Flow2 Tab6 EN - schodolez.infoschodolez.info/THYSSEN_VIDEO_AND_PICTURES/FLOW/Flow2_Fault_fi… · - Chapter 5 gives guidelines for dealing with error code E51, the overspeed governor

Flow2 stairlift

Tab 06: Systematic fault finding

©

ATb

Flow2 stairlift

Tab 06: Systematic fault finding

2006 ThyssenKrupp Accessibility B.V.

ll rights reserved
he information in this manual may not under any circumstances be given to someone else, reproduced or publishedy any means without the prior written permission of Product Management.

2007.03.07Flow2 stairliftTab 06: Systematic fault finding

1

Table of Contents

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

2 Systematic faultfinding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.1 Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.2 Collecting information and defining the problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32.3 Fault analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42.4 Carry out corrective action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.5 At the customer’s home, or in the workshops? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72.6 Monitor the effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82.7 Correct completion of a fault notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

3 Flow subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103.1 The power supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113.2 The drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133.3 The horizontal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143.4 The swivel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153.5 The controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174.2 Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174.3 Overview of possible error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

5 Error code E51 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345.1 Bad rail connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.2 Stairlift stopped at emergency end stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 355.3 Overspeed governor has operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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2

1 Introduction

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 tabThis 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.



3

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 switchingThe 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 definitionSystematic 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 customerExamples 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 demonstrateThe 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



4

Systematic fault finding

Review the historyConsult 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 switchingThe 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 faultYou 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.

CAUTIONIn 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


2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding


Distinguish possible causesYou 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 switchingAt 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 workYou 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 switchingUsually 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 causesYou will eliminate the possible causes in the sequence you have just determined.

Diagnostic equipmentYou 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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6


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

- your fingers (play in the system).

The example of the lamp switchingSuppose 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 switchingA fault tree could be as follows:

CAUTIONMake sure you know what you’re measuring!

TIPMake 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




Find the real causeObviously 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.

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

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

Fig. 2-4 Take account of ESD



8


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!

CAUTIONFor 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




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.

NOTEIt 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.



10

3 Flow subsystems

optocoupleroverspeed governor

optocouplercreep switch

Mai

n ci

rcui

t boa

rd

Pow

er m

odul

e charging contact: J5

on/off: J1

min: J3plus: J2

charging contacts

Encoder board

brake

Fuse

blue

red

red

blac

k

Drive

Driv

eLe

vel

level motor

mot

or m

odul

e dr

ive

mot

or m

odul

e le

vel

MC

M s

wiv

el

seat

Sen

sor

boar

d

optocoupleranti-squeeze

optocouplerswivel seat-nul

Sw

ivel

enco

der

swiv

el s

eat

mot

or

Elec

tric

al c

asse

tte

Rec

eive

r m

odul

e

Ser

vice

boa

rd

J4: p

ower

boa

rdJ5

: mot

or 1

J13:

en

code

rJ8

: bra

keJ6

: mot

or 2

J7: m

otor

3J1

5: c

reep

J11:

RF

mod

ule

J16:

sen

sor

boar

d

J16:

ser

vice

On/Off switch



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 (Uin) 220 +/- 10% (VAC)

Transformer Output terminals (Uuit) 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



12

Flow subsystems

Guidelines for fault findingCheck 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.

NOTEOn 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.



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 findingThe 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

SafetyMicro-

processor

IC drive

PowerFETs

Drive motor

Enco

der

Bra

ke

Motor module

Power moduleBatteries

Main board

Overspeed governor

Fig. 3-2 Drive system



14

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 findingThe 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 2

Gyro

Main board

Sensor board

Main Micro-

processor

SafetyMicro-

processor

IC level

PowerFETs

Horizontal motor

Motor module

BatteriesPower module



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 findingThe 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

SafetyMicro-

processor

Main board

MCM

Power module

Encoder

Swivel motor

Fig. 3-4 Swivel system



16

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

SafetyMicro-

processor

ReceiverIC

Transmit-ter/

receiverReceiver board

Main board

Call and park unit

Armrest control

Attendant con-trol



17

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



18

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, 6The 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


- 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.


