Stoeltjes Lift Thyssen Access Flow2

Flow2 - Stairlift
Tab 06: Systematic fault ﬁnding
Access Business Development Division

TK
Flow2 - Stairlift
Tab 06: Systematic fault finding
© 2009 Access Business Development Division.
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.
2009.01.30 Flow2 - Stairlift Tab 06: Systematic fault finding
Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Systematic fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2.1 Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Collecting information and defining the problem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Fault analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Carry out corrective action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.5 At the customer’s home, or in the workshop? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Monitor the effect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.7 Correct completion of a fault notification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3 Flow 2 subsystems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.1 Versions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 The power supply system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.3 The drive system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4 The horizontal system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5 The swivel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6 The controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Error handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Overview of possible error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
3
Tab 06: Systematic fault finding Flow2 - Stairlift 2009.01.30
4
1 Introduction
There is really only one good method for tracing the cause of a problem and that is the systematic
method. Rather than testing or replacing components at random, it is best to follow a systematic
approach to eliminate possible causes until the actual cause is found.
Systematic fault finding is the method of systematically reducing the area in which the fault may be
present based on:
- Information provided by the user.
- Your knowledge of the system
- A methodology.
- Suitable measuring techniques.
Systematic fault finding offers the following benefits:

- You follow a fixed and familiar method.
- The work is carried out more efficiently. Nothing is done twice.
- Structured notes are made of all the 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 of 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.
5
Introduction
6
2 Systematic fault finding
2.1 Method
Dealing with a fault notification in a systematic manner involves the following steps.
1. Collecting information.
2. Defining the actual problem.
3. Analysing the area in which the fault has occurred (looking for the actual cause of the problem).
4. Carrying out the corrective action (repairing or replacing the relevant component).
5. Examine the effect.
Example of a broken lamp

The method is clarified using a simple example of a lamp fitted with
a halogen light bulb.
Fault notification:
“The lamp doesn’t work.”
Fig. 2-1 Lamp switching
2.2 Collecting information and defining the problem

Problem definition
Systematic fault finding starts by gaining good insight into the problem. This insight is gained by
collecting as much information as possible.
In some instances, a customer may be extremely dissatisfied with the product. It will then be very
difficult to get the necessary information from the customer. In such situations, it is necessary to be
very patient and to also investigate the problem yourself.
Questions to ask the customer

Examples of questions that the customer can be asked include:
- What happened recently?
- When does the problem occur?
- Have any changes been made to the product?
- Has there been 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.
7
Systematic fault finding
Review the history

Consult the logbook to find out whether the stair lift 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. The cause of the problem could be at a lower level.

The desk lamp’s bulb blows repeatedly. The bulb has already been replaced twice in the past month,
whilst these bulbs normally last for years. It is time for a thorough inspection of the system.
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!
Defining the area of the fault
Distinguish possible causes
Determining the work order
Eliminate causes
Finding the actual cause
Fig. 2-2 Fault analysis steps
Define the area of the fault

The area of the fault can be defined on the basis of the definition of the problem and knowledge of
the system. The problem area is the collection of all those parts of the system that could contribute to
the problem.
8
Distinguish possible causes

In the area of the fault, mark out the regions that you can test individually to see whether they
function correctly. Adopt a systematic approach. For example, if a subsystem can be tested as a
whole, do not begin by testing the individual components.

In the first instance, it is possible to split the area of the fault into the power supply and the actual
lamp. If the correct voltage is applied to the light’s fitting, then it can be concluded that the power
supply is in order. In that case, it is not necessary to inspect the wiring, the switch, the transformer or
the plug socket.
Determine the sequence of your work

Write down the components that could possibly contribute to the problem. Try to eliminate the
possible causes, but first determine the order in which the work must be carried out.
Determine the work order based on your knowledge of the system, your experience and the
information that has already been collected. Write down the possible causes and determine the order
based on:
- 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 may decide to start
by testing that component. Only decide to do so when the test can be carried out quickly and easily.

