Diagnostico YALE MR16 (c849)
March 16, 2023 | Author: Anonymous | Category: N/A
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SERVICE
Section: DIAGNOSTIC
DIAGNOSTICS
DI DIAG AGNO NOST STIC ICS S ...................................................... ........................... .............................................. ................... 68
DESCRIPTION OF AC2 INVERTER ALARMS DRIVE DRI VE CONT CONTRO ROL L ..................................................... .......................... .......................................... ............... 68
DESCRIPTION OF AC2 INVERTER ALARMS PUMP PUM P CONTRO CONTROL L .......................... ..................................................... .......................................... ............... 72
DESCRIPTION DESCR IPTION OF OF CAN I/O A ALARM LARMS S .......................... ...................................... ............ 74
DESCRIPT DESC RIPTION ION OF MHYRIO MHYRIO ALARMS ALARMS ..................................... ............................ ......... 76
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Date: Mar. 2002
Part No.: 524162546
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SERVICE
Section: DIAGNOSTIC
1.0
DIAGNOSTICS
This section contains descriptions of all the possible alarm for each of the modules. Note that, with the CAN-BUS system, whenever an alarm condition occurs on one module all the other modules will lock up. Those modules not affected by the alarm condition will lock up and display the alarm WAITING...... indicating the name of the controller on which the alarm was generated. The user can access the faulty controller and display the alarm through any of the controllers using the procedure SET MODEL ( see see “Programming”).
1.1
ALARMS
The controllers store stor e the last 5 alarm events in their memory, recording the relative identifica identification tion code, the number of times that the same alarm alar m has been activated and the temperatur temperature e of the controller at the time the alarm was tripped. These alarms are displayed on the display unit (SICOS controller) along with the name of the module on which the alarm was generated. Connect the console to the module thus identified and interrogate the ALARMS the ALARMS submenu contained in the MAIN MENU.
2.0 2.0 C I T S O N G A I D
DES DESCRI CRIPTI PTION ON OF AC AC2 2 INV INVERT ERTER ER AL ALARM ARMS S - DRIVE DRIVE CON CONTRO TROL L
WATCH DOG:
The test is performed in both “running” and “standby” conditions. It is an internal self-diagnostic test of the logic. If the alarm persists - replace the controller. controller.
EEPROM KO:
Fault in memory area where the configured parameters are stored; this alarm inhibits truck operation. Switch the keyswitch off and then on again: if the alarm condition does not reappear, remember that the previously stored parameter settings will have been cancelled and replaced by the default values. If the alarm persists - replace the controller. controller.
LOGIC FAILURE #1:
This alarm signals the intervention of an undervoltage/overvoltage protection. There are two possible causes: a) A real undervoltage/overvoltag undervoltage/overvoltage e event has o occurred; ccurred; in which which case turn the keyswitch off and then on again. b) Fault in the hardware hardware section section of the logic logic board that that controls controls overvoltage overvoltage protection - replace the controller. controller.
LOGIC FAILURE #2:
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Fault in the hardware section of the logic board that controls the feedback of the phase voltages. Replace the controller
Part No.: 524162546
Date: Mar. 2002
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SERVICE
Section: DIAGNOSTIC
LOGIC FAILURE #3:
Fault in the hardware section of the logic board that controls the hardware current protection. Replace the controller.
