ThyssenKrupp Flow2 User manual

Brand: ThyssenKrupp

Model: Flow2

Type: User manual

ThyssenKrupp Flow2 is a versatile and reliable stairlift designed to provide a safe and comfortable way to navigate staircases in your home. With its compact design and easy-to-use controls, the Flow2 offers a range of features to enhance your mobility and independence.

Flow2 stairlift

Tab 06: Systematic fault finding

Flow2 stairlift

Tab 06: Systematic fault finding

The information in this manual may not under any circumstances be given to someone else, reproduced or published

by any means without the prior written permission of Product Management.

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Table of Contents

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2 Systematic faultfinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

2.2 Collecting information and defining the problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.3 Fault analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

2.4 Carry out corrective action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.5 At the customer’s home, or in the workshops? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.6 Monitor the effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.7 Correct completion of a fault notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Flow subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3.1 The power supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 The drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.3 The horizontal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.4 The swivel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3.5 The controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.2 Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.3 Overview of possible error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5 Error code E51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

5.1 Bad rail connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.2 Stairlift stopped at emergency end stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

5.3 Overspeed governor has operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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1Introduction

There is actually only one good method to find the actual cause of a problem, and that is a

systematic manner. Rather than testing or replacing components at random, you adopt a systematic

approach to eliminating possible causes until you have found the real cause.

Systematic fault finding is the systematic reduction of the area of the fault on the basis of:

- the information provided by the user

- your knowledge of the system

- a methodology

- appropriate measurement techniques.

Systematic fault finding offers the following benefits:

- You use a fixed and well-known methodology to carry out the work.

- You work efficiently. You do not duplicate anything.

- You make structured notes of all your findings. This simplifies communications with your

colleagues and Technical Support in the event that you get stuck. “In which step did you get

stuck? How did you get to that step?”

Layout of the tab

This tab contains the following information:

- Chapter 2 explains the method used for systematic fault finding.

- Chapter 3 gives an overview of the various subsystems and a few guidelines for fault finding.

- Chapter 4 describes all the possible error codes with a few guidelines for fault finding.

- Chapter 5 gives guidelines for dealing with error code E51, the overspeed governor has been

activated.

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2 Systematic faultfinding

2.1 Method

Dealing with a fault notification in a systematic manner involves the following steps.

1. Collect information.

2. Define the actual problem.

3. Analyse the area of the fault (look for the actual cause of the problem).

4. Carry out the corrective action (repair or replace the relevant component).

5. Examine the effect.

The example of the lamp switching

The method is clarified using a simple example, a lamp fitted with a

halogen light bulb.

Fault notification:

“The lamp doesn’t work.”

2.2 Collecting information and defining the problem

Problem definition

Systematic faultfinding begins by gaining a good insight into the problem. You gain this insight by

collecting as much information as possible.

In some instances the customer is extremely dissatisfied with the product. You will then find it very

difficult to get the information you need from the customer. In such situations you will need to be very

patient, and you will need to investigate for yourself.

Questions to ask the customer

Examples of questions you can ask the customer include:

- What has happened recently?

- When did the problem occur?

- Have any changes been made to the product?

- Have you had a thunderstorm recently?

- Has anyone else used the product?

Get the customer to demonstrate

The best approach is to get the customer to demonstrate what he or she did at the time the problem

occurred. In this way you can see straightaway whether the problem is caused by an incorrect action

by the customer, which is the case in some 10% of all notifications.

Fig. 2-1 Lamp switching

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Systematic fault finding

Review the history

Consult the logbook to find out whether the stairlift was serviced recently, or whether any similar

notifications of faults have been made in the past.

The example of the lamp switching

The desk lamp’s bulb blows repeatedly. The bulb has already been replaced twice in the past month,

whilst normally these bulbs last for years. It’s time for a thorough inspection of the lamp.

2.3 Fault analysis

During the fault analysis you repeatedly work through the following steps, whereby you continually

go into further depth until you examine the smallest replaceable components!

Define the area of the fault

You can define the area of the fault on the basis of the problem definition and your knowledge of the

system. The problem area is the collection of all those parts of the system that could contribute to the

problem.

CAUTION

In the event of the repeated occurrence of a fault do not simply repeat the corrective

action. The cause of the problem could be at a lower level.

Define the area of the fault

Distinguish possible causes

Determine the sequence of your

work

Eliminate causes

Find the real cause

Fig. 2-2 Fault finding steps

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Systematic fault finding

Distinguish possible causes

You make a distinction in the area of the fault on the basis of the components that can be tested

individually to determine their performance. You adopt a systematic approach. For example, when

you can test an entire sub-system you do not begin by testing the individual components.

