Untitled-1

000137.52049 issue 0200

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

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. You will require 1 foot per 1.5m of track

plus 1.

2A Feet assembly plates and nuts/washers 1

assembly per foot.

3Track 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

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

section of the extrusion to accept the track

joining bolts.

On the underside there are also two holes,

as shown in Fig. 1.

Torque setting 8-9Nm.

2Offer up the adjacent track section, and

bolt both together (Fig. 2).

Ensure the bolts are secure (Torque setting

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. Slacken and rotate the upper final

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

correctly located in the groove when the stop

is secured.

Re assemble as shown in (Fig. 3).

Tighten securely. (Torque setting 8 - 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

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

brackets to slide to their required 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.

7Tuck the harness into the groove as 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

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 When the track sections are assembled 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

fit it into the groove. (It is an identical section

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

up the charging point cables to the two way

feed cable (Fig. 5C).

One of the wires on the grey two way cable

is has a black line moulded in for continuity

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

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

Figure 5D and 5E are schematics of 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

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

Ensure the track is the correct 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

show the individual components of 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

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.

4Offer 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 single front

adjuster on each foot (Fig. 13).

Do not tighten the screws until the track

angle is correct for vertical alignment along

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.

6Tighten 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

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 Lay the power unit with its front face down.

2Take off the top and rear covers from the

power unit to reveal the main PCB and

wiring connectors (Fig. 16).

Follow the sequence stated in the

schematic electrical diagrams, Appendix 1

Note: All wires have numbered collars

for identification purposes.

Fully tighten the foot to stairtread screws. (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

Fit the power unit to the track

1Take off the top cover from the power unit

2 Lay the power unit with its rear face down.

3 Slide the power unit fitting rail into the power

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).

2.5mm² battery link across the flying battery

leads.

0.5mm² underpan link across the 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: These will change when hand of stairlift

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

White

Down

Toggle

link

Minivator 1000 series Installation Manual

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

the seat chassis interface, to set the angle

of the seat and footplate (see Fig. 17 - 19).

2Offer the seat chassis to the power unit

(Fig. 20), and using the nuts, bolts and

washers supplied secure the seat chassis

to the power unit, ensuring that the chassis

is in the correct vertical alignment.

Fit the flanged bolt in the radial slot and

assemble the eccentric washer by rotating

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.

Tighten the retaining bolts to torque 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

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 Remove the seat stem retaining 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

retaining spigot on the seat (Fig. 23), taking

care not to damage the micro switch.

5 Ensure the seat stem assembly can rotate

into its lockable positions and that the micro

switch is undamaged.

Replace the retaining collar, washer and

bolt and tighten (Fig. 24).

Note:

It may 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

6 Push out the required seat stem hole in

the base moulding. (These are held with

three moulded stems for ease of removing).

Slide the moulding over the 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

To fit the seat to the chassis

1 Place the seat chassis top moulding on

the chassis, and feed the harness and seat

stem (and seat assembly) through the

holes in the moulding and chassis (Fig.

28).

4 When all the checks are 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

Fit upholstery to the seat

The seat backrest and cushions are held in place

with Velcro pads (Fig. 32).

To remove and replace armrest upholstery

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 In fra-Red

unit

Philips head

screws (2)

Minivator 1000 series Installation Manual

Program the stairlift and handset

Rotate the seat through 90

to gain access

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

DOWN button on the remote control (Fig. 35).

3B If the lift is at the bottom of the stairs press

the UP button on the remote control (Fig. 35)

4 Release the red button.

The lift and remote control are now programmed

for normal operation.

Should the lift require any additional

programming, first determine if the program is

standard, by pressing park on the hand set.

The lift should head 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 Remove the 4 screws from the rear covers

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: Ensure each set of handsets have

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

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

turning approximately 45% 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

wires through the arm mounting moulding.

Tighten the mounting screws securely and

refit the cover moulding.

7 Fit the opposite arm following the sequence

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

correctly positioned in its transparent dome

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

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

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 Locate the power supply in 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

shaped end stop through 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

at this stage, to position the stairlifts static

position relative to the end of the track.

Note: They are held in place on a Velcro

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

Minivator 1000 series Installation Manual

Fit the hand control holder

Fit the hand control holder to the wall in the

required position using the fixings supplied (Fig.

45).

When the stairlift assembly is complete and

tested satisfactorily demonstrate all the

features on the hand control.

Note; the hand controller can be fixed into the

holder by locking it with the supplied plastic

moulding.

7Tuck the 2 way connecting block and wiring

into the track.

Fit the track end cap, ensuring that no

wires are trapped (Fig. 44).

8Test the final installation.

6 Fit the track top plastic finishing extrusion,

sliding under the power unit, and snapping

it into place, (Fig. 43).

Fig. 45

Fig. 44

Fig. 43

Track top plastic finishing

extrusion

Move lift up

Move lift

down

Park and lift

folding rail

Hinge track

down

Hinge track up

Minivator 1000 series Installation Manual

4aFit the screws

b Adjust the rail angle to ensure the stairlift

is vertical using the adjuster screw as

shown in Fig. 47. (Bottom plate only shown

- for clarity).

