Minivator 1000 series User manual

000137.52049 issue 2 12 2004
Minivator 1000 series
Installation Manual

Contents
First check that all the required components are available: 4
Special installation tools 4
To assemble the track 5
Fit the charge strip assemblies 6
To fit the end caps 8
To assemble the track to the feet 9
To assemble the track to the staircase 10
To change the power unit hand - Electrics 11
Fit the power unit to the track 12
Fitting the seat chassis to the power unit 13
Assembling the seat 14
To fit the seat to the chassis 16
Fit upholstery to the seat 17
To remove and replace armrest upholstery 17
Program the stairlift and handset 18
To change the hand required for control 19
Connect the track loom to the transformer, and test at final installation 20
Fit the hand control holder 21
Fit the powered folding rail 22
Changing the seat position 24
Appendix 1 Electrical diagram - Right hand 30
Appendix 2 Electrical diagram - Left Hand 31
Appendix 3 Electrical diagram - options. To build a standard left hand unit 32
Appendix 4 To change the power unit hand - Electrics 32
Appendix 5 Electrical diagram - options. To build a standard right hand unit 33
Fault analysis 34
Fault analysis - Other possible problems and tests 34
Minivator 1000 series Installation Manual
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Minivator 1000 series Installation Manual
4
First check that all the required
components are available:
1 Lengths of track. Please note before
assembly ensure the track is the correct
length.
If it requires cutting you must use the
appropriate grade of saw.
2 Feet.Youwillrequire1footper1.5moftrack
plus 1.
2A Feet assembly plates and nuts/washers 1
assembly per foot.
3 Track Joining plates. You will require 2 per
joint.
4 Power unit.
5 Seat chassis and seat.
6 Upholstery:- Backrest.
Seat cushion (2).
Armrest Cushion (2).
7 Fitting Kit.
Special Installation Tools
1 Feeder track (Power pack to track).
2 Driving seat toggle loom.
3 300mm screwdriver extension.
Note:
The installation engineer must check with Minivator for the latest Installation
Manual issue No.

Minivator 1000 series Installation Manual
5
Fig. 1
To assemble the track
1 Bolt in the track joining plates to one
section of track extrusion (Fig. 1).
Note: There are 2 holes in the top rebated
sectionof the extrusionto accept thetrack
joining bolts.
Ontheunderside there are alsotwoholes,
as shown in Fig. 1.
Torque setting 8-9Nm.
2 Offer up the adjacent track section, and
bolt both together (Fig. 2).
Ensuretheboltsaresecure(Torquesetting
8-9Nm).
3 Continue the process until the required
length is reached.
Fig. 3
4 The top and bottom final limit stops are
factory fitted to the rear face of the track
extrusion.Slackenandrotatetheupperfinal
limit stop, so that it does not contact the
power pack as it is loaded on to the track.
Note: Ensure the positioning lugs are not
damaged when the stop is rotated.
Note: Ensure the positioning lugs are
correctlylocatedinthegroovewhenthestop
is secured.
Re assemble as shown in (Fig. 3).
Tightensecurely.(Torquesetting8-9Nm).
Final limit stop
Retaining lugs
Rotate top stop
to avoid
contact with the
power pack as
it is loaded
Retaining
groove for
hexagon
headed
screw 7 inches (180mm)
Fig. 2

Minivator 1000 series Installation Manual
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Fig. 4A
Fig. 4
5 The stairlift end stop brackets are factory
fitted.
The upper end stop must be removed to
load the power pack.
To re fit the end stop slide the retaining
hexagon headed screws into the track
extrusion, as shown in Fig. 4.
Screw up the nuts loosely, to allow the
bracketsto slide to theirrequired positions.
Tighten securely. (Torque setting 8-9Nm).
Retaining
groove
Stairlift
end stop
bracket
Final
limit stop
35mm
6 Hinge track only. Fit the hinge track latch
switch on to the track extrusion, as shown
in figure 4A.
Note: This must be fitted prior to fitting
the override stops and end stops.
7 Tuck the harnessinto the grooveas shown
in figure 4B, and hold the harness in place
with the plastic studs as shown in figure
4B, and connect to the hinge track loom.
Fig. 4B

