Handicare MINIVATOR 2000 User manual

INSTALLATION MANUAL
MINIVATOR 2000
XXXXXXXX

2 MINIVATOR 2000 INSTALLATION MANUAL
Pre-installation check list
1 Check that all of the required components
are available.
a Track Drawing e Power pack
b Track f Seat and upholstery
c Stanchions g Fitting kit
d Feet
Note: Before assembly you must ensure
that all of the required track is to the correct
specification, the stanchions supplied are the
correct length, the correct number have been
supplied and the corresponding number of
feet are available. In order to do this you need
to cross reference the items supplied to the
drawing supplied. Please refer to Appendix 4
for further details.
2 Installation tools required
Minivator 2000
installation manual
Smart Seat
Issue No of this manual is 0611-1
ORIGINAL LANGUAGE ENGLISH
• Loading toggle
• Loading bars
• Shorting links
• 8mm Spanner
• 13mm Spanner
• 17mm Spanner
• No. 3 Pozidrive
• Nylon electricians
pull through – at
least the length of
the track
• Track Lubricant:
Copaslip, or
Gleitmo 350
• 2.5mm Allen key
• 3mm Allen key
• 4mm Allen key
• 5mm Allen key
• 6mm Allen key
(ball ended)
• Superglue (inside
track only)
Note: The installation engineer must check
with Minivator for the latest installation manual
issue number.

MINIVATOR 2000 INSTALLATION MANUAL 3
Track assembly
1 Study the drawing provided. This will
be similar to the one shown below
(Figure 1). See Appendix 4 for a
larger version of this example.
Items required:
• Track drawing
• Fitting kit
• Track
• Feet
• Stanchions
• Red cable
Track assembly
Tools required:
• 6mm Allen key
• 17mm Spanner
• Nylon electricians
pull through
Figure 1

4 MINIVATOR 2000 INSTALLATION MANUAL
Track assembly
Figure 2
Figure 3
Internal curve tracks
An inside curve track is one that runs around the
shortest side of the staircase such that the track
bends away from you when you look at the stairs.
An example of an inside curve track can be seen in
Appendix 5.
The installation of an inside curve and outside curve
track is identical until very near to completion of the
installation. The additional steps that are required are
featured in the corresponding part of the installation
manual (page 15).
Hinge track installations
A hinge track is a folding section of track that can be
moved away from the bottom of the stairs so that it
does not cause an obstruction or hazard.
Note: See Appendix 3 for hinge track settings.
1 The hinge track section must be installed before
the rest of the track.
a Position the hinge track section in to the feet
with the back of each foot 60 mm from the
stringer or line of any obstruction, e.g. window
sill (Figure 2).
b Release the motor by pressing on the motor
release to allow the arm of the hinge to be
moved.
c Lower the arm and position the hinge on
the treads correctly so that the track reaches
the floor.
d The grey wire with a bullet connector must
be connected to all of the communication
contacts on the top track. In order to achieve
this connection you should:
i Pull some grey cable from the hinge to the
first comms contact in the TOP tube.
ii In the BOTTOM tube pull a red and a
grey cable from the first +ve charge contact
to the top of the stairs (Figure 3). The
connection of these will be covered in the
Track Electrical Connection section.
e Follow the normal track installation procedure
from step 2 to complete the installation.

MINIVATOR 2000 INSTALLATION MANUAL 5
Track assembly
Figure 4
Figure 5
f Once the track installation is complete cut any
excess threaded rod protruding from the top
of the foot to prevent it stopping the lift early.
Note: If the top communications contacts are
not connected to the hinge section the lift will
not work.
2 Place a foot on each of the risers as shown in
the drawing for your installation. For example
the drawing in Appendix 4 would require feet
to be positioned as follows:
a Ground floor x 2 c Riser 3 (Foot 14)
i 1 foot with a lower d Riser 5 (Foot 15)
collar height at the e Riser 7 (Foot 16)
start as shown (Foot 11) f Riser 9 (Foot 17)
ii 1 standard foot next g Riser 11 x 4
to Riser 1 (Foot 12) (Foot 18,19,20,21)
b Riser 1 (Foot 13) h Riser 12 (Foot 22)
3 Lay the corresponding stanchion next to the
corresponding foot (Figure 4) on the riser ready
for track fixing bolts. Grease the stanchion lugs
as you go. The drawing (Figure 5) has a table
that shows the length of the stanchion that has
to be inserted at each foot position. To ease
identification the stanchions are labelled with
their number and length. For example for the
track shown in Appendix 4:
a Stanchion 11 (length 322mm) should be
inserted in to Foot 11 with the reduced collar
length on the ground floor.
b Stanchion 14 (length 721mm) should be
inserted in to Foot 14 on Riser 3 etc.
4 Starting from the bottom of the stairs you
will assemble the bottom track. First identify
the section of bottom track that is required.
In Appendix 4 this would be track sections
2 and 3.
Note: Gradient and straight sections can
now be supplied as single pieces. This is
indicated on the drawings provided by an
F and L shown respectively, next to the track
section numbers.