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



Error messages

Possible solution


- If the error keeps appearing, try to restore a recent backup of the standard factory rail data from the flash card.

Reset Switch off and on.

Modes 0, 2

Error code E04


Error message Table-data corrupted

Description This fault indicates that the stored table data 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

Possible solution


- If the error keeps appearing, try to restore a recent backup of the standard factory rail data from the flash card.


Modes 0, 2

Error code E05


Error message Safety MCU not responding

Description This error indicates that safety processor does not answer requests from the main processor.

Priority Highest



20

Error messages

Possible solution


- Reprogram the safety processor.



Modes 0, 2

Error code E06


Error message Safety mcu programming failure

Description Programming the safety processor failed.

Priority Highest

Possible solution


- Reprogram the safety processor.

- Replace the memory card.



Modes 0, 2

Error code E10


Error message Relay circuit error

Description This error indicates that the main power relay on the power board does not switch on and off correctly. This can be the result of sticking contacts or defective parts.

Priority Average

Possible solution

- Replace the power board.

- If the error persists, replace the cassette.


Modes 0, 1, 2, 3, 4, 5, 6



Error messages

Error code E11


Error message Brake circuit error

Description This indicates that the main motor brake does not switch on and off properly. This can be the result of defective components on the main board.

Priority Average

Possible solution

- Replace the main board.


Modes 0, 1, 2, 3, 6

Error code E20


Error message Invalid main drive position

Description This error indicates that the signals from the encoder on the shaft of the main motor are incorrect.

Priority High

Possible solution


- Replace the encoder cable.

- Replace the encoder module.



Modes 0, 1, 2

Error code E21


Error message Invalid swivel position

Description This message indicates that the swivel position is incorrect.



22

Error messages

Priority High

Possible solution


- Check the connections on the sensor board and on the main board.

- Check in mode 3 whether the swivel function can be nulled with the middle [E] button on the service board.If this is not possible, replace the opto cable and if necessary also the cable between the levelling board and the main board.

- If the above solutions do not rectify the fault, the main board can be replaced.

- If this last solution does not rectify the fault, the swivel assembly can be replaced.


Modes 0, 1, 2

Error code E30


Error message Swivel-zero opto circuit error

Description This error code indicates that the optocoupler of the swivel null point outputs wrong signals.

Priority High

Possible solution


- Check the connections on the sensor board level board and on the main board.

- Replace the null opto + cable.

- Replace the cable between the levelling board and the main board.



Modes 0, 2



Error messages

Error code E31


Error message Squeeze opto circuit error


Priority High

Possible solution


- Check the connections on the sensor board and on the main board.

- Replace the squeeze opto with the cable.

- Replace the cable between the levelling board and the main board.



Modes 0, 2

Error code E32


Error message OSG optocoupler circuit error

Description Indicates that the overspeed governor optocoupler outputs wrong signals.

Priority High

Possible solution


- Check the connections on the service board and the main board.

- Connect a loose opto and test it.If necessary, replace the OSG opto + cable.

- Replace the cable between the service board and the main board.



Modes 0, 2



24

Error messages

Error code E33


Error message Tornswitch opto circuit error


Priority High

Possible solution


- Replace the opto + cable.



Modes 0, 1, 2

Error code E40


Error message Drive motorboard H-bridge malfunction

Description This error indicates that the hardware of the main motor motor module has an internal shortcircuit or that the motor itself is not connected.

Priority High

Possible solution

- Check the connections of the module to the drive motor, power module and the main board. Check especially that the ribbon cable connector is properly seated in the connector on the main board.

- If the error persists, the motor board can be replaced.