Minivator 1000 series Installation Manual
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Charge strip assemblies
1 The charge strips are factory fitted. They
are pre assembled and snap into the
retaining groove in the track extrusion as
shown in Fig. 5 and 5A.
2 Whenthetracksectionsareassembled the
gap between the top and bottom charge
strip assemblies must be filled with the
supplied filler strip.
Measure the gap between the charge
strips, cut the filler strip to length and snap
fititinto the groove. (Itisanidenticalsection
to the charge strips).
2 Feed the two core grey cable through the
track as shown in figure 5B
3 Using the two way connecting blocks wire
upthecharging point cables tothetwo way
feed cable (Fig. 5C).
Oneof the wireson the greytwo way cable
ishas a black line mouldedin forcontinuity
identification purposes.
5 Choose the most appropriate position for
the power supply.
Note: If this is at the top of the staircase
the bottom nut plate and end cap can
be fitted to the track.
Where the power supply is located at
the bottom, fit only the nut plate, to
enable the charging circuitry to be
connected to the tpower supply at the
final stage of fitting.
Fig. 5A
‘Snap’ fit the
charge strips
into this groove
Fig. 5B
Fig. 5C
Fig. 5
‘Snap’ fit the
charge strips
into this
groove

Minivator 1000 series Installation Manual
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To fit the end caps
1 Carefully tuck the connector and harness
into the track extrusion (Fig. 6)..
2 Slide in the nut plate pressing (Fig. 6 - this
is retained by barbed sprung sections
which lock against the inside of the track
extrusion).
Note:
Take care not to damage the charging
wiring as the pressing is being fitted
Figure5Dand5Eareschematicsof the charging
wiring within the track
Fit the
bottom nut
plate
pressings
Grooves in
extrusion
Fig. 7
Fig. 6
Tuck the
harness
and
connector
into the
extrusion
Charge polarity
Fig. 5D
Schematic of
track wiring
Right Hand Rail
Charge polarity
Twin cable
Charge
contacts with
flying leads
Two way
connecting
blocks
Fig. 5E Schematic
of track wiring - Left
Hand Rail

Minivator 1000 series Installation Manual
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3 Fit the end cap (Fig. 8), taking care that
the end cap moulding retaining screw is
not over tightened, and that it avoids the
wiring.
Hint: Pre-assemble the end cap, nut plate
pressing and retaining screw,
This assembly can then be feed into the
extrusion and secured as shown.
2 Only finger tighten the nuts at this stage,
to allow the foot to be adjusted in position
on the stair tread.
Note: The foot must be fitted with the
straight edge (three hole side) against the
wall.
To assemble the track to the feet
Ensurethetrack is thecorrect length before you
commence assembly.
1 Slide the foot assemblies into the track.
The foot retaining plate locates into the
extrusion, as shown in Fig. 9. Fig 10 & 11
showtheindividualcomponentsof the foot
assembly
Note:The pressings can be assembled
from the top or bottom of the track.
Fig. 9
Foot retaining
plate
Slot in track
accepts retaining
plates
Fig. 10
Retaining plates slide in track
Mounting foot- top only shown
Do not over tighten the
screw
End cap
Fig. 8

Minivator 1000 series Installation Manual
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To assemble the track to the staircase
3 Stand the feet on to the stairs, with one
foot on the top tread, and one foot on the
first tread, with the spacing even in
between.
If possible fit one foot over the splice, or
as close as possible to it.
4 Offer the track assembly to the stairs, and
fix the feet to the stair treads, see Fig. 14
for fitting dimension.
With the screws supplied locate the feet
using three rear screws per foot.
5 Vertically align the track along its whole
length, using a spanner on the singlefront
adjuster on each foot (Fig. 13).
Do not tighten the screws until the track
angleiscorrectforverticalalignmentalong
its whole length.
Fig. 13
Screw the adjuster up or
down to achieve the
correct level - using a
10mm A/F wrench,
(under the foot) or a
6mm Allen key (before
fittting the fixing screw)
Finally ‘snap’ fit the
plastic covers over the
adjusting screws
When all the feet are
correctly adjusted
tighten all the fixing
screws.
Three fixing screws on each foot
Fig. 12
Note the bottom foot component is shown in
isolation for clarity
Fig. 11
Mounting foot-
base
Mounting foot-
top bracket
Mounting foot-assembly bolt.
Use the hole closest to the
nose of the stair tread.
6 Tighten all feet to the track, and the feet
pivot bolts.
7 ‘Snap’ fit the protective plastic covers over
the adjuster assemblies.
Failure to align the track and feet
correctly prior to tightening the
screws will twist the feet and lead
to permanent damage.

