Acorn 80 Manuel
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 +44 (0)871 200 2448
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
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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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