Track assembly
6 MINIVATOR 2000 INSTALLATION MANUAL
Figure 6
Figure 7
Figure 8
5 In the drawing shown in Appendix 4 the first
section is actually a straight section with a
gradient decrease section manufactured as a
single piece of track. The straight section (2)
has 44 teeth (44 S) and it is 484mm long.
The gradient decrease section (3) has 13
teeth (13 GD R665) and it is bent on a 665mm
radius. The protective packaging that the track
is delivered in will be marked to indicate the
track section or sections that it contains and
whether or not it is a top track or bottom track
section (Figures 6 and 7).
Note: Do not remove the blue rack protection
cover at this stage.
6 Unpack the correct section of track and
align the corresponding hole with the second
stanchion i.e. DO NOT FIT A BOLT IN TO
THE FIRST STANCHION AT THIS TIME.
7 Using an M10 bolt from the fitting kit, fix the
first section of track to the second stanchion
(Figure 8). In Appendix 4 this would be foot 12.
8 Repeat step 6, referring to the drawing for
detail, until the first track joint is reached.
9 Push the cable pull through the track section
from the bottom to the top.
10 Find the next section of track that is required.
In the example shown in Appendix 4 this
would be section 4, a 119 tooth, 1308mm
long straight section.
Note: To reduce the installation time required
some of the track may be delivered pre-
assembled. This will be marked on the
packaging.
11 Fit the two sections together ensuring that the
cable pull through is not trapped.
12 Use an alignment tool to align the holes
(Figure 9).
13 Connect the two sections of track together
using the supplied M10 bolts and nuts. To
avoid over tightening track bolts it is advised
that these bolts only be hand tightened to a
torque not exceeding 15Nm (Figures 10/11).

Track assembly
MINIVATOR 2000 INSTALLATION MANUAL 7
Figure 9
Figure 10
Figure 11
Figure 12
Note: If the bolts joining track sections, or
attaching track to stanchions, are over-
tightened it can deform the track leading to poor
ride quality. A higher torque may be required to
get the bolt through the track but 15Nm must
be the maximum applied during the final stage.
Note: Apply a small amount of grease to the
jointing plug.
14 Continue as per steps 6-11 until you have
installed the complete bottom track.
DO NOT FIT THE LAST BOLT TO THE
TOP STANCHION at this time.

Track assembly
8 MINIVATOR 2000 INSTALLATION MANUAL
Figure 14
Figure 15
Figure 16Figure 13
15 Check that the stanchions are fitting fully in
to the feet by trying to lift each foot in turn
(Figure 12).
Note: Some surveys do not truly represent
the staircase. In this situation you may find
that a few of the stanchions do not sit fully
into the feet once the bottom track has been
assembled.
16 If you can lift any feet by more than 5mm
follow the procedure below:
a Unbolt the corresponding stanchion from
the track.
b Fit a packing ring in to the foot collar
(Figure 13). If you can lift the foot by:
i 5-10mm – fit a 5mm packing ring.
ii 10-15mm – fit a 10mm packing ring.
iii more than 15mm – order a replacement
stanchion with a length that is increased
by the distance that it is possible to lift
the foot from the floor.
c Repeat as necessary for each foot that can
be lifted from the riser.
17 Repeat the track installation process (steps
6-11) for the top rail.