The example of the lamp switching

At first, you can make a distinction between two components of the lamp: the power supply, and the

actual lamp. When the correct voltage is applied to the light’s fitting then it can be concluded that the

power supply is in order. So it won’t be necessary to inspect the wiring, the switch, the transformer,

and the wall socket.

Determine the sequence of your work

You have made a note of a number of components that could possibly contribute to the problem. You

will try to eliminate these possible causes; however, you will first need to determine the sequence in

which you are going to carry out the work.

You determine the sequence on the basis of your knowledge of the system, your experience, and the

information you have already collected. Make a note of the possible cause, and determine the

sequence on the basis of:

- the probability that the component is faulty

- the ease with which you can test the appropriate performance of the component.

It is possible that although it is very unlikely that a specific component is faulty you nevertheless

decide to begin by testing the component. You will decide to do so only when the test can be carried

out quickly, and with ease.

The example of the lamp switching

Usually the problem is simply a blown bulb. However, with a halogen light bulb this is not always so

easy to determine. You don't have the right lamp with you for testing it; there are so many different

types and sizes. Nevertheless, in this instance it is easy to test the power supply. So you begin with

this test before you decide to go to the store to buy a new bulb.

Eliminate the causes

You will eliminate the possible causes in the sequence you have just determined.

Diagnostic equipment

You can use the following diagnostic equipment to test the appropriate performance of a component:

- the Flow2 error indication system

- hyperterminal / PDA (training required)

- a multimeter to measure the resistance, voltage and current (AC or DC)

- sliding callipers and a measuring tape

- a digital spirit level

- your ears (a rattle in the system)

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Systematic fault finding

- your nose (a smell of burning on a printed circuit board)

- your fingers (play in the system).

The example of the lamp switching

Suppose that you’ve removed the bulb from the fitting. You now measure the resistance of the wires

to the fitting by measuring directly across the terminals of the switch. You measure 2 Ohms.

Consequently, you conclude that there’s a short-circuit in the wiring. Wrong! The switch is switched

on, and consequently you also measure the resistance of the transformer winding. You can measure

the resistance of the wiring properly only by disconnecting the wires from the transformer.

The example of the lamp switching

A fault tree could be as follows:

CAUTION

Make sure you know what you’re measuring!

TIP

Make a note of all your findings, and draw a fault tree. Use these to keep a record of the

causes you have been able to eliminate. You can use numbers to indicate the sequence

in which you work.

Lamp does not light

2. Lamp broken 3. No voltage at fitting 1. Lamp not properly

screwed into fitting

4. Dirty fitting

4. Switch defective1. No voltage at the trans-

formator

2. Loose contact in the wir-

ing to the lamp

3. Short circuit in the wiring

to the lamp

3. Short circuit in the wiring

to the transformer

2. Loose contact in the wir-

ing to the transformer

1. No voltage at the wall

socket

4. Transformer defective

Fig. 2-3 Example fault tree

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Systematic fault finding

Find the real cause

Obviously it’s easy to replace the faulty component and ‘rectify’ the fault. However.......

Components can become faulty for a variety of reasons. For example:

- Lightning struck close by yesterday.

- The product is poorly maintained.

- The component is at the end of its serviceable life.

- The component is too heavily loaded by the user.

- The component wasn’t fitted or connected correctly.

- Etc.

2.4 Carry out corrective action

Do everything you can to resolve the cause of the problem. In many instances you will then also need

to give the customer sound advice about the use and maintenance of the product. Show the

customer how to use the product and how he/she must maintain and clean it.

2.5 At the customer’s home, or in the workshops?

Repairs to the drive unit can be difficult and take a great deal of time. You probably won’t really want

the customer to be watching you the whole time. In such a situation it will be better to take the drive

unit with you to the workshops so that you can carry out the repair in more peaceful surroundings.

Take account of ESD!

Usually you won’t feel that you are building up an electrostatic

charge; however, you certainly will notice the discharge. At some

time in the past we’ve all experienced an irritating shock on getting

out of a car or touching a metal railing.

These shocks are caused by electrostatic discharges (ESD = Electro

Static Discharge). They result in minor muscle contractions, and

they’re annoying – but they are not dangerous for us.

CAUTION

Make sure you look for the real cause of the problem!

TIP

Do so only when you can arrange for a replacement drive unit in good time.

Fig. 2-4 Take account of ESD

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Systematic fault finding

However, electrostatic discharges certainly can disrupt electronic

circuits, corrupt data signals, and damage electronic components

or equipment.

2.6 Monitor the effect

Always check that the corrective action has solved the problem. Have the customer carry out a test

trip to see for him/herself.

2.7 Correct completion of a fault notification

You have had to replace a defective or damaged part so that the stairlift now works properly again.

You tidy up the workplace and as an extra extra service, if time allows, you can also service the

stairlift. In this way the customer will probably be most satisfied.