- Measure the resistance with a multimeter between the connection to the motor and the housing. This must be greater than 200 kilohms. Caution! The motor must not be connected to the electronics while making this measurement. If the resistance is too low, the motor must be replaced.



Modes All



Error messages

Error code E41


Error message Level motor board H-bridge malfunction

Description This error indicates that the hardware of the level motor module has an internal shortcircuit or that the motor itself is not connected.

Priority High

Possible solution

- Check the connections of the module to the level motor, power module and the main board. Check especially that the ribbon cable connector is properly seated in the connector on the main board.




Modes All

Error code E42


Error message Swivel motor board H-bridge malfunction

Description This error indicates that the hardware of the swivel motor motor module has an internal shortcircuit or that the motor itself is not connected.

Priority High

Possible solution

- Check the connections of the module to the swivel motor, power module and the main board. Check especially that the ribbon cable connector is properly seated in the connector on the main board.




Modes All



26

Error messages

Error code E50

Type of error System error / user error

Error message Low battery

Description Indicates that the batteries are empty.

Priority High

Possible solution

- Position the lift at the charging contact.

- Check that the charger is working.

- Check the battery fuses (40 A)

- Check the battery wiring.


Modes 0, 1, 2, 3, 4, 5, 6

Error code E51


Error message Osg tripped

Description This message indicates that the overspeed governer has been activated.

Priority Average

Possible solution

See Error code E51


Modes 0, 2

Error code E52


Error message Levelling ouside limits

Description The chair is tilted because of a levelling error.

Priority Average



Error messages

Possible solution

- Switch to mode 3 and press the [E] button. Levelling must now move to the 0 position. If the levelling of the chair works correctly, this error can have occurred because the lift went around a corner too quickly so that the level motor was unable to keep the chair horizontal. It is also possible that the level motor had insufficient force in this situation. If the nulling of the chair does not work in mode 3, there is a hardware fault.

- Check the connections on the sensor board.

- Check the cable between the sensor board and the main board.

- Check the connections on the motor module of the level motor.

- Replace the sensor board if it behaves suspiciously.

- Replace the motor module of the level motor if it behaves suspiciously.


Reset Switch off and on

Modes 0, 1, 2

Error code E53

Type of error User error / system error

Error message Left-handed squeeze condition

Description The lift has been stopped by an obstacle on the left side of the chair.

Priority Low

Possible solution

- If possible, allow the lift to move to the right and remove the obstacle.If error code E54 appears, switch the lift to mode 3 and use the [I] and [D] buttons to 'release' the lift from the squeeze condition.

- If the error occurs without there being a squeeze condition, check the squeeze opto and the connection cable.Replace defective parts.

Reset Stop the lift

Modes 0, 2



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Error messages

Error code E54

Type of error User error / system error

Error message Right-handed squeeze condition

Description The lift has been stopped by an obstacle on the right side of the chair.

Priority Low

Possible solution

- If possible, allow the lift to move to the left and remove the obstacle.If error code E54 appears, switch the lift to mode 3 and use the [I] and [D] buttons to 'release' the lift from the squeeze condition.

- If the error occurs without there being a squeeze condition, check the squeeze opto and the connection cable.Replace defective parts.

Reset Stop the lift

Modes 0, 2

Error code E55


Error message Command error

Description Incorrect command received from a control.

Priority Low

Possible solution

- Remove the joystick from the control concerned and place it back again.

- Switch the control off and on again by briefly disconnecting the batteries.

- Switch the stairlift off and check the ribbon cable and the connectors between the main board and the receiver module. Then switch the stairlift back on again.


Modes 0, 2



Error messages

Error code E56


Error message Pre-levelling error

Description Horizontal motor not powerful enough to set the chair straight.

Priority Low

Possible solution

- Switch the stairlift off and on.