Electrical connections
MINIVATOR 2000 INSTALLATION MANUAL 9
Track electrical connections
Items required: Tools required:
• Track drawing • 6mm Allen key
• Fitting kit • 3mm Allen key
• Track • 2.5mm Allen key
• Feet • 13mm Spanner
• Stanchions
1 Use the pull through that you fitted inside the
track to pull the red cable through the track
(Figure 14).
2 Decide if the power supply will be installed at
the top or bottom of the staircase.
3 Remove the end caps from the bottom track
at the top and bottom of the stairs (Figure 15).
4 Connect the positive charge contact to the
cable that you pulled through the track at
the top and bottom of the stairs using the
supplied terminal blocks.
Hinge track installations
Each stanchion next to a charge comms contact
should be drilled (Figure 16). For the first
occurrence of charge comms contacts you must:
a Connect the grey cable from the hinge
track to the grey cable that you have pulled
through the top track.
b Insulate this connection and push it through
the hole in the front of the track.
c Feed the grey cable from behind the
comms contact out of the track and into the
stanchion and out of the top of the stanchion.
d Connect the comms contact to the grey wire
in the top track using a connector block.
e Connect some more grey cable to this
connector block and feed it into the
stanchion and out of the top of the stanchion.
f Insulate the connector block behind the
comms contact and then push it into
the track.
g Connect the two grey cables that are
protruding from the top of the stanchion
with a connector block, insulate and then
push in to the top of the stanchion.
For every further intermediate comms contact:
a Pull the grey wire out of the bottom track
behind the charge contact.
b Splice a length of grey cable from this and
feed it in to the stanchion and out of the top
of the stanchion.
c Feed the grey wire from the comms contact
in to the stanchion and out of the top of the
stanchion.
d Connect the two grey cables that are
protruding from the top of the stanchion
with a connector block, insulate and then
push in to the top of the stanchion.
For the top comms contact:
a Pull the grey wire out of the bottom track
behind the charge contact.
b Feed the grey wire into the stanchion and
out of the top of the stanchion.
c Feed the grey wire from the comms contact
into the stanchion and out of the top of the
stanchion.
d Connect the two grey cables that are
protruding from the top of the stanchion
with a connector block, insulate and then
push in to the top of the stanchion.

Electrical connections
10 MINIVATOR 2000 INSTALLATION MANUAL
5 At the end of the track that you will be
connecting the power supply to continue
the installation as follows:
a Remove the paint from the stanchion and
rail (Figures 17 and 18).
b Connect the negative charge connection
loom to the track (Figures 19 and 20).
c Feed the cable from the charge contact
through the hole at the rear of the positive
charge contact into the stanchion
(Figure 19).
d Feed the end of the negative charge
connection loom through the same hole
and out of the stanchion.
e Drill hole and then run the power supply
lead into the back of the stanchion foot and
out of the top of the stanchion (Figure 21).
f Connect the power supply to the two way
connecting block (Figure 22). Red to white
and black to black.
g Insulate the two way connecting block
with electrical installation tape and carefully
insert the block into the track (Figure 23).
h Repeat step f above at the other end of the
track.
i Replace the end cap at the BOTTOM OF
THE STAIRS ONLY (Figure 24).
6 Fit the remaining bolts in to the top and
bottom track sections for the first and last
stanchion.
7 Fit the power supply to the wall using the
supplied bracket.
8 Terminate the power supply to the available
AC supply.
Note: All mains wiring must comply with the
local standards in force at the time of installation.
Do not fix the power supply to the stringer.
Figure 17
Figure 18
Figure 19

Electrical connections
MINIVATOR 2000 INSTALLATION MANUAL 11
Figure 20
Figure 21
Figure 22
Figure 23
Figure 24