Fit the powered folding rail

1 Splice the hinge rail section to the main track

as per the track assembly instructions, and

fit the required number of feet, and then

proceed as follows:-

2Offer up the folding rail to the adjacent track

section, and bolt loosely together at this

stage (Fig. 46).

3 Fasten the foot/rail assembly to the stair

tread:-

Due to the overhang of the operating

gear train and the possible position of

the foot you may only be able to locate

1 or 2 fixing screws in the foot. If this is

the case use the following procedure.

Fig. 47

Fig. 46

Locate as many screws as are accessible

Gear train

cover

Folding

rail

Rail joining

bolts on top

and bottom

of the rail

Angle adjuster

with flats, and

hexagon for

adjusting

Minivator 1000 series Installation Manual

c Withdraw the foot top bracket/bottom

bracket bolt (Fig. 48).

d Unscrew the rail joining bolts and

withdraw the folding rail assembly (Fig. 46).

e Locate the remaining screws (Fig. 49).

f Reassemble the folding rail to the fixed

rail, (see Fig. 43).

Torque setting 8-9Nm.

Fig. 48

Fig. 49

Fig. 50

Locate the

remaining

screw(s)

Screw the adjuster up or

down to achieve the

correct level - using a

10mm A/F spanner,

(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.

Fig. 50A

g Relocate and secure the top bracket/

bottom bracket bolt (Fig. 50).

h Finally snap fit the protective plastic

covers over the adjuster assemblies.

6 Fit the track top finishing extrusion on all

rails.

Minivator 1000 series Installation Manual

Changing the seat position

The seat can be mounted at the left or right

side of the seat chassis.

Refer to Figures 51, 52, 53

Note:

The seat stem should be fitted to the upper

side of the unit.

On the left for right hand stairs.

On the right for left hand stairs.

1 Unclip the front cover, and remove the

female terminals from the switch and

neon on the front cover, and unclip the 8

way seat harness connector (Fig. 51).

2 Remove the seat cushions and backrest

upholstery to gain access to the wiring,

and unclip the plugs on the seat PCB and

on the infra red unit.

3 Remove the two tube retaining bolts (Fig. 52),

nuts, and flat plate, and carefully withdraw

the seat assembly from the chassis (Fig.

53).

Fig. 53

Front cover

cut away for

clarity

Seat harness

connector

Fig. 51

Fig. 52

Minivator 1000 series Installation Manual

4 Lay the seat on its back, with foam rubber

to stop any movement, and to avoid

damage.

5 Remove the screws locating the bottom

cover moulding and remove the moulding

(Fig. 54).

6 Remove the micro switch.

7 Remove the seat stem retaining nut,

washer and collar seat stem retaining nut,

washer and collar (Fig. 55), and withdraw

the seat stem and spacing washer (Fig.

56).

Fig. 55

Fig. 56

Remove the 2

screws retaining

the bottom cover

Fig. 54

Seat stem

retaining

nut, washer

and collar

Seat

stem

Spacing

washer

Micro switch

Minivator 1000 series Installation Manual

6Unbolt the reaction block (Fig. 58).

Unbolt the spring reaction bracket (Fig. 58).

8 Slide the latching bar out.

8 Remove the circlips from the latching

levers (Fig. 57), and remove the levers.

9 Remove the 4 countersunk Allen screws

retaining the seat mounting plate (Fig. 59),

and remove the plate.

10 Remove the micro switch loom from its

present inlet hole (Fig. 59).

Spring

reaction

bracket.

Reaction

block

Latching bar

C/sunk

Allen

screws

Fig. 58

Fig. 59

Remove circlips

and withdraw

the latching

levers

Fig.57

Micro switch

Loom

Minivator 1000 series Installation Manual

10 Replace the plate in the required position,

and tighten the Allen screws to 20Nm.

(Fig. 60).

11 Replace the micro switch in the position

indicated in Figure 61, and feed the loom

through the moulded hole as shown in (Fig.

60 and 61) and reconnect the spade

terminals.

12 Feed the latching bar, and reaction bracket

into the seat,

Note: The positions of the reaction bracket

and spring must be a mirror image of the

original assembly, so that the latching yoke

lines up with the latching plate (Fig. 62).

13 Fit the spring reaction bracket and tighten

to 20Nm. (Fig. 62).

Fig. 60

Fig. 61

Fig. 62

Micro switch

Minivator 1000 series Installation Manual

14 Fit the latching levers into their bearings

and over the latching bar and replace the

circlips (Fig 63).

Ensure the latching mechanism operates

freely.

16 Snap out the plastic covering the new

position required for the seat stem

(Fig. 65), and replace the cover (Fig. 66).

15 Fit the nylon spacing washer with the inner

bevelled portion against the weld on the

plate and the seat stem in the position

shown, with the large notch rotated 90

anti-clockwise (Fig. 64).

