Access Flow2 User manual

Thyssenkrupp Accessibility
www.ThyssenKruppAccessibility.com
A Thyssenkrupp
Elevator
company
Flow2 - Stairlift
Tab 06: Systematic fault finding
© 2015 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.

2015.04.16 Flow2 - Stairlift Tab 06: Systematic fault finding
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1Connection diagram ...................................................................................................... 5
2Connections on control board.......................................................................................... 6
3Subsystems ................................................................................................................. 7
3.1 Power supply..........................................................................................................7
3.2 Drive system ..........................................................................................................7
3.3 Level system ..........................................................................................................8
3.3.1 Control board connection.........................................................................................8
3.3.2 Hub board..............................................................................................................8
3.3.3 Sensor board..........................................................................................................8
3.3.4 Safety sensor board ................................................................................................8
3.3.5 Locations of the sensors ..........................................................................................9
3.4 Swivel system.........................................................................................................9
3.5 Controls.................................................................................................................9
3.6 Status indication (light and audio signals) ................................................................10
3.6.1 On the drive front cover: ........................................................................................10
3.6.2 On a Call and Park station:.....................................................................................10
3.6.3 On the UI: ............................................................................................................10
3.6.4 Audio only:...........................................................................................................10
4Error and warning messages..........................................................................................11
4.1 Error and warning list ............................................................................................12
4.2 Error handling.......................................................................................................13
4.3 Warning messages................................................................................................23
5Appendix ....................................................................................................................26
5.1 Main menu...........................................................................................................26
5.2 Mode 2 ................................................................................................................27
5.3 Mode 3 ................................................................................................................28
5.4 Mode 4 ................................................................................................................29
5.5 Mode 5 ................................................................................................................30
5.6 Mode 6 ................................................................................................................31
5.7 Mode 7 ................................................................................................................32
5.8 Mode 8 ................................................................................................................33
5.9 Mode 9 ................................................................................................................34

2015.04.16 Flow2 - Stairlift Tab 06: Systematic fault finding
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2015.04.16 Flow2 - Stairlift Tab 06: Systematic fault finding
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1Connection diagram
Service Board
Controlboard Apollo
30A
Fuse
K4
Accu Accu
K4
K4
- +
K1
Chargingcontacts On/Off switch
K3 K5
2x 7Ah 12V ELD switch OSD switch
K6
Receiver
K10
Hub board
K14 K15 K16
Nulsensor
Swivel
K19 K20
Sensor
board
K21
Antisqueeze
swivel
Swivel motor Level motor
K23 K22 K28
K29
K30
Drive motor
Brake
K31 K32
Handlebar
Chair
K34
UI
K35 K33
Blue led
on cover
K2
4x Through
Cable Guide
Through
Cable Guide
Through
Cable Guide
Through
Cable Guide
Through
Cable Guide
-+- +
Motor cable + encoder
Wired User
Interface
Main level
sensor
Motor power cable Encoder cable Encoder cable Motor power cable 1 Motor power cable 2
K36
Installation
joystick
Adapter
AutoswivelAutoswivel
J105 J104 J102
J600 J1004 J1001 J1300 J706 J700 J701 J300
J201
J200/202/203 J101/102/103 J104/105/106
J100 J600
J1400 J1401
J103
USB
J400
J100 J102
J101
J103
J100
Safety
sensor
board
K17
Safety
level
sensor
J106

2015.04.16 Flow2 - Stairlift Tab 06: Systematic fault finding
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2Connections on control board

2015.04.16 Flow2 - Stairlift Tab 06: Systematic fault finding
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3Subsystems
3.1 Power supply
The green LED on the control board will be flashing bright if voltage is present on the control board.
When the system is in sleep mode the LED will be on constantly but will be faint.
3.2 Drive system
Brake connector
Main motor connectors
(2x)
Encoder connector

2015.04.16 Flow2 - Stairlift Tab 06: Systematic fault finding
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3.3 Level system
3.3.1 Control board connection
3.3.2 Hub board
3.3.3 Sensor board
3.3.4 Safety sensor board
Level motor connector
Level motor encoder connector
Control board connector
Hub board connector
Hub board connector
Safety sensor board connector
Sensor board connector
Hub board connector
Zero opto connector
Squeeze opto connector