Usually the problem is simply a blown light bulb, but with a halogen light bulb, this is not always so
easy to determine. Also, you may not have the correct lamp with you for testing; there are so many
different types and sizes. In this instance, it is easy to test the power supply. Start with this test
before deciding to purchase a new light bulb.
Eliminate the causes

Eliminate the possible causes in the work order that has just been determined.
diagnostic equipment
The following diagnostic aids can be used to test whether a component works correctly:
- 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).
- Your nose (a smell of burning on a printed circuit board).
- Your fingers (play in the system).
9
CAUTION
Make sure you know what you are measuring!

Suppose that you’ve removed the bulb from the fitting. Measure the resistance of the wires to the
fitting by measuring directly across the switch terminals. For example, a value of 2 Ohms is
measured. Consequently, you conclude that there is a short circuit in the wiring. This conclusion is
wrong! The switch is switched on and the resistance of the transformer coil has also been measured.
You can measure the resistance of the wiring properly only by disconnecting the wires from the
transformer.
TIP
Record all your findings and draw a fault tree. Use this to keep a record of the causes that
have been eliminated. Use numbers to indicate the order in which the work is carried out.

A fault tree could be as follows:
Lamp does not work.
2. Lamp broken 3. No voltage at fitting 1. Lamp not properly

screwed into fitting 4. Dirty fitting
3. Short circuit in the wiring 2. Loose contact in the 1. No voltage at the

wiring to the lamp transformer 4. Switch defective
to the lamp
3. Short circuit in the wiring 2. Loose contact in the 1. No voltage at the 4. Transformer defective
to the transformer wiring to the transformer wall socket
Fig. 2-3 Example fault tree
Find the real cause

Obviously, it is easy to replace the faulty component to ‘rectify’ the fault. However.......
10
CAUTION
Make sure you look for the actual cause of the problem!
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 was not fitted correctly or was not connected correctly.
- Etc.
2.4 Carry out corrective action

Do everything possible to rectify the cause of the problem. This often means that it will be necessary
to give the customer advice concerning 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 workshop?

Repairs to the drive unit can be difficult and may take a long time. You will then rather not have the
customer watch you work the whole time. In such a situation it will be better to take the drive unit with
you to the workshop so that you can carry out the repair in more peaceful surroundings.
TIP
Only do so if you can arrange for a replacement drive unit in good time.
Take account of ESD!

An electrostatic charge will usually build up without you being aware
of it, but you will notice it when it is discharged. 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 are
annoying, but they are not dangerous to people. Fig. 2-4 Take account of ESD
11
However, electrostatic discharges certainly can disrupt electronic

circuits, corrupt data signals, and damage electronic components
or equipment.
Fig. 2-5 Wear the wristband!
CAUTION
ESD may feel like a pin-prick to humans, but it is like being struck by lightning for a chip!
Therefore, always take precautions against ESD and wear an anti-static wristband.
Connect the anti-static wristband 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.
2.6 Monitor the effect

Always check that the corrective action has rectified the problem. Allow the customer to test drive the
product himself/herself.
2.7 Correct completion of a fault notification