12 MINIVATOR 2000 INSTALLATION MANUAL
Power pack
Loading the power pack
Items required: Tools required:
• Power pack • Loading toggle
• Shorting links
• Loading bars
1 Take off the front cover from the power unit
(Figure 25).
Power footplate only
Note: Do not force the footplate down
– you will damage the actuator.
a Protruding from the top of the power pack
is a black and a red set of leads (Figure 26).
Connect these to the 9V remote handset
battery to lower the footplate, giving access
to the panel. If the footplate does not lower
reverse the connections.
2 Fit the power pack loading bars to the top of
the track (Figure 27).
3 Feed the power pack on to the loading bars
(Figure 28).
4 Refit the batteries.
5 Connect the dummy seat toggle looms:
a Driving toggle 8 way connector (Part No.
181001.50083) and conversion loom
(SIM22900) – seat, direction, key switch
and swivel (can only be fitted one way)
(Figure 29).
b 2.5mm battery link (Part No. 181001.52036)
across the flying battery leads – red link wire
(Figure 30).
Note: Ensure that this connection is not
earthed as it will blow a fuse.
6 Taking care not to damage the charge contacts,
drive the power pack on to the track using the
driving toggle.
Note: Ensure that the top and bottom trunnions
are correctly engaged to the corresponding
teeth on the top and bottom track (Figure 31).
NOTE: IF THE POWER PACK IS
LOADED WITHOUT CORRESPONDING
ENGAGEMENT OF THE TOP AND
BOTTOM TRUNNIONS; AND THE POWER
PACK IS OPERATED IT WILL CAUSE
PERMANENT DAMAGE TO THE POWER
PACK. FIGURE 32 SHOWS HOW AN
INCORRECTLY LOADED POWER
PACK WILL APPEAR.
If this occurs a new power pack MUST
be ordered as a matter of safety.
Figure 25
Figure 26

MINIVATOR 2000 INSTALLATION MANUAL 13
Power pack
Figure 27
Figure 28
Figure 29
Figure 30
Figure 31
Figure 32

14 MINIVATOR 2000 INSTALLATION MANUAL
Power pack
7 When the power pack is fully and correctly
engaged with the rack, remove the loading
bars from the track (Figure 33).
8 Remove the dummy seat toggle looms.
9 Refit the end stop and end cap to the top
and bottom tracks (Figure 34).
Figure 34
Figure 33

-ve +ve
MINIVATOR 2000 INSTALLATION MANUAL 15
Inside curve rail
Inside curve rail
Items required: Tools required:
• Magnets • Superglue
The procedure for the installation of an inside
curve track is identical to that of an external
curve track with the following additions.
1 Once the track has been assembled and fixed
to the stairs it is necessary to fit magnets at
the beginning and end of each bend in the
track. This magnet will be detected by a reed
switch on the power pack trunnion. It will slow
the lift down as it approaches a bend and
then speed it up as it exits the bend.
a Position the magnets on the bottom track
(Figures 35 and 36).
b Drive the lift from the bottom of the track
up the stairs. The lift should slow down as
it enters the bend (passes the first magnet)
and speed up again when it exits the bend
(passes the second magnet). If the lift does
not behave as expected send it back to the
bottom of the stairs, reverse the polarity of
both magnets and retest.
c Once tested and aligned correctly
superglue the magnets into place.
Note: The polarity of the magnets can be
identified as shown in Figure 37. The polarity
must be opposite at the entrance and exit of
the bend.
Note: Ensure that the bolt is parallel to the
track (Figure 37).
NOTE: THE MAGNETS MUST BE PLACED
IN THE CORRECT POSITIONS TO ENSURE
THE SAFE TRAVEL OF THE STAIRLIFT.
Figure 35
Figure 36
Figure 37

16 MINIVATOR 2000 INSTALLATION MANUAL
Seat base
Fitting the seat base
Items required: Tools required:
• Seat base • 10mm socket
• 10mm spanner
• Narrow nosed pliers
• 6mm Allen key
1 Remove the seat post from the pack, feed
the seat loom through and attach the post
to the seat base using the five bolts provided
(Figure 38).
2 Place the seat chassis top moulding onto the
pack (Figure 39).
3 The seat to footplate height is determined by
the holes that are selected in the seat stem.
The minimum seat height is 480mm. The hole
spacing relates to a 25mm adjustment in seat
height.
4 Feed the two seat retaining bolts through
the required holes in the seat stem; selecting
the appropriate seat height for the client by
using the corresponding holes to the height
that is required, and tighten to 25Nm. torque
(Figure 40).
Figure 39
Figure 40Figure 38