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3.3.5 Locations of the sensors
3.4 Swivel system
3.5 Controls
Hub board
Sensor board
Basesensor on control board
Swivel connector
(Motor + encoder combined)
Safety sensor board
Sensor board
Safety sensor board

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3.6 Status indication (light and audio signals)
Status LEDs can be found on the drive front cover, the UI, the Call and Parks and Attendant control.
The audio signals are generated on the control board.
3.6.1 On the drive front cover:
A constant blue LED on the service front cover + Single Ping (2800 Hz) will be lit when the
stair lift is switched on
3.6.2 On a Call and Park station:
Constant green LED + Double ping (2600 Hz):
oThe stair lift is about to start (sound starts within 1 sec after the joystick has been
operated on the UI or a C/P).
Flashing green LED:
oC&P batteries are almost empty
Orange LED (both green and red):
oForeign RF
3.6.3 On the UI:
Constant green LED + Double ping (2600 Hz):
oThe stair lift is about to start (sound starts within 1 sec after the joystick has been
operated on the UI or a C/P).
Flashing red LED + warning sound (intermittent ping of 2800Hz every 0.5 seconds):
oTrack not tested after track modification
oChair level beyond 2 degrees
oUnexpected negative charging contact
oPosition beyond maximum track length
oSwivel invalid pulse
oSwivel invalid opto signal
oUser emergency stop test warning (maintenance due)
Flashing red LED + warning sound (intermittent ping of 2800Hz every 1 second):
oC&P is blocked due to recent UI operation
Flashing red LED + error sound (fast intermittent pings of 2800Hz every 0.5 seconds):
oThe stair lift has encountered an obstacle and has stopped. Lift will only move in
opposite direction.
Constant red LED + error sound (fast intermittent pings of 2800Hz, 7 times a second):
oThere is a malfunction in the stair lift.
Flashing green LED while operating the C&P:
oC&P batteries are almost empty
3.6.4 Audio only:
Two-tone beep (high 2400Hz - low 1750Hz) during 3 seconds, repeated every 13 seconds:
oThe lift is not on a charging point
Double beep (1750 Hz):
oELD is operated

2015.04.16 Flow2 - Stairlift Tab 06: Systematic fault finding
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4Error and warning messages
The Flow2 software has a number of error and warning messages. When a fault occurs the code is
shown asa 2-digit number in the display preceded by an “F”, a warning is preceded by a “C”.
There are also source codes “S”, these will give further information for a hardware error. These will be
shown in the display after the F24 error
F24 / S6 / F24 / S6 / …
Hardware error, in 15V supply.