You have had to replace a defective or damaged part so that the stair lift now works properly again.
You tidy up the workplace and as an extra service, if time allows, you can also service the stair lift.
In this way the customer will probably be most satisfied.
Now it is time to complete the financial and administrative side of the fault notification:
1. Determine whether the fault or the damage is covered by the warranty.
2. 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?).
Fig. 2-6 Reject label
3. If required, return the faulty component to TKA.
4. Complete the logbook, so that the next service engineer knows what your findings were and
knows how the notification was dealt with.
12
It is extremely important to 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.
13
14
3 Flow 2 subsystems
3.1 Versions
As of March 2009, the drive unit of the Flow2 will be equipped with new electronic circuit boards and
new software.
To obtain EMC approval, the number of signal and power cables has been reduced. In addition, a
number of improvements have been made. The problem with installation of the chassis cables
(earthing problem), for instance, has been resolved in this version.
In the new version, the Power module, the Motor module drive, the Motor module level and the MCM
swivel seat module have been combined in a single assembly. This assembly consists of a Control
board and a Power module. The Control board is in inserted into the Power module from above. As a
result, the cassette no longer has various levels, which makes replacements very easy.
15
Flow 2 subsystems
Service
board
J16: service
J11: RF module
Receiver
module
Electrical cassette
optocoupler
optocoupler Speed limiter
J15: creep
creep switch
MCM swivel
J7: motor 3
swivel
motor
encoder
seat
seat
Swivel
Sensor board
optocoupler
J16: sensor
antisqueeze
Main circuit board
board
optocoupler
seat swivel null
motor module
level
level
J6: motor 2
motor
Level
J8: Brake
Brake
Encoder
board
encoder
Drive
J13:
motor module
drive
Drive
J5: motor 1
Blue
charging
charging contacts
Power module
contact: J5 Red
J4: power board
on/off: J1
Fuse
On/Off switch
neg.: J3
pos.: J2
Black
Red
Fig. 3-1 Schematic diagram Flow2 up to 2009-03
16
Flow 2 subsystems
3.2 The power supply system

3.2.1 Power supply system up to 2009-03
If the stair lift does not work, a malfunction may have occurred in the stair lift power supply.
Glass fuses
Fuse 40 A Charging circuit Power module
Charging contact
Transformer/
rectifier
Fig. 3-2 The power supply
The following voltages can/must be measured.
Component Measurement point Voltage (V)

Main board Connector J4 12 Vdc
Power module 3V3, 5V and 12V, as indicated on the 3V3, 5V and 12V
printed circuit board
Between the “plus” and “min” Battery voltage
Transformer Input terminals (Uin) 220 +/- 10% (VAC)
Transformer Output terminals (Uuit) 33 +/- 10% (VDC)
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 LED Meaning

Power module Green LED Lit when all output voltages are present.
17
Flow 2 subsystems
Guidelines for fault finding

Check whether the green LED on the power module is lit when the stair lift 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 main board and check whether the
green LED lights again. If the LED lights, the fault is in the associated cable or 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 stair lift 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.
3.2.2 Power supply system as of 2009-03

As of March 2009 a new Power module is built into the drive unit. Differences compared to the unit
described above:
- The glass fuses have been replaced by PolyFuses. These are thermal fuses that briefly
interrupt the circuits in the event of an overload or short circuit. By switching the stairlift off and
on again, these fuses are reset.
- The 12 Volt connection has been eliminated.
- The Power module has been integrated with the Control board. This Control board is equipped
with 4 LEDs that show the status of the Flow2.
18
Flow 2 subsystems
Fig. 3-3 LED signals on the Control board
The LEDs should be interpreted as follows:
LED Meaning
SAFE Shows that the safety processor and software are active and working
correctly.
The LED flashes.
MAIN Shows that the main processor and software are active and working correctly.
The LED flashes.
3V5 Shows that the 3 Volt supply voltage on the Power module is present.
The LED is lit continuously.
5VSW Shows that the 5 Volt supply voltage on the Power module is present.
The LED is lit continuously as long as the electronics have not switched to
stand-by mode.

Check whether the LEDs on the control panel are lit as shown in the table above. This indicates that
all the supply voltages are present and that the processors are active. If the 3V5 and/or the 5VSW
LED is/are 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 on/off switch on?
- Is the main power circuit fuse still intact?
- Are the connectors on the batteries and the power module secure?
- Switch the Flow2 off and on again to reset the PolyFuses.
- 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
19
Flow 2 subsystems
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.
If all of these items have been checked and the 3V5 and/or the 5VSW LED still does/do not light when
the stairlift is switched on, replace the Power module.
3.3 The drive system