CHECK UP NEEDED:
This message warns the operator that the programmed maintenance interval has expired. The alarm appears when the parameter CHECK UP DONE of the CAN I/O module is set to ON and then the keyswitch is reset. By default it is set to OFF
INCORRECT START:
This alarm appears when the starting sequence is not correct. Possible causes: a) Fault in the oper operator ator presence sensor sensor or the start sensor sensor - Replace the sensor b) Operator err error or in carrying carrying out the starting starting sequence - Carry out the correct starting sequence. c) Incorrect wiring wiring - make make sure wiring is connected correctly d) If the fault persists persists - replace the controller controller
FORW + BACK:
The test performed continuously. continuousl y. An alarm is signalled whenever a two drive requests are made simultaneously. Possible causes: a) Faulty wiri wiring ng - make sure wiring wiring is connected connected correctly correctly b) Check the tr travel avel direction direction sensors - if faulty, replace replace the sensor sensor c) Drive request request operation incorrect - Repeat Repeat the drive request operations operations in the correct sequence e) If the fault persists persists - replace the controller controller
HANDBRAKE:
The truck fails to start because the contact of the parking brake pushbutton pushbutton is open. Possible causes: a) The pa parkin rking g brake brake is on - release release it b) Parking br brake ake pushbutton pushbutton short circuited circuited - replace replace the pushbutton pushbutton c) Operator error error - Release Release the parking parking brake in in correct manner manner
When the keyswitch is closed, the inverter attempts to charge the capacitors through a power resistor Rc, and checks that the capacitors have been charged within a certain time period: if not, an alarm is generated and the main contactor will not be closed.
CAPACITOR CHARGE:
Possible reasons: a) The chargin charging g resistor contact contact is open - replace replace the controller controller b) There is a fau fault lt in the charging charging circuit - replace replace the controller controller c) There is a problem problem in the power power module module - replace the controller
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Part No.: 524162546
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SERVICE
Section: DIAGNOSTIC
VMN LOW (24V): VMN HIGH (48V)
This test is performed during the t he initial diagnostic procedure and in standby. In these conditions, conditions, due to the two grid-bias resistors and that all the Mosfets of the bridge are open, open, the voltage at point “A” should be equal to VB/2 (24V). If this is not the case, the alarm is generated; this alarm is also generated on closing the power Mosfets one at a time alternatively alternativ ely towards ground and towards +VBat (48V) and verifying that the voltage is 0 or +VBat. If not, the alarm is generated. Possible causes : a) There is a problem problem in the motor connections connections or in the motor motor power circuits; check that the three phase are connected correctly; heck for any dispersion of motor current to earth; b) Fault in the inverte inverterr - replace the control controller ler
STBY I HIGH:
Test performed in standby condition. It checks that the current is 0. If the current is 0, the Hall effect effect sensor will produce a vo voltage ltage of 2.5V 2.5V.. If this does not happen, the resulting alarm will inhibit truck operations. Possible causes: a) Fault in the current sensor - Replace the controller b) Fault in the logic logic unit - replace replace the controller controller
MAIN CONTACTOR ALARMS
COIL SHORTED:
This driver can take1.5A continuously and is protected against short circuit. When the keyswitch is closed, the microprocessor checks the driver of the main contactor and the protection circuit comprised of the flip flop FF. FF. If it does not respond correctly to the stimulus from the microprocessor, the alarm is signalled. Replace the controller. The flip flop FF provides hardware control of the current in the coil of the main contactor. contactor. If the current is too high, the FF opens the main contactor and the alarm is signalled. Check for external short-circuits and that the ohms value of the main contactor coil is correct. If not, replace the controller. controller.
DRIVER SHORTED:
When the keyswitch is closed, the microprocessor checks that the coil of
C I T S O N G A I D
main contactor is not shorted. If the coil is shorted, this alarm is generated - replace the controller CONTACTOR DRIVER:
When the initial diagnostics procedure has been completed, the drive logic closes the main contactor and checks checks the voltage on the driver drain. drain. If the driver has been programmed to drive the coil of the contactor with PWM at 50%, then the analogue input read by the microprocessor should be approx. 2.5V. The alarm is signalled if the voltage differs from this value - replace the controller.
CONTACTOR OPEN:
The main contactor is driven by the logic logic unit, but the contactor is not closed. There are two possible reasons: a) The coil connections connections are interrupted or poorly connected Make the connections correctly b) The contacts contacts of the contactor contactor do not not work correctly correctly Check the contactor contacts and, if necessary, replace them.