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4.1 Error and warning list
F01
Obstruction in current drive direction detected: left
F53
Swivel position is found to be incorrect
F02
Obstruction in current drive direction detected: right
F54
Safety code is found to be incorrect
C04
Level beyond 2 degrees
F55
Brownout is triggered while moving
F05
Level beyond 5 degrees
C56
An unexpected negative contact was detected
F06
Drive speed beyond track operating range
C58
A negative contact was expected but not detected
F07
Level beyond 7 degrees
C60
The track position value is beyond the maximum track length
F08
Level sensor deviation
C61
The swivel sync opto 0 is detected at an unexpected swivel position
F09
Hardware failure of the main drive
C62
The swivel sync opto has an inverted value
F10
Hardware failure of the level drive
F63
Main drive moment detected without user input
F11
Hardware failure of the swivel drive
F64
Level drive moment detected without user input
F12
Drive motor current trip or overvoltage occurred
F65
Swivel drive moment detected without user input
F13
Level motor current trip or overvoltage occurred
F66
Wrong direction detected for main drive
F14
Swivel motor current trip or overvoltage occurred
F67
Wrong direction detected for level drive
F15
HALL sensor failure of the main drive
F68
Wrong direction detected for swivel drive
F16
HALL sensor failure of the level drive
F69
CPU startup check fails (includes code CRC check)
F17
HALL sensor failure of the swivel drive
C70
Lift driving in normal mode without test run performed
F18
Drive speed beyond maximum limit
C71
User emergency maintenance counter elapsed
F19
Drive speed beyond ELD operating range
F72
User emergency maintenance counter elapsed
F20
Software inconsistency detected (assert)
C73
Position outside track bounds
F21
Battery voltage low while moving up
F74
Manual swivel not in position while starting
F22
Battery failure: under or overvoltage detected
F75
Battery voltage below upwards level
F23
Brake circuit failure detected
F76
Battery voltage recharge required
F24
HW Error detected
F77
Drive I²T critical Main
F25
Wrong HW/SW combination
F78
Drive I²T critical Level
F26
Reduce speed failed
C80
Drive I²T warning Main
F27
Normal stop failed
C81
Drive I²T warning Level
F28
Emergency stop failed
F83
Level sensors are off, but there's drive moment (allowed in service
because of mode -3-)
F29
Disable drive main failed
C85
Backup battery low (below 1.65V)
F30
Stop drive level failed
C86
Level sensor deviation > 4 degrees
F31
Stop drive swivel failed
C87
Swivel deviation > 10 degrees
F32
User emergency stop
F33
Overspeed (OSG) tripped
S1
HW release circuit failure
F34
Level sensor failure
S2
Swivel current measurement too low
F35
Level sensor failure
S3
Swivel current offset calibration failed
F36
Level sensor failure
S4
Level current offset calibration failed
F37
Swivel position outside operating range (+/- 110 deg)
S5
Drive current offset calibration failed
F40
OSG opto failure
S6
+15V outside of limits
F41
ELD opto failure
S7
+5V outside of limits
F42
Swivel zero opto failure
S8
Reference voltage outside of limits
F47
Swivel squeeze opto failure
S9
+3V3 overload
F49
RF unit is not responding
S10
MCU internal failure
F50
Failed to read parameters (motor control or application)
S11
Check timeout
F51
Failed to read the track data
S12
Supply enable/disable circuit failure
F52
Drive position is found to be incorrect
S13
Main/Level/Swivel overcurrent protection failure

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4.2 Error handling
Error code
F01
Error message
Obstruction Left
Description
Obstruction in current (left) drive direction detected
Safety action
Emergency stop
Possible solution
Drive in opposite direction to move away from obstruction.
Error suppressed in
Mode -3- / ELD mode
Error code
F02
Error message
Obstruction Right
Description
Obstruction in current (right) drive direction detected
Safety action
Emergency stop
Possible solution
Drive in opposite direction to move away from obstruction.
Error suppressed in
Mode -3- / ELD mode
Error code
F05
Error message
Tilt > 5⁰
Description
Chair is more than 5⁰out of level
Safety action
Normal stop
Possible solution
Go 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 and the safety board
Check the cables between the sensor board, the safety board and the
control board.
Check the connections of the level motor on the control board.
Replace the safety board if it behaves suspiciously.
Replace the control board if none of the above solutions has helped
or if the fault keeps coming back.
Error suppressed in
Mode -3- / ELD mode
Error code
F06
Error message
Speed higher than programmed
Description
Speed is more that 130% from the programmed speed
Safety action
Normal stop
Possible solution
Possibly the rail data have not been programmed correctly: allow sufficient
distance between speed entries for acceleration and deceleration.
Error suppressed in
Mode -3- / ELD mode

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Error code
F07
Error message
Tilt > 7⁰
Description
Chair is more than 7⁰out of level
Safety action
Emergency stop / Stop level drive
Possible solution
Go 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 and the safety board
Check the cables between the sensor board, the safety board and the
control board.
Check the connections of the level motor on the control board.
Replace the safety board if it behaves suspiciously.
Replace the control board if none of the above solutions has helped
or if the fault keeps coming back.
Error suppressed in
Mode -3-
Error code
F08
Error message
Level sensors disparity
Description
There is a difference of more than 3⁰between the signals from the main
sensor and the safety sensor.
Safety action
Emergency stop / Stop level drive
Possible solution
Possibly one of the sensors is defective. Replace the sensor board and if this
doesn’t solve it, replace the safety board
Error suppressed in
Mode 3
Error code
F09
Error message
Drive failure main
Description
Hardware failure of the main drive
Safety action
Disable main drive
Possible solution
Replace main motor
Error suppressed in
--
Error code
F10
Error message
Drive failure level
Description
Hardware failure of the level drive
Safety action
Emergency stop / Stop level drive
Possible solution
Replace level motor
Error suppressed in
--
Error code
F11
Error message
Drive failure swivel
Description
Hardware failure of the swivel drive
Safety action
Emergency stop / Stop swivel drive
Possible solution
Replace swivel motor
Error suppressed in
--