The stair lift drive consists of an assembly of electronics, cables, motors and sensors. The following
figure shows a schematic of this.
Rail data
table
Speed Drive
limiter motor
Main
Encoder
Brake
Micro- IC drive
processor
Safety
Micro- Power
processor FETs
Main board Motor module
Power
module
Batteries
Fig. 3-4 Drive system

The horizontal 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.
20
Flow 2 subsystems
3.4 The horizontal system

The horizontal system consists of electronics, motors and sensors. The following is a schematic
diagram of the horizontal system.
Gyro Horizontal
motor
Main Inclination 1
Micro- IC level
processor
Inclination 2
Safety
Micro- Power Sensor board
processor FETs
Main board Motor module
Batteries
Power
module
Fig. 3-5 Horizontal system

The horizontal 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
21
Flow 2 subsystems
3.5 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- MCM
processor
Swivel motor
Safety
Micro-
processor
Main board
Power
module
Batteries
Fig. 3-6 Swivel system

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
22
Flow 2 subsystems
3.6 The controls

The following figure shows a schematic diagram of the receiver board.
Call and
park unit
Main
Micro-
processor
Control unit Receiver
Transmitter/ IC
receiver Safety
Receiver board Micro-
processor
Main board
Attendant
control
Fig. 3-7 Control system construction
Signals
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.

- Multiple controls communicate with the stair lift 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 stair lift.
- 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.
23
Flow 2 subsystems
3.6.1 Repeater
Under normal circumstances, the LED on the repeater will flash. If this is not the case, the connection
of the LED to the printed circuit board may be reversed. Open the housing of the repeater and switch
the connection of the LED to the printed circuit board. Check the operation of the LED and
reassemble the repeater.
Note: The repeater can function normally even when the LED connection is reversed.
24
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:
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 when the fault was recognised.
25
Error messages
The following faults can be generated:
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
Possible - Check the flat cable between the power module and the main board.
solution - Switch the lift off and on.
- Set the parameters and table back to the factory settings.
- If none of the above solutions has helped or if the fault keeps coming
back:
Version up to 2009-03: Replace the main board.
Version as of 2009-03: Replace the Control board.
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.
26
Error messages
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 - Switch the lift off and on.
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.
- 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
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
27
Error messages
Error code E04

Error message Table-data corrupted
Description This fault indicates that the stored rail 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
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
solution - Reprogram the safety processor.
Modes 0, 2
28
Error messages
Error code E06

Error message Safety mcu programming failure
Description Programming the safety processor failed.
Priority Highest
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 - Replace the power board.
solution - If the error persists, replace the cassette.
Modes 0, 1, 2, 3, 4, 5, 6
29
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 - Replace the main board.
solution
Modes 0, 1, 2, 3, 6
Error code E20

Error message Invalid maindrive position
Description This error indicates that the signals from the encoder on the shaft of the main
motor are incorrect.
Priority High
solution - Replace the encoder cable.
- Replace the encoder module.
Modes 0, 1, 2
30
Error messages
Error code E21

Error message Invalid swivel position
Description This message indicates that the swivel position is incorrect.
Priority High
solution - Check the connections on the sensor board and on the main board.
- Check in mode 3 whether the swivel function can be zeroed 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
31
Error messages
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
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 code E31

Error message Squeeze opto circuit error
wrong signals.
Priority High
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
32
Error messages
Error code E32

Error message OSG optocoupler circuit error
Description Indicates that the overspeed governor optocoupler outputs wrong signals.
Priority High
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
Error code E33

Error message Tornswitch opto circuit error
wrong signals.
Priority High
solution - Replace the opto + cable.
Modes 0, 1, 2
33
Error messages
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 - Check the connections of the module to the drive motor, power module
solution 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 kOhms. 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
34
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
short circuit or that the motor itself is not connected.
Priority High
Possible - Check the connections of the module to the level motor, power module
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 short circuit or that the motor itself is not connected.
Priority High
Possible - Check the connections of the module to the swivel motor, power module
Modes All
35
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 - Position the lift at the charging contact.
solution - Check that the charger is working.
- Check the fuse for the batteries (40A).
- Check the battery wiring.
Modes 0, 1, 2, 3, 4, 5, 6
36
Error messages
Error code E51