And now it’s time to complete the financial and administrative side of the fault notification:

1. You determine whether the fault or the damage is covered by the warranty.

2. You attach a reject label to the faulty or damaged component

which states:

- the manufacturer's number of the lift and the part number

- the date of replacement

- the appropriate fault code as specified in the TKA list

- an appropriate description of the fault

- an appropriate description of the fault notification and the

findings (what caused the fault?).

3. If required, you return the faulty component to TKA.

4. You complete the logbook, so that a later service engineer can read your findings and see how

you dealt with the notification.

Fig. 2-5 Wear the wristband!

CAUTION

For you ESD might be a pin-prick, but for a chip it’s like being struck by lightning!

Consequently, you should always take ESD precautions and wear the wristband. Connect

the wristband’s lead to a section of bare metal on the drive unit. You and the drive unit

will then have the same potential, and there will be no sparks.

Fig. 2-6 Reject label

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Systematic fault finding

It is extremely important that you take care to enter all the details correctly on the reject label. This

information enables TKA to:

- continually improve the quality of the product;

- determine whether the fault or the damage is covered by the warranty.

NOTE

It will not always be possible to decide immediately whether a fault or damage is covered

by the warranty. In such situations TKA will require full information about:

- the nature of the defect or the damage;

- the situation in which it occurred;

- the manner in which it occurred.

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3Flow subsystems

optocoupler

overspeed

governor

optocoupler

creep switch

Main circuit board

Power module

charging

contact: J5

on/off: J1

min: J3

plus: J2

charging

contacts

Encoder

board

brake

Fuse

blue

red

black

Drive

Level

level

motor

motor module

drive

motor module

level

MCM swivel

seat

Sensor board

optocoupler

anti-squeeze

optocoupler

swivel seat-nul

Swivel

encoder

swivel seat

motor

Electrical cassette

Receiver

module

Service board

J4: power board

J5: motor 1

J13:

encoder

J8: brake

J6: motor 2

J7: motor 3

J15: creep

J11: RF module

J16: sensor

board

J16: service

On/Off

switch

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Flow subsystems

3.1 The power supply system

If the stairlift does not work, a malfunction may have occurred in the stairlift power supply.

The following voltages can/must be measured.

The green LED on the power board shows the status of the power supply. All other LEDs can of

course be used as an indication of the presence of the supply voltage.

Component Measurement point Voltage (V)

Main board Connector J4 12 Vdc

Power module 3V3, 5V and 12V, as indicated on the

printed circuit board

3V3, 5V and 12V

Between the “plus” and “min” Battery voltage

Transformer Input terminals (U

) 220 +/- 10% (VAC)

Transformer Output terminals (U

uit

) 33 +/- 10% (VDC)

Component LED Meaning

Power module Green LED - Lit when all output voltages are present.

Fuse 40 A

Transformer/

rectifier

Charging contact

Charging circuit

Power module

Glass fuses

Fig. 3-1 The power supply

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Flow subsystems

Guidelines for fault finding

Check whether the green LED on the power module is lit when the stairlift is switched on. This

indicates that all the supply voltages are present. If the green LED is not lit, carry out the following

checks:

- Check whether the supply voltage on the power board meets the conditions.

- Measure the battery voltage between the "plus" and "min" terminals?

- Is the main power circuit fuse still intact?

- Are the glass fuses still intact?

- Is the on/off switch on?

- Are the connectors on the batteries and the power module secure?

- If the battery voltage is too low, it is possible that the battery charging is not working properly.

The charging process can be checked simply by measuring the DC voltage across the battery

terminals. To measure this, the stairlift must first be driven away from the charging contact and

then back onto the charging contact. The voltage should then gradually increase to the

maximum voltage.

- The problem can also be caused by other printed circuit boards and wiring.

- Disconnect the flat cable from the power module to the mainboard and check whether the

green LED lights again. If the LED lights, the fault is in the associated printed circuit board.

If all of these items have been checked and the green lamp on the power module still does not light

when the stairlift is switched in, replace the power module.

NOTE

On the power module there is a coil that can become very hot while the batteries are

being charged. This is normal.

The measuring points for the various voltages are indicated on the power module.

If the main power circuit fuse has blown, check the wiring from the batteries and the

printed circuit boards before you replace the fuse.

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Flow subsystems

3.2 The drive system

The stairlift drive consists of an assembly of electronics, cables, motors and sensors. The following

figure shows a schematic of this.

Guidelines for fault finding

The drive system is controlled and monitored by the software. Errors are indicated in the form of an

error code on the service board display. See Chapter 4 for the meanings of the error codes and

suggestions for resolving the fault.