- Sit straight up in the chair (stepping off is even better) and try to move the lift again. The chair must now be horizontal and the lift must move again. It is possible that an E52 error occurs during this movement. This is normal. Switch the stairlift off and on again. The E52 error may not occur again.

- If the stairlift remains still, there is something wrong with the horizontal system. Work through the possible solutions of E52.


Modes 0, 2

Error code E60

Type of error Mechanical fault

Error message Drive motor overload

Description The drive motor has been overloaded for a preset time (standard = 2 seconds).

Priority High

Possible solution


- Check the connections on the motor module.

- Check the mechanical part of the drive mechanism.

- Check whether replacing the motor module solves the problem.

- Check the brake connection.


Modes 0, 1, 2, 3, 4, 6



30

Error messages

Error code E61


Error message Level motor overload

Description The level motor has been overloaded for a preset time (standard = 2 seconds).

Priority High

Possible solution


- Check the connections on the motor module.

- Check the mechanical part of the level mechanism.



Modes 0, 1, 2, 3, 4, 5, 6

Error code E62


Error message Swivel motor overload

Description The swivel motor has been overloaded for a preset time (standard = 2 seconds).

Priority High

Possible solution


- Check the connections on the MCM.

- Check the mechanical part of the swivel mechanism.



Modes 0, 1, 2, 3, 4, 5, 6

Error code E70


Error message Swivelling outside limits



Error messages

Description This fault occurs when the swivel is turned more than 360º or because the swivel is not in the right position.

Priority Low

Possible solution

- Bring the swivel to the 0 position with the [E] button in mode 3. Then switch the lift off and on.

- Check the swivel optocoupler.

- Check the swivel encoder.

- If the fault persists, the programmed rail data must be checked.

Reset Stop the lift

Modes 0, 2

Error code E71


Error message RF error

Description This message indicates that the receiver board is not responding.

Priority Low

Possible solution


- If the fault persists, check the connection between the main board and the receiver module. Replace the receiver module if necessary.


Modes 0, 2

Error code E72


Error message Main drive brake skid error

Description This fault indicates that the brake is slipping.This test is carried out every time the lift is stopped.

Priority Low



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Error messages

4.3 Overview of possible error codes

Possible solution

- Check the brake/drive motor and replace if necessary.