Minivator 1000 series Installation Manual
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Figure 15 showing an end view of the track with
the top finishing extrusion in place and a foot
assembled to the track.
To change the power unit hand-Electrics
Note: Should the power unit require
changing hand, this must be done prior
to fitting to the track.
Then follow the sequence given in the
Appendix 3 and/or 4 to change the
electrics.
1 Laythepower unit withits front face down.
2 Take off the top and rear covers from the
power unit to reveal the main PCB and
wiring connectors (Fig. 16).
3 Follow the sequence stated in the
schematic electrical diagrams, Appendix 1
Note: All wires have numbered collars
for identification purposes.
Fullytightenthefoottostairtreadscrews.(Fig.14).
Recheck the vertical alignment of the track, fit
locking nut and tighten the front screw.
Note:
This can be done when the power unit has been
loaded on to the track.
Note: A long shaft Pozidrive screwdriver will be
required for this operation.
Fig. 14 shows typical view ‘on site’.
The rear finishing extrusion groove should be
approximately 100mm from the wall.
(Dependant on the wall condition, and so that
any obstacle will clear the back of the seat).
(NOT THE STAIRCASE STRINGER).
Note this should ensure a seat clearance from
the wall of 25mm.
Fig. 15
Foot
mounting
bracket
Top finishing
extrusion
Fig. 14
Use a long shaft screwdriver
to tighten the 3 screws
100mm
Stair Rail
To any obstacle that may
interfere with the back of
the seat
Fig. 16 Some wiring omitted for clarity
Numbered
collars
Dip
switches
for setting
direction
and speed
Main
motor
connections
Programming
button (Red)

Minivator 1000 series Installation Manual
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Fit the power unit to the track
1 Take off the top cover from the power unit
2 Lay the power unit with its rear face down.
3 Slidethepower unitfittingrailintothepower
unit, and lock the power unit into place,
using the plastic locking studs (Fig. 17).
5 Carefully locate the power unit/fitting rail
on to the track (Fig. 18).
Note: Ensure the charging loom is not
damaged.
When the fitting rail is securely attached,
tuck the charging loom into the cut out in
the fitting rail and check that it does not
protrude.
This ensures the power unit override will
not be activated when the unit is being
driven on to the track.
Remove the power unit lock and carefully
allow it to role on to the track, until it starts
to engage with the rack.
6 Connect the dummy seat toggle looms:-
6 way to 6 way (Can only be fitted one way).
8 way to 8 way (Can only be fitted one way).
2.5mm²batterylinkacrosstheflyingbattery
leads.
0.5mm²underpanlinkacrossthe underpan
loom (Violet to Red).
8 Way connections as follows:
Plug Green to Orange.
Plug the 0.5mm² toggle link into the
common (Blue) connection on the 8 way
connector, and to drive the lift connect to
(Brown - Up), or (White - Down).
Note:Thesewillchangewhenhandofstairlift
changes (White - Up), or (Brown - Down)
Drive the power on to the track (Fig. 19).
Warning: Do not hand wind the power
unit on to the track, as this could trip the
Over Speed Governor (OSG).
7 When the power unit is fully and correctly
engaged with the rack remove the fitting
rail from the track, and the dummy seat
toggle looms
Fig. 17
Cut out
on fitting
rail
Cut out
on fitting
rail
Fig. 18
Power unit
locking
stud
Power
unit
fitting rail
Power unit locking stud
Charging
loom, and cut
out on fitting
rail
Fig. 19
6 way
connector
Battery
leads (Red)
and link
loom
Underpan
(Violet &
Red) and
link loom
8 way
connector
Brown
Up
White
Down
Toggle
link

