Determine height of handrail above finished floor to comply with building code requirements. For 40mm diameter handrail, measure down 118mm from the top of handrail height, to mark the height of the bottom of stainless-steel handrail bracket wall plates.

Flick a chalk line or use a laser level to mark the height of the wall brackets on the wall. Critical to determine the accurate point where the power wiring comes through the wall noggin/batten and wall lining and that it is centrally located behind the handrail bracket (HB09FS) wall mounting plate, prior to plastering.

Install access wire handrail bracket (HB09FS). Drill and screw fix the wall plate through the wall lining into framing noggins or battens with 3 screws.

Handrails will be supplied in random lengths. Match lengths of handrail to sections of the wall to minimise wastage.

Measure timber rail lengths making the correct allowances for each section of wall.

Cut lengths of timber handrail using an 80 -100 tooth saw blade (specifications – 300mm diameter x 3.2mm thick x 96 teeth), or equivalent. Use equipment that will ensure all cuts are square and neat. If the rail is precoated you will need to apply masking tape to the handrail, prior to cutting, to minimise splintering or chip out.

Use the drilling jig (SSDJK40) supplied, clamp the rail on the plank and drill holes in the ends of the handrail. Sand cut the edges of the timber handrail slightly to apply a small bevel to remove any small splinters from cutting. Squirt lubricant on the joining fastener (JF01) prior to screwing the fasteners into the handrail ends.

Insert the Joining Fastener (JF01) into the hole at the end of the handrail with a hex key drive, turning in a clockwise direction, until the tapered piece is left protruding from the end of the handrail. Please try the first joint by securing a stainless-steel bend or end cap onto the joining fastener to confirm the joint is neat and tidy, prior to doing all the drilling for joining fasteners.

TIP – Please spray lubricant (Inox or similar) on joining fastener end, prior to inserting into the end of dowel rail. See how to use Intrim Connecta rail drilling jig to install end caps or bends.

Cut and install LED aluminium U Channel only, into handrail groove, (not diffuser), to match the timber rail lengths. Use an aluminium cutting saw blade, 80 -100 tooth saw blade (specifications – 300mm diameter x 3.2mm thick x 96 teeth – teeth to have a negative rake), or equivalent. Cut them 5mm shorter than the timber handrail ends that join onto a stainless steel Connecta rail component. Must also cut it 3mm shorter on each side of the HB09FS handrail bracket (power access handrail bracket) only. All standard HB02FS handrail brackets fit within the aluminium U channel.

Position the timber rail on saw stools and plank, with LED groove facing up and run a bead of high tack adhesive (Intrim Intense hold adhesive) in the centre of the groove along the length.

Place the aluminium U channel into the groove and apply downward pressure onto adhesive to help adhesion of U channel to timber handrail groove.

Measure and mark each length of the handrail, allowing for plastic spacers (SPL12) and handrail Brackets (HB02FS), to be evenly spaced at a maximum of 900mm centres for a 40mm diameter handrail. Wall mounting brackets (HB02FS) – distance from external corner of the wall, finished surface of wall lining, to centreline of first handrail bracket, to be 200mm. Distance from the internal corner of the wall, finished surface of the lining, to centreline of first handrail bracket, to be 345mm. Distance from wall opening or nib end, to centreline of first handrail bracket, to be 200mm.

Place the timber handrail on a plank with the groove in the underside of the handrail facing up, and clamp it to prevent rotation while installing components.

Locate the 165mm long red and black interconnection wiring harness (ICH165) in the side grooves of the grey plastic spacer (SPL12). Drill a 7/64” diameter hole through the centre hole of the plastic spacer through the aluminium U channel and fix it in place using a 6G x 5/8” long countersunk head timber screw.

Position handrail brackets (HB02FS), on top of the plastic spacer (SPL12)and drill 7/64” diameter holes and screw into the handrail groove, using 2 – 6G x 1” long countersunk head timber screws.

Ensure all brackets finish in the same rotation so they are ready for fixing to the wall.