Error message Osg tripped
Description This message indicates that the overspeed governor has been activated.
Priority Average
Indication 1 The stair lift has stopped at a rail joint.
Possible A bad rail section or something protruding under the rail has activated the
cause 1 emergency limit switch.
Possible 1. Move the stair lift in the opposite
solutions 1 direction with the control buttons on the
service board.
2. Disconnect the charging assembly (see
1
Tab 7, Section 3.4 - The charging
assembly).
3. Set the final limit switch back to the mid
position (see Fig. 4-1). Fig. 4-1 final limit switch in mid
4. Move the stair lift to a different position position
and refit the charging assembly.
5. Check the rack for protrusions, replace the locking pin as necessary with a
new one.
37
Error messages
Indication 2 The stair lift is at the top, level with an emergency end stop.
Possible cause The stair lift has not recognised all the pulses from the drive motor and has gone
2 past the stop position. The emergency end stop has tripped the final limit switch.
Possible 1. Disconnect the charging assembly (see Tab 7, Section 3.4 - The charging
solutions 2 assembly).
2. Remove the emergency end stop.
3. Set the final limit switch to the mid position (see Fig. 4-1).
4. Move the stair lift 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 final limit switch again (see Fig. 4-1).
6. Fit the charging assembly.
The OSG has now been repaired, but the cause of the stair lift 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.
Indication 3 The stair lift has stopped at a random position and the user has felt a violent
shock.
Possible The overspeed governor has operated because, for example, the stair lift was
cause 3 moving too quickly.
Possible 1. Disconnect the charging assembly (see Tab 7, Section 3.4 - The charging
solutions 3 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.
38
Error messages
Indication 4 The stair lift has stopped at a random position.

Possible The overspeed governor optocoupler or its cabling is defective.
cause 4
Possible First check the connector on the service board.
solutions 4 Then replace the optocoupler and/or the cabling.
Modes 0, 2
39
Error messages
Error code E52

Error message Levelling outside limits
Description The seat is tilted because of a levelling error.
Priority Average
Possible - Switch to mode 3 and press the [E] button. Levelling must now move to
solution the 0 position.
If the levelling of the seat 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 seat horizontal. It is also possible that the level
motor had insufficient force in this situation.
If the zeroing of the seat does not work in mode 3, there is a hardware
fault.
- Check the version of the main board. If this is a version prior to V2.4.0, it is
a good idea to replace the main board with a main board that has this
version or later.
- Check the version of the software. This must be at least version 1.70
(see tab 02).
- Check whether the earth connections on the main board have been
connected (see the member area on the website).
- 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.
Modes 0, 1, 2
40
Error messages
Error code E53

Error message Left-handed squeeze condition
Description The lift has been stopped by an obstacle on the left side of the seat.
Priority Low
Possible - If possible, allow the lift to move to the right and remove the obstacle.
solution 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 E54

Error message Right-handed squeeze condition
Description The lift has been stopped by an obstacle on the right side of the seat.
Priority Low
Possible - If possible, allow the lift to move to the left and remove the obstacle.
solution 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
41
Error messages
Error code E55

Error message Command error
Description Incorrect command received from a control.
Priority Low
Possible - Remove the joystick from the control concerned and place it back again.
solution - Switch the control off and on again by briefly disconnecting the batteries.
- Switch the stair lift off and check the ribbon cable and the connectors
between the main board and the receiver module. Then switch the stair lift
back on again.
Modes 0, 2
Error code E56

Error message Pre-levelling error
Description Horizontal motor not powerful enough to set the seat straight.
Priority Low
Possible - Switch the stair lift off and on.
solution - Sit straight up in the seat (stepping off is even better) and try to move the
lift again. The seat 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 stair lift off and on again. The E52 error may not occur again.
- If the stair lift remains still, there is something wrong with the horizontal
system. Work through the possible solutions of E52.
Modes 0, 2
42
Error messages
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
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 connection of the brake.
Modes 0, 1, 2, 3, 4, 6
Error code E61