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Error code
F12
Error message
Drive overload main
Description
Overcurrent main motor
Safety action
Disable main drive
Possible solution
Error suppressed in
--
Error code
F13
Error message
Drive overload level
Description
Overcurrent level motor
Safety action
Emergency stop / Stop level drive
Possible solution
Error suppressed in
--
Error code
F14
Error message
Drive overload swivel
Description
Overcurrent swivel motor
Safety action
Emergency stop / Stop swivel drive
Possible solution
Error suppressed in
--
Error code
F15
Error message
Hall sensor failure main
Description
Hall sensor failure of the main drive
Safety action
Disable main drive
Possible solution
Check cable and connection. If OK, replace main motor
Error suppressed in
--
Error code
F16
Error message
Hall sensor failure level
Description
Hall sensor failure of the level drive
Safety action
Emergency stop / Stop level drive
Possible solution
Check cable and connection. If OK, replace level motor
Error suppressed in
--
Error code
F17
Error message
Hall sensor failure swivel
Description
Hall sensor failure of the swivel drive
Safety action
Emergency stop / Stop swivel drive
Possible solution
Check cable and connection. If OK, replace swivel motor
Error suppressed in
--
Error code
F18
Error message
Overspeed
Description
Measured speed more than max. allowable rpm main motor (2780 rpm)
Safety action
Emergency stop
Possible solution
Error suppressed in
--

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Error code
F19
Error message
Speed too high during ELD use
Description
Measured speed more than 130% from normal ELD speed (1112 rpm)
Safety action
Emergency stop
Possible solution
Error suppressed in
--
Error code
F20
Error message
Software inconsistency
Description
Safety action
Disable main drive / Stop level drive / Stop swivel drive
Possible solution
(re-)install software
Error suppressed in
--
Error code
F21
Error message
Low battery voltage
Description
Battery voltage <19V while driving upwards
Safety action
Normal stop
Possible solution
Lift can be driven down to any halt position where the batteries have to be
charged to a minimum voltage before the lift can be driven upwards again.
While the lift is being charged F76 is shown in the display. The minimum
voltage is set at 25V by default but can be modified in mode -9-
Error suppressed in
Mode -3- / ELD mode
Error code
F22
Error message
Battery failure
Description
Battery voltage < 14V or > 30V
Safety action
Disable main drive / Stop level drive / Stop swivel drive
Possible solution
Replace batteries
Error suppressed in
ELD mode
Error code
F23
Error message
Brake circuit failure
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 control board.
Safety action
Disable main drive
Possible solution
Replace the control board.
Error suppressed in
--
Error code
F24
Error message
Hardware error
Description
All hardware errors that do not generate their own code
Safety action
Disable main drive / Stop level drive / Stop swivel drive
Possible solution
Error suppressed in
--

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Error code
F25
Error message
Hardware incompatible
Description
Wrong hardware / software combination
Safety action
Disable main drive / Stop level drive / Stop swivel drive
Possible solution
Replace hardware and/or software
Error suppressed in
--
Error code
F26
Error message
Speed reduction failed
Description
Safety action failed
Safety action
Normal stop
Possible solution
Error suppressed in
--
Error code
F27
Error message
Normal stop failed
Description
Safety action failed
Safety action
Emergency stop
Possible solution
Error suppressed in
Error code
F28
Error message
Emergency stop failed
Description
Safety action failed
Safety action
Disable main drive / Stop swivel drive
Possible solution
Error suppressed in
Error code
F29
Error message
Disable main drive failed
Description
Safety action failed
Safety action
Fully disable main drive
Possible solution
Error suppressed in
--
Error code
F30
Error message
Stop level drive failed
Description
Safety action failed
Safety action
Emergency stop / Fully disable level drive
Possible solution
Error suppressed in
--
Error code
F31
Error message
Stop swivel drive failed
Description
Safety action failed
Safety action
Emergency stop / Fully disable swivel drive
Possible solution
Error suppressed in
--