Note: Take care not to damage the micro

switch when assembling the seat stem.

Fit the seat stem retaining nut, washer and

collar (Fig. 61), and ensure the mechanism

operates smoothly prior to fitting the cover.

Fig. 63

Snap out the new seat

stem cover moulding

Fig. 65

Fig. 64

Nylon

spacing

washer

Seat stem

Minivator 1000 series Installation Manual

18 Replace the seat in the required position

(Fig. 66), refer to page 11 and 12 (Fitting

the seat), for details of the sequence.

19 Replace the seat upholstery as detailed on

page 12.

17 Fit the cover moulding using the two plastic

nuts (Fig. 66).

Fig. 66

Fig. 67

Minivator 1000 series Installation Manual

Appendix 1 electrical diagram - right hand

Fig. 68 Appendix 1

Minivator 1000 series Installation Manual

Appendix 2 electrical diagram - Left Hand

Fig. 69 Appendix 2

Minivator 1000 series Installation Manual

Appendix 3 electrical diagram - options. To build a standard left hand unit

Numbered

collars

Dip

switches

for setting

direction

and speed

Main

motor

connections

RED lead

Black lead

Programming

button (Red)

Fig. 70 Appendix 3

Fig. 71 Appendix 3

Appendix 4 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

schematically in Fig. 71 Appendix 3 and/

or Fig. 73 Appendix 4 to change the

electrics.

1 Lay the power unit with its front face down.

2Take off the top and rear covers from the

power unit to reveal the main PCB and

wiring connectors (Fig. 16).

Follow the sequence stated in the schematic

electrical diagrams, Appendix 1

Note: All wires have numbered collars

for identification purposes.

A pair of pointed nose pliers will be

required to change the main motor leads

over; care must be taken to avoid

damaging the cover insulators when

performing the operation.

Minivator 1000 series Installation Manual

Numbered

collars

Dip

switches

for setting

direction

and speed

Main

motor

connections

RED lead

BLACK lead

Programming

button (Red)

Appendix 5 electrical diagram - options. To build a standard right hand unit

Fig. 72 Appendix 4

Fig. 73 Appendix 5

Minivator 1000 series Installation Manual

Fault Analysis

Lift dead

No green LED indication

Lift dead

No LED indication

Lift running at half

speed

Battery charger

information

Check key switch is ON before removing covers. Has lift overrun onto final limits?

LED will extinguish when final limit is actuated.

With voltmeter, check battery volts across B+ & B- on control board. If more than 23V, pull

out both green connector blocks. After approximately 5 seconds there will be a bleep and

the red LED will glow. This means there is a short circuit on the wiring.

If no bleep or LED replace board.

Very low battery volts, final stage before lift stops.

Check dip-switch settings.

Lift will run at half speed when immediately after power-up, the handset is used to move

the lift UP or DOWN.

Connect voltmeter across B+ & B- on the control board.

Momentarily press up or down button on remote control, lift will bleep and the volts will dip

down, then increase back to original voltage. If this happens the charger is OK

Also look for the Green LED on front panel to be permanently illuminated. If its flashing,

lift not receiving charge. Check charge contacts on track with voltmeter.(Should read

approximately 40V DC). Check polarity of charge contacts on rail. Lower contact should

be +, upper contact should be - on a left-hand track. Vice versa on right-hand track i.e.

lower -, upper +.

Check continuity from lift charge contact butterfly to connection into controller for BOTH

positive & negative looms.

Are the butterfly contacts on the lift making contact with charge contacts on track?

Green LED

(On lift front panel)

Red LED

Red LED flashing

Yellow LED

Flashing yellow LED

Buzzer

INDICATES

Power ON

Permanently illuminated

Flashing with buzzer

LED extinguished when

direction selected

Holding switch (Key) OR

Final limit OR

OSG

Battery charger not connected

plus one or more of above

Battery condition

Brake not connected

Relay fault

Short bleep on starting

Continuous bleeping for 20

seconds with flashing green

LED (front panel)

Extended bleep on start

FAULT

Battery charger connected

Battery charger not

connected

Brake not connected

Off

Lift has over-run its limit

OSG tripped

Battery volts less than 21V

when first connected

Battery volts fallen below

16.5V when running

Check brake circuit

Tap large black relay, if LED

still flashing replace control

board

Normal

Battery charger not

connected

Battery has reached 30% of

usable power

POSSIBLE REMEDIES

Check battery charger

circuits

Check brake circuits

Turn key ON

Wind lift off the cam on track

Reset OSG

Allow batteries to charge

Possibly due to heavy

usage if charger OK

Fault Analysis-other possible problems and tests

Minivator 1000 series Installation Manual

Minivator Ltd. 82, First Avenue, Pensnett Estate, Kingswinford,

West Midlands. DY6 7FJ. England.

Tel. 44(0)1384 408700. Fax. 44(0)1384 408719 E mail. [email protected]