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SERVICE
Section: DIAGNOSTIC
AUX OUTPUT KO:
The microprocessor controls the driver of the electromagnetic brake. If the driver output does not match the signal from the microprocessor, this alarm is signalled. Replace the controller.
HIGH TEMPERATURE:
The temperature of the inverter exceeds 75°C. The maximum current is reduced proportionally to the temperature increase. The inverter locks up at 100°C. If this alarm is signalled when the inverter is cold: a) Fault in temperature sensor - replace the controller b) Faul Faultt in the logic unit - replace replace the con controlle troller r
MOTOR TEMPERATURE: This warning is displayed if the analogue signal exceeds the trip threshold. If this happens when the motor is cold, check the wiring. If the wiring is OK - replace the controller. The temperature sensor used is a PTC with 10mV/°C. It provides an output of 2.73V at 0°C and 3.73V at at 100°C; if this output falls falls to 0 or rises to +5V, this means that the sensor is broken or the circuit is interrupted replace the sensor THERMIC SENSOR KO:
The inverter temperature sensor is monitored continuously and a warning signal (Inverter) is generated if the temperature is outside the permitted range. When this alarm is signalled, check the sensor connection.
WAITING .............:
This alarm can appear in systems comprised of a number of modules connected by a Can Bus. A module has detected a fault, and the drive cannot close the main contactor due to the alarm condition on this module (which the drive can identify by way of the CAN-BUS). The alarm indicates the module on which the fault has been detected (e.g. Waiting Pump)
CAN BUS KO:
This alarm is signalled if the inverter fails to receive any messages via the CAN-BUS. First check the wiring. If the wiring is OK - replace the controller
BATTERY LOW:
If the “battery check” option is set to ON, a battery discharge algorithm algorithm is applied. When the charge level falls to 20%, this alarm is signalled and the current is reduced to half the programmed level. Lifting is inhibited, but the retractable carriage and slow drive functions remain operational so that the truck can be driven back to the t he charging station.
ENCODER ERROR:
This alarm is generated if the encoder input is subjected to a large surge (more than 20Hz in 32mSec); this means that the encoder is faulty - replace the encoder
SAFETY:
This alarm is generated if the safety input is open (this input opens the line of the main contactor driver) Look for the alarm on the EPS controller.
WRONG SET BATTERY:
This alarm is generated if the battery voltage differs significantly from the nominal value (48V) on start up. Normally it is due to an incorrect “adjust battery” setting. Set the correct battery value in the “Adjust Battery” parameter of the “Config Menu’ ADJUSTMENT”.
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Date: Mar. 2002
Part No.: 524162546
Page: 71
SERVICE
Section: DIAGNOSTIC
3.0 3.0
DES DESCRI CRIPTI PTION ON OF AC AC2 2 INV INVERT ERTER ER AL ALARM ARMS S - PUMP PUMP CON CONTRO TROL L
WATCH DOG:
The test is performed in both running and standby condition. It is an internal self-diagnostic test of the logic. If the alarm persists - replace the controller. controller.
EEPROM KO:
Fault in memory area where the configured parameters are stored; this alarm operation the truck. Switchinhibits the keyswitch off of and then on again: if the alarm condition does not reappear, remember that the previously stored parameter settings will have been cancelled and replaced by the default values. If the alarm persists - replace the controller. controller.
LOGIC FAILURE #1:
This alarm signals the intervention of an undervoltage/overvoltage protection. There are two possible causes: a) A real un undervoltage/ove dervoltage/overvoltage rvoltage event event has occurred; occurred; turn the keyswitch keyswitch off and then on again. b) Fault in the hardware hardware section of the logic logic board that contro controls ls overvoltage overvoltage protection - replace replace the controller
LOGIC FAILURE FAILURE #2:
Fault in the hardware section of the logic board that controls the feedback of the phase voltages - replace the controller.