MINIVATOR 2000 INSTALLATION MANUAL 17
Fitting the seat back
Fitting the seat back
Items required: Tools required:
• Seat back • 6mm ball ended Allen key
Redundant connections are present to allow
easy re-handing of seats. Connections must
be made according to the handing of the
stairlift; i.e. for a stairlift with left-hand toggle
switch and key switch (always together on
one side), those connections must be made
to left hand arm. The right arm will then
house a powered footplate switch (if fitted).
1 Place the seat back onto the seat base and
using a ball ended 6mm Allen key secure
it with the four bolts and washers provided
(Figure 41).
2 Make the upper seat wiring connections
as follows (Figure 42);
a Key switch connection:
green and orange to green and orange.
b Toggle switch: blue, white and brown
to blue, white and brown
Figure 41
Figure 42

18 MINIVATOR 2000 INSTALLATION MANUAL
Fitting the seat back
Arm Switched Powered Footplate Only
c Powered footplate:
Twin yellow to twin yellow
Note: The toggle switch connection must be
made through the interlock loom to enable the
arm interlock functionality (Figure 43).
3 Tidy the cables to the back of the seat
(Figure 44).
Emergency Swivel Lever
1 Feed the anti-tamper seal through the
emergency swivel lever (Figure 45).
2 Near the front flap of the seat there is a large
and a small hole. Pass the anti-tamper seal
through the small hole, then feed it back
through the larger hole and back on itself
through the hole in the end of the anti-tamper
seal. The lever should be attached on the
down side of the lift.
3 Pull the anti-tamper seal tight and trim off any
excess to leave the lever hanging securely.
Note: The user must be informed that the
lever is for emergency use only.
To use, the lever should be twisted to break the
anti-tamper seal. The lever can then be inserted
into the swivel lever socket. It must be held in
place to operate the swivel mechanism.
Figure 43
Figure 44
Figure 45

MINIVATOR 2000 INSTALLATION MANUAL 19
Electrical connections / upholstery
Electrical connections
Items required: Tools required:
• None • None
1 Make seat and footplate electrical connections
(Figure 46).
a Connect the power switch (2 x red).
b Connect the diagnostic display
(red, black and yellow).
c Connect the key switch loom
(orange and green).
d Connect the toggle loom
(white, blue and brown).
e Connect the seat loom earth ring terminal
(black).
f Connect the infra-red receivers on the left
and right sides of the pack (blue sleeved).
Powered footplate only
g Connect the powered footplate looms
(twin yellow and grey comms).
Power swivel only
h Connect the grey powered swivel loom.
2 Test the function of the powered features,
including the toggle (see pages 25/27).
3 Replace and re-fit the pack front cover.
Fitting the seat upholstery
Items required: Tools required:
• Seat upholstery • Screw driver
1 Clip in the seat back, starting with the top two
clips (Figure 47) and then screw in the seat
belt cover mouldings.
2 Fit the main seat cushion.
3 Fit the seat flap cushion.
4 Fit the arm upholstery. Starting at the front,
press the upholstery into the arm recess
(Figure 48).
Figure 46
Figure 47
Figure 48

20 MINIVATOR 2000 INSTALLATION MANUAL
Remote control handsets
Remote control handsets
Items required: Tools required:
• Handsets • No. 2 Pozi-drive
The 2000 series stairlift may be supplied with
infrared or radio frequency remote controls,
dependant on the requirements of the
installation. The infrared remote control has a
red dipswitch cover on the rear, whilst the radio
frequency remote control has a green dipswitch
cover on the rear (Figure 49). If you are still
unsure as to the type of remote control system
you have fitted refer to your drawing or remove
the pack underpan and look to see if a radio
receiver board has been fitted (Figure 50).
Programming
The infra-red remote control handsets supplied
with the lift should work out of the box. If the lift
does not travel up and down the stairs when the
corresponding handset buttons are pressed, or
if there are multiple lifts in one area, follow the
procedure set out below.
1 Remove the cover from the power pack
(Figure 51).
2 Bring both handsets to the lift and then
programme the handset to the board in the
following way.
a For single lift applications:
i Press and hold the red button on the
PCB (Figure 52) – a yellow LED will
illuminate on the PCB.
ii Press any button on the handset and the
yellow light will go out.
iii Programming is complete.
Note: Low energy light bulbs can interfere
with the infrared signal causing the lift to stop
and start. Reprogramming the handsets with
the lights on can resolve this problem.
Figure 49
Figure 50
Figure 51