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Error code
F32
Error message
User emergency stop
Description
User has removed joystick out of UI
Safety action
Emergency stop
Possible solution
Error suppressed in
Mode -3- / ELD mode
Error code
F33
Error message
OSD tripped
Description
The overspeed device has been activated
Safety action
Emergency stop
Possible solution
Error suppressed in
Mode -3-
Error code
F34
Error message
Level sensor failure drive
Description
Defective gyro sensor on control board
Safety action
Emergency stop / Stop level drive
Possible solution
Replace control board
Error suppressed in
Mode -3-
Error code
F35
Error message
Main level sensor failure chair
Description
Defective sensor on sensor board
Safety action
Emergency stop / Stop level drive
Possible solution
Replace sensor board
Error suppressed in
Mode -3-
Error code
F36
Error message
Safety level sensor failure chair
Description
Defective sensor on safety sensor board (behind chairleg)
Safety action
Emergency stop / Stop level drive
Possible solution
Replace safety board
Error suppressed in
Mode -3-
Error code
F37
Error message
Swivel beyond operating range
Description
Swivel has turned more than 110⁰
Safety action
Normal stop
Possible solution
Error suppressed in
Mode -3- / ELD mode
Error code
F40
Error message
Opto failure OSD
Description
Defective opto overspeed device
Safety action
Normal stop
Possible solution
Replace opto
Error suppressed in
Mode -3- / ELD mode

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Error code
F41
Error message
Opto failure ELD
Description
Defective opto emergency lowering device
Safety action
Normal stop
Possible solution
Replace opto
Error suppressed in
Mode -3-
Error code
F42
Error message
Opto failure swivel zero
Description
Defective opto swivel zero
Safety action
Normal stop
Possible solution
Replace opto
Error suppressed in
Mode -3- / ELD mode
Error code
F47
Error message
Opto failure squeeze
Description
Defective squeeze opto
Safety action
Normal stop
Possible solution
Replace opto
Error suppressed in
Mode -3- / ELD mode
Error code
F49
Error message
Receiver board failure
Description
Defective receiver board
Safety action
Normal stop
Possible solution
-Check cable and connections and receiverboard version.
Replace if damaged.
-Replace receiver board
Error suppressed in
Mode -3- / ELD mode
Error code
F50
Error message
Parameters corrupt
Description
Failed to read parameters (motor control or application)
Safety action
Normal stop
Possible solution
Reboot / Mode -9- CLR, please note to backup your raildata.
Error suppressed in
Mode -3-
Error code
F51
Error message
Rail data corrupt
Description
For example: less than 2 halt positions or speed entries programmed
Safety action
Normal stop
Possible solution
Program correctly or restore by Mode -9- (RES)
Error suppressed in
Mode -3- / ELD mode
Error code
F52
Error message
Drive position unknown
Description
Reset point not “seen” (yet).
Safety action
Normal stop
Possible solution
Drive to reset point in mode -3-
Error suppressed in
Mode -3- / ELD mode

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Error code
F53
Error message
Swivel position unknown
Description
Reset point (zero opto) not “seen” (yet).
Safety action
Normal stop
Possible solution
Find reset point using [E] button in mode -3-.
Error suppressed in
Mode -3- / ELD mode
Error code
F54
Error message
Data corrupt
Description
Safety code is found to be incorrect.
Safety action
Disable main drive / Stop level drive / Stop swivel drive
Possible solution
In mode -9- first clear rail data (Crd), than restore (rES). If this does not clear
the fault, the rail data have to be programmed manually.
Error suppressed in
--
Error code
F55
Error message
Brownout while moving
Description
Power is switched off or fails during ride
Safety action
Disable main drive / Stop level drive / Stop swivel drive
Possible solution
Check battery cable connection, fuse and measure voltage on battery
control board connector.
Error suppressed in
--
Error code
F63
Error message
Unexpected main motor movement
Description
Main motor turns without user input (UI, RF, ELD, service buttons or
installation joystick.
Safety action
Disable main drive
Possible solution
Error suppressed in
--
Error code
F64
Error message
Unexpected level motor movement
Description
Level motor turns without user input (UI, RF, ELD, service buttons or
installation joystick.
Safety action
Emergency stop / Stop level drive
Possible solution
Error suppressed in
--
Error code
F65
Error message
Unexpected swivel motor movement
Description
Swivel motor turns without user input (UI, RF, ELD, service buttons or
installation joystick.
Safety action
Emergency stop / Stop swivel drive
Possible solution
Error suppressed in
--