ThyssenKrupp Flow2 Manual
Systematic fault finding
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- Assembly instruction manual (41 pages) ,
- User manual (26 pages) ,
- User manual (35 pages)
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Table of Contents
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Summary of Contents for ThyssenKrupp Flow2
- Page 1 Flow2 stairlift Tab 06: Systematic fault finding...
- Page 2 Flow2 stairlift Tab 06: Systematic fault finding © 2006 ThyssenKrupp Accessibility B.V. All rights reserved 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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Page 3: Table Of Contents
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Table of Contents 1 Introduction ........... . . 2 2 Systematic faultfinding . -
Page 4: Introduction
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 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. -
Page 5: Systematic Faultfinding
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 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). -
Page 6: Fault Analysis
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 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. CAUTION In the event of the repeated occurrence of a fault do not simply repeat the corrective action. - Page 7 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)
- Page 8 Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Systematic fault finding your nose (a smell of burning on a printed circuit board) your fingers (play in the system). CAUTION Make sure you know what you’re measuring! The example of the lamp switching Suppose that you’ve removed the bulb from the fitting.
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Page 9: Carry Out Corrective Action
2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding Systematic fault finding Find the real cause Obviously it’s easy to replace the faulty component and ‘rectify’ the fault. However..CAUTION Make sure you look for the real cause of the problem! Components can become faulty for a variety of reasons. -
Page 10: Monitor The Effect
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Systematic fault finding However, electrostatic discharges certainly can disrupt electronic circuits, corrupt data signals, and damage electronic components or equipment. 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. - Page 11 2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding 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;...
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Page 12: Flow Subsystems
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Flow subsystems optocoupler overspeed optocoupler governor creep switch optocoupler anti-squeeze optocoupler swivel seat-nul level motor brake Encoder board Drive blue charging charging contact: J5 contacts On/Off on/off: J1 switch min: J3 plus: J2... -
Page 13: The Power Supply System
2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding Flow subsystems 3.1 The power supply system If the stairlift does not work, a malfunction may have occurred in the stairlift power supply. Glass fuses Charging circuit Power module Fuse 40 A... - Page 14 Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 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.
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Page 15: The Drive System
2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding 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. Rail data table Drive Overspeed... -
Page 16: The Horizontal System
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 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. Horizontal Gyro motor Main Inclina- IC level... -
Page 17: The Swivel System
2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding 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. Rail data table Encoder Main Micro- processor... -
Page 18: The Controls
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Flow subsystems 3.5 The controls The following figure shows a schematic diagram of the receiver board. Call and park unit Main Micro- processor Receiver Armrest control Transmit- ter/ receiver Safety Receiver board... -
Page 19: Error Messages
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.). - Page 20 Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Error messages Possible Check the flat cable between the power module and the mainboard. solution 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.
- Page 21 2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding Error messages Possible Switch the lift off and on. 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.
- Page 22 Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Error messages Possible Switch the lift off and on. solution Reprogram the safety processor. Replace the main board if none of the above solutions has helped or if the fault keeps coming back. This is an extreme measure.
- Page 23 2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding Error messages Error code Type of error System error 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.
- Page 24 Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Error messages Priority High Possible Switch the lift off and on. 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.
- Page 25 2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding Error messages Error code Type of error System error Error message Squeeze opto circuit error Description This error code indicates that the optocoupler of the swivel null point outputs wrong signals. Priority...
- Page 26 Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Error messages Error code Type of error System error Error message Tornswitch opto circuit error Description This error code indicates that the optocoupler of the swivel null point outputs wrong signals. Priority...
- Page 27 2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding Error messages Error code Type of error System error 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.
- Page 28 Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Error messages Error code Type of error System error / user error Error message Low battery Description Indicates that the batteries are empty. Priority High Possible Position the lift at the charging contact.
- Page 29 2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding Error messages Possible Switch to mode 3 and press the [E] button. Levelling must now move to solution 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.
- Page 30 Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Error messages Error code 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.
- Page 31 2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding Error messages Error code Type of error System error Error message Pre-levelling error Description Horizontal motor not powerful enough to set the chair straight. Priority Possible Switch the stairlift off and on.
- Page 32 Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Error messages Error code Type of error Mechanical fault Error message Level motor overload Description The level motor has been overloaded for a preset time (standard = 2 seconds). Priority High Possible Switch the lift off and on.
- Page 33 2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding 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 Possible Bring the swivel to the 0 position with the [E] button in mode 3.
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Page 34: Overview Of Possible Error Codes
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 Error messages Possible Check the brake/drive motor and replace if necessary. solution Reset Switch off and on. Modes 0, 2 4.3 Overview of possible error codes Code Comment Reset Priority Mode Software inconsistency error... - Page 35 2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding Error messages Code Comment Reset Priority Mode Left-handed squeeze condition Stop 0, 2 Right-handed squeeze condition Stop 0, 2 RF command error Switch off High 0, 2 Pre-levelling timeout error Switch off...
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Page 36: Error Code E51
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 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. -
Page 37: Bad Rail Connection
2007.03.07 Flow2 stairlift Tab 06: Systematic fault finding 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. -
Page 38: Overspeed Governor Has Operated
Tab 06: Systematic fault finding Flow2 stairlift 2007.03.07 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).