LOGIC FAILURE #3:
Fault in the hardware section of the logic board that controls the hardware current protection - replace the controller.
INCORRECT START
This alarm appears when the starting sequence is not correct. Possible causes: a) Fault in the pump start microswitch microswitch - identify identify the faulty joystick and replace it. b) Operator error in in carrying carrying out out the starting sequence sequence - Carry out the correct starting sequence. c) Incorrect wiring - make sure wiring wiring is connected correctly correctly d) If the fault persists persists - replace replace the controlle controller r
CAPACITOR CHARGE:
When the keyswitch is closed, the inverter attempts to charge the capacitors through a power resistor Rc, and checks that the capacitors have been charged within a certain time period. If not, an alarm is generated and the main contactor will not be closed. Possible reasons: a) The charging resistor contact is open - replace replace the controller controller b) There is a fault in the charging circuit circuit - replace the controller c) There is a problem in the power module - replace replace the controller controller
VMN LOW (24V): VMN HIGH (48V)
This test is performed during the t he initial diagnostic procedure and in standby. Possible causes : a) There is a problem problem in the motor connections connections or in the motor motor power circuits; check that the 3 phases are connected correctly; check if there is loss to earth from the motor; b) Fault in the inverte inverterr - replace the control controller ler
STBY I HIGH:
Test performed in standby. Checks that the current is 0. If not, the resulting alarm inhibits operation of the truck.
C I T S O N G A I D
Possible causes: a) fault in the current sensor- replace replace the controller b) Fault in the logic logic unit - replace replace the controller controller
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SERVICE
Section: DIAGNOSTIC
COIL SHORTED:
When the keyswitch is closed, the microprocessor checks the driver of the flasher FF SR. If it does not respond to the stimulus from the microprocessor,, this alarm is signalled - replace the controller. processor controller.
DRIVER SHORTED:
When the keyswitch is closed, the microprocessor checks that the driver of the flasher is not short-circuited; If this alarm is signalled - replace the controller
CONTACTOR DRIVER:
When the initial diagnostics procedure has been completed, the logic checks the voltage of the driver drain. If the voltage is not low, the alarm is signalled - Replace the controller
HIGH TEMPERATURE:
The temperature of the inverter exceeds 75 °C. The maximum current is reduced proportionally to the temperature increase. The inverter locks up at 100 °C. If this alarm is signalled when the inverter is cold: a) Fault in temperature sensor - replace the controller b) Faul Faultt in the logic unit - replace replace the con controlle troller r
MOTOR TEMPERATURE: This warning is displayed if the analogue signal exceeds the trip threshold. If this happens when the motor is cold, check the wiring. If the wiring is OK - replace the controller The temperature sensor used is a PTC with 10mV/°C. It provides an output of 2.73V at 0°C and 3.73V at at 100°C; if this output falls falls to 0 or rises to +5V, this means that the sensor is broken or the circuit is interrupted replace the sensor THERMIC SENSOR KO:
The inverter temperature sensor is monitored continuously and a warning signal (Inverter) is generated if the temperature is outside the permitted range.. When this alarm is signalled, and the controller temperature does not correspond - replace the sensor
AUX OUTPUT KO:
The microprocessor controls the driver of the controllers cooling fan. If the driver output does not match the signal from the microprocessor, this alarm is signalled. Replace the controller.
WAITING WAITIN G ..............: ............ ..:
This alarm can appear in systems comprised of a number of modules connected by a Can Bus. One of the modules has detected a fault and informed the pump control inverter via the Can Bus. The pump controller is waiting for the ok signal. Look for the fault on the module indicated in the alarm.
CAN BUS KO:
Diagnostics of the CAN-BUS line is only available when the inverter uses this connection (depends on the software version): This alarm is signalled if the inverter fails to receive any messages via the CAN-BUS. First check the wiring. If the wiring is OK - replace the controller
BATTERY LOW:
If the “battery check” option is set to ON, a battery discharge algorithm is applied. When the charge level falls to 20%, this alarm is signalled and the current is reduced to half the programmed level. Lifting is inhibited, but the retractable carriage and slow drive functions remain operational so that the truck can be driven back to the t he charging station.