Minivator 1000 series Installation Manual
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Fitting the Seat Chassis to the power unit
1 Remove the front cover from the seat
chassis, to gain access to the mounting
slots.
Note: There are two pairs of straight slots
to give height adjustment to the footplate/
seat dimension
Note: they also allow the footplate/seat to
be adjusted towards or away from the
stairtread nose (Fig. 20).
Note: The power unit has arced slots on
theseat chassisinterface, to set the angle
ofthe seat andfootplate (see Fig.17 - 19).
2 Offer the seat chassis to the power unit
(Fig. 20), and using the nuts, bolts and
washers supplied secure the seat chassis
tothepowerunit,ensuringthat the chassis
is in the correct vertical alignment.
Fit the flanged bolt in the radial slot and
assembletheeccentric washer byrotating
to locate it within the large slot and secure
with the M8 flange nut.
Note: Do not fully tighten the assembly at
this stage, as you will need to adjust the
footrest for vertical alignment.
Note: Do not pinch any harnesses whilst
assembling the chassis.
Tightentheretainingboltstotorque setting
33Nm. (Fig. 21).
Fig. 21
2 pairs
of slots
Assembly
nuts and
bolts
Top pressing
cut away for
clarity
Fig. 20
Eccentric
washer
M8 Flange
nut & bolt
The eccentric washer must be
fitted to ensure the correct
location of the seat assembly

Minivator 1000 series Installation Manual
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Fig. 22
Fig. 23
Micro switch
Seat stem assy.
Retaining
spigot
Nylon spacing
washer
Retaining bolt, collar and washer
Fig. 24
Assembling the seat
1 Lay the seat rear face down on a suitable
non scratch surface.
2 Removethe seat stemretaining bolt ,collar
and washer (Fig. 22).
3 Fit the nylon spacer washer with its
bevelled inner diameter against the weld
(Fig 22).
4 Slide the seat stem assembly over the
retainingspigotontheseat (Fig. 23), taking
care not to damage the micro switch.
5 Ensure the seat stem assembly can rotate
intoitslockablepositionsandthatthemicro
switch is undamaged.
Replace the retaining collar, washer and
bolt and tighten (Fig. 24).
Note:
Itmay be advisable to remove the micro
switch to avoid damage and to replace
it after the seat stem assembly is fully
fitted.

Minivator 1000 series Installation Manual
15
6 Push out the required seat stem hole in
the base moulding. (These are held with
threemouldedstems for ease ofremoving).
Slidethe moulding overthe seat stem(Fig.
25) and fit using the plastic slotted head
female screws provided (Fig. 26).
7 Slide the ‘V’ shaped loom down the seat
stem, with the single 8 way connector at
the bottom (Fig. 27).
Fig. 25
Fig. 26
Plastic slotted head
female screws
Push out the required
seat stem hole
Fig. 27

Minivator 1000 series Installation Manual
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To fit the seat to the chassis
1 Place the seat chassis top moulding on
thechassis,andfeedtheharnessandseat
stem (and seat assembly) through the
holes in the moulding and chassis (Fig.
28).
4 Whenall the checksare satisfactory fit the
seat chassis front cover, plug in the wiring
harness to the cover mounted switch and
neon (Fig. 30).
2 Feed the two seat retaining bolts through
the required holes in the seat stem and
footrest chassis. Fit the strengthening
plate, and the two retaining nuts and
tighten to 25Nm. torque (Fig. 29).
NOTE: TAKE CARE WHEN FEEDING
THE RETAINING BOLTS NOT TO
DAMAGE THE SEAT WIRING
HARNESS.
3 When fitted check for correct action of the
latching mechanism on the seat swivel
assembly. Check for any chafing on the
wiring harness. Connect the seat chassis
harness to the power unit.
Fig. 28
Fig. 29
Fig. 30

Minivator 1000 series Installation Manual
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Fit upholstery to the seat
Theseatbackrestandcushionsare held in place
with Velcro pads (Fig. 32).
Toremoveand replace armrestupholstery
Remove both armrest pads by rotating the
armrests vertically and unscrewing the Philips
head screws to release the armrests (Fig. 33).
5 Connect the 2 top plugs into their
respective sockets on the seat PCB and
infra red unit (Fig. 31).
Fig. 32
Fig. 33
Fig. 31
To Infra-Red
unit
Philips head
screws (2)