Modes 0, 2

Code Comment Reset Priority Mode

E01 Software inconsistency error Switch off Highest 0, 1, 2, 3, 6

E02 Service unit circuit error Switch off Highest 0, 2

E03 Read parameter error Switch off Highest 0, 2

E04 Table-data corrupted Switch off Highest 0, 2

E05 Safety MCU not responding Switch off Average 0, 2

E06 Safety MCU programming failure Switch off Highest All modes

E07 Safety MCU read failure Switch off High 0, 2

E10 Relay circuit error Switch off Average 0, 1, 2, 3, 4, 5, 6

E11 Brake circuit error Switch off Average 0, 1, 2, 3, 6

E20 Invalid main drive position Switch off High 0, 1, 2

E21 Invalid swivel position Switch off High 0, 1, 2

E30 Swivel-zero opto circuit error Switch off High 0, 2

E31 Squeeze opto circuit error Switch off High 0, 2

E32 Osg opto circuit error Switch off High 0, 2

E33 Tornswitch opto circuit error Switch off High 0, 1, 2

E40 Drive motor board h-bridge malfunction Switch off High All

E41 Level motor board H-bridge malfunction Switch off High All

E42 Swivel motor board H-bridge malfunction

Switch off High All

E50 Low battery Switch off High 0, 1, 2, 3, 4, 5, 6

E51 Osg tripped Switch off Average 0, 2

E52 Levelling error Switch off Average 0, 1, 2



Error messages

E53 Left-handed squeeze condition Stop Low 0, 2

E54 Right-handed squeeze condition Stop Low 0, 2

E55 RF command error Switch off High 0, 2

E56 Pre-levelling timeout error Switch off High

E60 Drive motor overload Switch off High 0, 1, 2, 3, 6

E61 Level motor overload Switch off High 0, 1, 2, 3, 4, 5, 6

E62 Swivel motor overload Switch off High 0, 1, 2, 3, 4, 5, 6

E70 Swiveling outside limits Stop Low 0, 2

E71 RF error Switch off Low 0, 2

E72 Main drive brake skid error Switch off Low 0, 2

Code Comment Reset Priority Mode



34

5 Error code E51

According to the list of error codes, error code E51 means that the overspeed governor has tripped.This can have various causes. It is therefore important to find out under what conditions the problem occurred. Therefore ask the user about the conditions when the problem occurred:

- What was the position of the stairlift?

- Was the stairlift going upwards or downwards?

- Who was sitting on the stairlift?

- What exactly happened?

- Was there a shock or did the stairlift quietly come to a halt?

Using the answers an indication can be given of the cause.

Indication Possible problem Action

The stairlift has stopped at a rail joint.

A bad rail section or something protruding under the rail has activated the emergency limit switch.

See Section 5.1.

The stairlift is at the top, level with an emergency end stop.

The stairlift has not recognised all the pulses from the drive motor and has gone past the stop position. The emergency end stop has tripped the emergency end switch.

See Section 5.2.

The stairlift has stopped at a random position and the user has felt a violent shock.

The overspeed governer has been activated.

See Section 5.3.

The stairlift has stopped at a random position.

The overspeed governor optocoupler or its cabling is defective.

First check the connector on the service board. Then replace the optocoupler and/or the cabling.



Error code E51

5.1 Bad rail connection

A bad rail section or something protruding under the rail has activated the emergency limit switch.

This is done as follows:

1. Move the stairlift in the opposite direction with the control buttons on the service board.

2. Disconnect the charging assembly(see Tab 7, Section 3.4 - The charging assembly).

3. Set the emergency end switch back to the mid position (see Fig. 5-1).

4. Move the stairlift to a different position and refit the charging assembly.

5. Check the rack for protrusions, replace the locking pin as necessary with a new one.

5.2 Stairlift stopped at emergency end stop

The stairlift has not recognised all the pulses from the drive motor and has gone past the stop position. The emergency end stop has tripped the emergency end switch.

This is done as follows:

1. Disconnect the charging assembly (see Tab 7, Section 3.4 - The charging assembly).

2. Remove the emergency end stop.

3. Set the emergency end switch to the mid position (see Fig. 5-1).

4. Move the stairlift to a different position.Ride the lift up if it stopped while moving downwards, and down if it stopped while moving upwards.This moves the lift away from the obstacle.

5. Check the emergency end switch again (see Fig. 5-1).

6. Fit the charging assembly.

The OSG has now been repaired, but the cause of the stairlift moving too far has not yet been resolved.

1. Check the wiring on the printed circuit boards.

2. Check the drive motor encoder and the wiring.

3. Replace any defective or suspect parts.

4. Make a few test rides to ensure that everything works properly again.

Fig. 5-1 Emergency end switch in mid position

1



36

Error code E51

5.3 Overspeed governor has operated

The overspeed governor has operated because, for example, the stairlift was moving too quickly.This is done as follows:

1. Disconnect the charging assembly (see Tab 7, Section 3.4 - The charging assembly).

2. Disconnect the complete overspeed governor and check for dirt or loose parts that could have interfered with the operation of the overspeed governor (see Tab 7, Section 3.5 - The overspeed governor).

3. Thoroughly check the drive unit. Pay particular attention to the drive system.

4. Replace any defective or suspect parts.

5. If no clear cause can be found, replace the complete drive unit.


Documents

Flow2 Tab6 EN - schodolez.infoschodolez.info/THYSSEN_VIDEO_AND_PICTURES/FLOW/Flow2_Fault_fi… · - Chapter 5 gives guidelines for dealing with error code E51, the overspeed governor