Critical to keep the LED strip in the same rotation so continuity is consistent throughout the whole installation, with (+ positive) and (– negative) always in the same rotation. Calculate the overall length of the Flexy LED strip required, between the interconnection wiring harnesses (ICH165). Cut a strip to length at join marks (50mm increments) and attach it to interconnection wiring harnesses. Make sure you remove enough adhesive-backed tape on the strip at each end, prior to connecting to the wiring harness.

Lay the strip in the aluminium U channel and position the wiring harnesses so the LED strip sits neatly and flat. Peel all the adhesive tape away from the back of the LED strip and press it into place. Install LED strip between standard handrail bracket (HB02FS) and access wire handrail bracket (HB09FS). Cut an LED strip and connect it to the wiring harness at the (HB02FS) handrail bracket end.

Calculate the overall length of the strip between the handrail brackets and cut longer, to the next 50mm join mark. Do not remove the rest of the adhesive tape on this section of the LED strip. Install LED strip between standard handrail bracket (HB02FS) and a stainless steel connect rail 90-degree bend (SS4090B). Place masking tape over the loose ends of the LED strip, to stop it from falling out of the handrail groove when installing the handrail to the wall.

Confirm circuit continuity in LED connections, prior to installing the diffuser. Measure, mark and cut the diffuser to length, with heavy-duty scissors, to fit between handrail brackets and connection points. Press and clip the diffuser into place over all sections that the LED strip has been completed. Do not clip the diffuser into the place where the LED strip has not been completed. (wiring access and stainless steel Connecta rail bend sections). Peel protective film coating from all fitted diffusers.

Install access wire plastic spacer (SPL17). Separate and feed red and black power wires coming out of the access wire handrail bracket (HB09FS), through the spacer, making sure wires are in the same rotation as the LED light strip, to form continuity. Locate on top of the stainless-steel flat saddle of the handrail bracket.

Position the handrail in the correct place on top of the access wire handrail bracket (HB09FS), and drill and screw all handrail brackets (HB02FS), in line with chalk/laser line on the wall, through wall lining, into wall battens or noggins. Push cover plates onto handrail bracket wall plates.

Connection at access wire handrail bracket (HB09FS) – cut the strip to the correct length. Using the strip-to-wire connector (STWP8), and pliers, connect the power wires to the LED strip.

Remove the rest of the adhesive tape on this section of the LED strip and press it into place.

Fix handrail to handrail bracket (HB09FS) – drill 7/64” diameter holes and screw into the handrail groove, using 2 – 6G x 1” long countersunk head timber screws. Cut and fit diffuser.

Install stainless bends and end caps. Bends come with wiring interconnection wiring harnesses. Locate the hole in a 90^o stainless-steel bend over the end of the joining fastener in the timber handrail, making sure the wiring is housed into the machined slot at the end of the bend, so it does not interfere with the handrail joint. Rotate bend or end cap until parallel and properly orientated. Insert the Allen key provided into the hole in the underside of the stainless-steel accessory and tighten the grub screw. Over-tightening may cause damage to thread in stainless steel accessory.

Connection at stainless-steel 90^o bend (SS4090B) – Cut LED strip to correct length and connect to wiring harness at (SS4090B) stainless-steel 90^o bend, end. Remove the rest of adhesive tape on this section of LED strip and press into place. Cut and fit diffuser. Install all the handrails, using the steps as previously outlined.

Cut and fit diffuser. Install all the handrails, using the steps as previously outlined.

Complete all wiring connections at joins. Confirm continuity in each run of LED strip lighting.

Install diffuser at all the joins.

Glue the end of the handrail and fix the end cap or bend into the joint fastener at the end of the handrail. See how to Glue Stainless Steel 90 degree ConnectaRail Bends with Epoxy Adhesive.

Fix stainless steel ends/wall returns in place and tighten them with the help of Allen key.

Your installation of Connectarail with LED strip lighting is complete.