Minivator 1000 series Installation Manual
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Program the stairlift and handset
1 Rotatethe seat through 90
O
to gainaccess
to the main control board as shown in Fig.
34.
2 Press the red button on the main control
board (adjacent to the green connectors)
and keep it held down (Fig. 34).
Note: Wiring has been omitted for clarity.
3A If the lift is at the top of the stairs press the
DOWNbuttonontheremotecontrol(Fig.35).
3B If the lift is at the bottom of the stairs press
theUPbuttonontheremotecontrol(Fig.35) .
4 Release the red button.
Theliftandremotecontrolarenowprogrammed
for normal operation.
Should the lift require any additional
programming, first determine if the program is
standard, by pressing ‘park’ on the hand set.
Theliftshouldhead upwards in ‘standard’ mode.
Then move the dip switches on the main
controller board to the required settings (Fig.
36).
Finally fit the power unit top cover.
Should there be more than one lift operating in
the same vicinity the handsets will require
programming.
1 Removethe4screws from the rearcovers
and remove the covers to gain access to
the dip switches, which can be set in 4
different positions as shown in Fig. 37.
2 Set the switches as required and replace
the rear covers.
Note:Ensureeachsetofhandsetshave
the same dip switch settings.
Fig. 34
Fig. 35
Move lift up
Move lift
down
RED
button
Main
control
board
Fig. 37
Dip
Location of Main
controller board PCB
Fig. 36

Minivator 1000 series Installation Manual
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To change the hand required for control
The chair is factory supplied for the user to use
their right hand for controlling the chair.
To change the control position:
1 Carefully unplug all armrest wire sockets
from the printed controller board (PCB)
located in the rear centre seat backrest
(Fig. 38), taking care to note the sockets
correct positions on the PCB.
2 Unclip the wires from their mountings on
the seat.
3 Remove the both armrest pivot covers, by
turningapproximately45% and lifting clear
(Fig. 39).
4 Unfasten the retaining screws on the
controller arm and carefully withdraw the
arm and control wires through the arm
mounting (Fig. 38, 39).
5 Unfasten the opposite arm and thread the
safety shut off wires through the arm
mounting.
6 Fit the control arm on to its required
mounting, carefully threading the control
wiresthrough thearm mountingmoulding.
Tightenthe mounting screwssecurely and
refit the cover moulding.
7 Fittheopposite armfollowingthesequence
outlined in 7 (Fig. 40 shows completed
sequence).
8 Refit the sockets on to their respective
plugs on the control PCB (refer to Fig. 38),
and ensure the infra red detector is
correctlypositionedinitstransparentdome
in the rear of the backrest.
Note: If the detector is not correctly
positioned the hand control will not
operate the stairlift.
Fig. 39
Arm retaining screws
Arm retaining screws
Armrest pivot cover
Fig. 38
PCB
Fig. 40
Connect all
wires to seat
PCB
Power unit
and seat
chassis looms
Infra Red
detector

Minivator 1000 series Installation Manual
20
Connect the track loom to the Power
Supply and test at final installation
Note: The Minivator 1000 series stairlift
is battery operated from the 33V output
power supply, and can therefore be
safely connected to the household
mains supply via the normal ring main.
1 Locatethe power supplyin an appropriate
position, and connect to the mains at a
fused spur or with a fused plug on to the
normal household ring main.
Note: All mains wiring must comply
with the standards in force at the time
of installation.
2 Connect the charging point wiring to the
transformer (Fig. 41, 41A, 41B).
3 Slide in the nut plate (this is retained by
springed sections which lock against the
iside of the track extrusion), as shown in
Fig. 42
(See also page 5 and 6).
4 Fit the final limit stop (Fig. 42).
5 Earth bond the track at base of the ‘L’
shapedendstopthrough the M5 clearance
hole specifically for cable connection.
6 Fit the top end stop to the stringer side of
the track (Fig. 42).
7 The magnetic limit stops can be adjusted
atthis stage, to position thestairlift’sstatic
position relative to the end of the track.
Note:Theyareheld inplaceonaVelcro
backing strip. The whole strip must be
moved to give final adjustment.
Fig. 42
Fig. 41
Fig. 41B Schematic of track wiring - Left Hand track
Twin cable
Power supply
End stop Final
limit
stop
Magnetic
limit stops
Nut plate
Two way
connecting
block
Fig. 41A Schematic
of track wiring - Right
Hand track
Power supply
33V Output
Charge polarity
Charge
contacts with
flying leads