORMAL OPERATION
Displayed when the lift is operating correctly.
Lift is in Standby Condition and
ready to use
Lift is in Standby Condition but
holding switch is set to off
Lift is moving up the rail
Lift is moving down the rail
Lift is at its correct stopped
position
Batteries are fast charging
(small light on)
Batteries are trickle charging
(small light flashing)
1Switch off lift at on/off switch.
2 Put call in using rocker switch in required direction.
3Switch on lift with on/off switch whilst holding the call in on the rocker switch.
4The lift will now drive.
OVERRIDE INSTRUCTION
The following instruction should assist the installer/engineer if a fault is present.

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ACORN 80 Maintenance & Service Manual
SECTION 6
Testing & Setting
PROGRAMMING MODES
Displayed when the lift is being
programmed.
No datum is set
Datum search is on
Programming mode is on
Programming the terminal
limits (charge point positions)
6.1.3 Fault Conditions
For a full list of fault codes. See Appendix 5.
6.1.2 Programming Modes
6.1.4 Information Labels
These Information labels must be fitted on the Stairlift.
ON FRONT COVER
Warning. The safe working load is one person only at a maximum weight of 120kg (265 pounds – 19 stone).
ON HAND WINDING COVER
Emergency Handwind. Please remove cover for access.
INSIDE HAND WINDING COVER
Ensure lift power is off. Ensure no obstructions! Insert Hand Winding Wheel and rotate to move carriage.

16 ACORN 80 Maintenance & Service Manual
SECTION 6
Testing & Setting
The front cover must be removed to access the PCB. The Stairlift is supplied with
the electronic levelling correctly calibrated.
The potentiometer MUST NOT BE TURNED as this would affect the electronic
out of level shut down.
IF THE POTENTIOMETER NEEDS TO BE ADJUSTED REFER TO APPENDIX 7.
6.2 Levelling Potentiometer
6.3 Programming
6.3.1 Programming Summary
This procedure describes how to completely program the Stairlift. If the batteries are disconnected at any time
the program will be retained, except for the Datum Position and Top Terminal limit, which then must be
re-programmed in.
The lift orientation is set Left Hand or Right Hand for the program. Factory set.
A datum position is set at the top of the rail as the lift leaves the top charge point.
The top charge point position is set (Terminal Limit).
Carriage speeds are programmed in as the lift moves down the rail.
The bottom charge point position is set (Terminal Limit).
Programming is then completed for both up and down travel.
Three carriage speeds are possible:
CREEP SPEED (slow) is the default setting and is used just before stopping.
BEND SPEED when moving around vertical, inside horizontal bends and helical bends. It is also used as an
intermediate speed.
FULL SPEED along straight rail sections.

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ACORN 80 Maintenance & Service Manual
SECTION 6
Testing & Setting
6.3.2 Pre-power Up Checks
6.3.3 Power Up Sequence
6.3.4 Calibrating The Levelling
Remove the front cover and check that all programming switches are in the off position, to the left. Select LEFT
or RIGHT hand install. Check that the correct hand has been selected, as these switches should not be changed
at all from now.
Check that the seat holding switch is switched off. Connect the positive leads from both batteries to the
positive spade connectors on the board. The board will display the bottom right hand corner decimal point.
Switch on the seat holding switch. The selected hand of the lift will be displayed momentarily, then the
no datum set symbol will be displayed. The lift cannot be moved with this displayed.
ONLY TO BE DONE IF THE PCB HAS BEEN CHANGED. Now switch the PROGRAM MODE to ON.
Datum search will be displayed. Call the lift with either the rocker switch or the remote in either
direction. Using a spirit level on the footrest, finely adjust the potentiometer until the lift is level. Once
the level position is set, the potentiometer should not be altered after programming or the whole rail
MUST be programmed again.
6.3.5 Programming The Top Terminal Limit
Call the lift down off the charge point. As the positive charge plunger leaves
the charge point, the programming rail symbol will be displayed. This sets the
“datum point”.
This is a reference point for the memory during programming of the rail. Stop
the lift and drive it back up onto the final limit striker will be displayed. Note
that the top terminal limit will be approximately 10-15mm down from the final
limit stop position. Adjust the striker to the required position. This position
depends on the angle of the rail at this point. When the correct position is
found, call the lift down the rail off the charge point, and then back up onto the
final limit for a second time. The carriage is now ready for programming down
the full length of the rail.

18 ACORN 80 Maintenance & Service Manual
SECTION 6
Testing & Setting
6.3.6 Programming The Rail
Drive the carriage 50mm down the rail using the portcullis as a reference point. Then select BEND SPEED to
ON. Continue programming in bend speed until the portcullis is a further 180mm. If required full speed can be
selected. Full speed should be used on straight sections of rail and external horizontal bends. On all vertical,
internal and helical bends switch FULL SPEED to OFF when the portcullis is 100mm from the upside joint of
the bend. When the portcullis is 440mm past the downside joint of the bend switch FULL SPEED to ON. Repeat
through all of the bends to the bottom of the rail.
6.3.7 Programming The Bottom Terminal Limit
If approaching the bottom charge point in full speed, switch FULL SPEED
to OFF when the portcullis is 180mm above the bottom charge point
reference point.
Move the lift down the rail until the portcullis is 150mm past the bottom
charge point reference point then switch BEND SPEED to OFF. This
selects CREEP SPEED (default).
Drive the carriage onto the bottom final limit striker. This should be set so
that the final limit stop is approximately 10-15mm further down than the
required terminal limit stop position. While still in program mode drive the
lift up so that both charge plungers are on the charge point.
Switch PROGRAM MODE to OFF (into run mode). The standby symbol
will be displayed.

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ACORN 80 Maintenance & Service Manual
SECTION 6
Testing & Setting
No datum is set
Datum search is on
Programming mode is on
Programming the terminal limits
(charge point positions)
During programming the LED display will show:
The rail can be marked before
programming to indicate where speed
settings must be altered.
The portcullis flap (P) on the carriage
is used as a reference point for
marking the rail.
6.3.8 Setting Up
In program mode the lift is moved at slow speed using the direction controller on the arm rest. The illustration
shows the lift on a horizontal top section of rail but the principles are the same for sloping rail sections.
1Ensure that the lift is away from the top charge point.
2Move the lift until it makes full contact with the top charge point.
3Move the lift away from the charge point until the contact pins clear the charge point plates.
This sets the datum (D)
4Move the lift back past the top charge point until it stops itself on the top final limit switch. This sets the Top
Terminal Limit (T1)

20 ACORN 80 Maintenance & Service Manual
SECTION 6
Testing & Setting
ON SOME SHORT SECTIONS OF RAIL IT MAY NOT BE PRACTICAL TO APPLY FULL SPEED
BEFORE A BEND IS REACHED, IN THIS CASE LEAVE IN BEND SPEED AND MOVE LIFT IN
DOWNWARD DIRECTION.
1Start with the lift parked at the top of the stairs and start in CREEP SPEED (C).
2Move the lift 50mm in the down direction then switch BEND SPEED to ON (B).
3Move the lift in the down direction a further 180mm then switch FULL SPEED to ON (F) (if applicable).
4On vertical bends when the portcullis is 440mm past the second joint line switch FULL SPEED to ON.
5On 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).
6Repeat this procedure for all vertical, inside horizontal and helical bends on the installation.
6.3.9 Setting Lift Speeds