Rail data

table

Main

Micro-

processor

Safety

Micro-

processor

IC drive

Power

FETs

Drive

motor

Encoder

Brake

Motor module

Power module

Batteries

Main board

Overspeed

governor

Fig. 3-2 Drive system

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Flow subsystems

3.3 The horizontal system

The horizontal system consists of electronics, motors and sensors. The following is a schematic

diagram of the horizontal system.

Fig. 3-3 Horizontal system

Guidelines for fault finding

The drive system is controlled and monitored by the software. Errors are indicated in the form of an

error code on the service board display. See Chapter 4 for the meanings of the error codes and

suggestions for resolving the fault.

Inclina-

tion 1

Inclina-

tion

Gyro

Main board

Sensor board

Main

Micro-

processor

Safety

Micro-

processor

IC level

Power

FETs

Horizontal

motor

Motor module

Batteries

Power module

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Flow subsystems

3.4 The swivel system

The swivel system consists of electronics, motors and sensors. The following is a schematic diagram

of the swivel system.

Guidelines for fault finding

The swivel system is controlled and monitored by the software. Errors are indicated in the form of an

error code on the service board display. See Chapter 4 for the meanings of the error codes and

suggestions for resolving the fault.

Batteries

Rail data

table

Main

Micro-

processor

Safety

Micro-

processor

Main board

MCM

Power

module

Encoder

Swivel motor

Fig. 3-4 Swivel system

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Flow subsystems

3.5 The controls

The following figure shows a schematic diagram of the receiver board.

Signals

Guidelines for fault finding

- Multiple controls communicate with the stairlift receiver board. If one of the controls no longer

works, the fault is in the control. If none of them works any longer, the fault is in the stairlift.

- Hold a control close to the antennas on the receiver board. If the control then works, the signal

is weak or the signal is being disrupted.

- Check the batteries in the control.

- Check the direction and the connection of the antennas on the receiver board.

- There are two antennas mounted on the receiver board. Adjust these antennas so that they do

not touch the frame. Shorting to the frame can be a reason for poor communication.

Receiver board Green LED • Flashes if the processor is working.

• Is continuously lit when receiving a valid command.

Red LED • Is continuously lit when receiving an invalid

command.

Fig. 3-5 Control system construction

Main

Micro-

processor

Safety

Micro-

processor

Receiver

Transmit-

ter/

receiver

Receiver board

Main board

Call and

park unit

Armrest control

Attendant con-

trol

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4 Error messages

4.1 General

The Flow2 software has a number of error messages. When a fault occurs the code is shown as a 2-

digit number in the display preceded by an ‘E’.

Error codes have the highest priority and will therefore overrule other messages (mode, battery

voltage, etc.).

When fault finding it can be important whether the code was generated by the main processor or the

safety processor. The safety processor always gives the main processor the chance to generate an

error code itself. If the main processor does not do that, while it is necessary, the safety processor

takes action. When the code is generated by the safety processor, there will be a point between the

‘E’ and the error code in the display. The point is not shown when the error is generated by the main

processor. Thus ‘E10’ is generated by the main processor and ‘E.10’ by the safety processor.

The error codes mean the same thing.

4.2 Error handling

This chapter describes the possible error messages and how these error messages can be

interpreted, resolved and reset.

The following concepts require some explanation:

The following faults can be generated:

Priority: This indicates the priority of the fault.

When more than one fault is generated, the fault with the highest priority is

shown in the display.

Mode: This indicates the position of the mode switch in which the fault was recognised.

Error code E01

Type of error Control error

Error message Software inconsistency error

Description Occurs when all controls are out and the main relay is still switched on after 3

seconds. The error indicates that 'somewhere' in the control a wrong decision

has been made.

Priority Highest

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Error messages

Possible

solution

- Check the flat cable between the power module and the mainboard.

- Switch the lift off and on.

- Set the parameters and table back to the factory settings.

- Replace the main board if none of the above solutions has helped or if the

fault keeps coming back. This is an extreme measure.

Reset Switch the lift off and on.

Modes 0, 1, 2, 3, 6

The error is disabled in mode 4 and 5.

Error code E02

Type of error System error

Error message Service unit circuit error

Description Indicates that the service board is defective or not switched on.

Priority Highest

Possible

solution

- Switch the lift off and on.

- Check whether the connectors are firmly pushed home.

- Check whether the cabling is damaged. Replace this if necessary.

- Check whether replacing the service board solves the problem.

- Replace the main board if none of the above solutions has helped or if the

fault keeps coming back. This is an extreme measure.

Reset Switch the lift off and on.

Modes 0, 2

Error code E03

Type of error System error / control error

Error message Read parameter error

Description This fault indicates that one of the stored settings is corrupt. This message

mainly appears when, during switching on, the parameter settings are read out.

Because the lift cannot operate without correct rail data, a standard table is

created where the speed is set to 30% and the swivel angle to 0º.

Priority Highest

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