Error message Level motor overload
Description The level motor has been overloaded for a preset time (standard = 2 seconds).
Priority High
solution - Check the connections on the motor module.
- Check the mechanical part of the level mechanism.
Modes 0, 1, 2, 3, 4, 5, 6
43
Error messages
Error code E62

Error message Swivel motor overload
Description The swivel motor has been overloaded for a preset time (standard = 2 seconds).
Priority High
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
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 - Bring the swivel to the 0 position with the [E] button in mode 3.
solution 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
44
Error messages
Error code E71

Error message Rf error
Description This message indicates that the receiver board is not responding.
Priority Low
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
Possible - Check the brake/drive motor and replace if necessary.
solution
Modes 0, 2
45
Error messages
Error code E73

Type of error Drive motor
Error message Main drive overspeed
Description 1. Pulse counter does not work.
2. The motor is running too fast.
Priority High
Possible 1. Check the pulse counter in mode 3.
solution 2. Check motor power cables / flat cables
Modes 3
Error code E74

Type of error Drive motor
Error message Standing motor
Description Dead point in the motor
Priority High
Possible - Replace drive motor and describe the error message clearly on the
solution warranty card.
Modes 0, 2
46
Error messages
Error code E75

Type of error Swivel motor
Error message Standing motor
Description Dead point in the motor
Priority High
Possible - Replace drive unit and describe the error message clearly on the warranty
solution card.
- Check/replace cable between motor and Power module.
- Replace Power module.
Modes 0, 2
47
Error messages
4.3 Overview of possible error codes
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 maindrive 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
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
48
Error messages
Code Comment Reset Priority Mode

E70 Swivelling 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
E73 Main drive overspeed Switch off High 3
E74 Standing motor (drive) Switch off High 0,2
E75 Standing motor (swivel) Switch off High 0,2
49
Error messages
50

Stoeltjes Lift Thyssen Access Flow2

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Flow2 - Stairlift

Tab 06: Systematic fault ﬁnding

Access Business Development Division

© 2009 Access Business Development Division.

All rights reserved

2 Systematic fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Systematic fault finding offers the following benefits:

Layout of the tab

2 Systematic fault finding

Example of a broken lamp

Fig. 2-1 Lamp switching

2.2 Collecting information and defining the problem

Questions to ask the customer

Get the customer to demonstrate

Systematic fault finding

Review the history

Example of a broken lamp

2.3 Fault analysis

Defining the area of the fault

Distinguish possible causes

Determining the work order

Finding the actual cause

Fig. 2-2 Fault analysis steps

Define the area of the fault

Systematic fault finding

Distinguish possible causes

Example of a broken lamp

Determine the sequence of your work

Example of a broken lamp

Eliminate the causes

Systematic fault finding

Example of a broken lamp

Example of a broken lamp

Lamp does not work.

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

3. Short circuit in the wiring 2. Loose contact in the 1. No voltage at the

Fig. 2-3 Example fault tree

Find the real cause

Systematic fault finding

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

2.4 Carry out corrective action

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

Take account of ESD!

These shocks are caused by electrostatic discharges (ESD = Electro

Systematic fault finding

However, electrostatic discharges certainly can disrupt electronic

Fig. 2-5 Wear the wristband!

2.6 Monitor the effect

2.7 Correct completion of a fault notification

Systematic fault finding

Systematic fault finding

Fig. 3-1 Schematic diagram Flow2 up to 2009-03

3.2 The power supply system

Fuse 40 A Charging circuit Power module

Fig. 3-2 The power supply

The following voltages can/must be measured.

Component Measurement point Voltage (V)

Transformer Output terminals (Uuit) 33 +/- 10% (VDC)