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Date: Mar. 2002
Part No.: 524162546
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SERVICE
Section: DIAGNOSTIC 4. 4.0 0
C I T S O N G A I D
DESC DESCRI RIPT PTIO ION N OF CA CAN N II/O /O ALA ALARM RMS S
VACC NOT OK:
Throttle high in standby standby without enabling signal from start microswitch or accelerator incorrectly programmed a) Program the po potentiometer tentiometer from the “Program “Program Vacc” Vacc” option of the “Main “Main Menu”. b) Replace the potentiometer potentiometer if circuit is interrupted
PEDAL WIRE KO:
Drive above maximum programmed value. Checkpotentiometer the wiring connections; if OK, replace the potentiometer. potentiometer .
POT #1 NOT OK:
Lifting potentiometer high in standby without enabling signal or incorrectly programmed a) Program the potentiometer b) Replace the joystick
POT #2 NOT OK:
Carriage potentiometer high in standby without enabling signal or incorrectly programmed a) Program Program the the potentio potentiometer meter b) Replace Replace the joystick joystick
POT #4 NOT OK:
Translation potentiometer high in standby without enabling signal or incorTranslation rectly programmed a) Program Program the the potentio potentiometer meter b) Replace Replace the joystick joystick
CAN BUS KO TR:
The periodic messages from the drive control have not arrived before timeout a) Look for the alarm on the drive control inverter b) Check Check the CAN BUS BUS connecti connections ons
CAN BUS KO PU:
The periodic messages from the pump control have not arrived before timeout a) Look for the alarm on the pump control control inverter b) Check Check the CAN BUS BUS connecti connections ons
CAN BUS KO VALVE:
The periodic messages from the Mhyrio have not been received before timeout a) Look for the the alarm on the the Mhyrio Mhyrio module module b) Check the CAN BUS connections of the Mhyrio Mhyrio module
CAN BUS KO JOY:
The multifunction joystick does not send its periodic messages before timeout a) Check the joystick connections connections and re-make correctly if necessary b) If the fault persist persists s - replace the the joystick joystick
CAN BUS KO EPS:
The periodic messages from the EPS have not been received before timeout -> drive is forced to slow a) Check the EPS connections connections and re-make them if necessary b) Check Check for alarms alarms on the the EPS module module
CHECK UP NEEDED:
Programmed maintenance request. The parameter is set to OFF so the alarm does not occur. If the parameter is set to ON, a warning is displayed advising the operator to have serviced. To resetthe thetruck alarm, set the CHECK UP DONE parameter in Set Model to ON and reset the keyswitch.
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Part No.: 524162546
Date: Mar. 2002
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SERVICE
Section: DIAGNOSTIC
EEPROM KO:
Error in parameter management in the EEPROM Replace the controller
BATTERY OUT:
CANIO input. The alarm is signalled when the battery is not correctly inserted. Lifting is inhibited, but the retractable carriage and slow drive functions remain operational so that the truck can be driven back to the charging station. Alternatively Alternativ ely the battery battery position position sensor sensor may be incorrectl incorrectly y adjusted adjusted or faulty faulty - adjust or replace the sensor.
FORW+BACK:
Forward and reverse travel controls pressed simultaneously. This alarm is signalled when the forward and reverse travel requests are made simultaneously.
INCORRECT START:
Active drive and/or pump request on power up.i.e. request made before activation of the operator present present button. Repeat the correct power power up sequence main switch, keyswitch, operator present pushbutton, drive request)
POWER FAILURE #1:
Short on one of the digital outputs of the CAN I/O. The CANIO provides two digital outputs: a) Reverse travel or or truck in motion motion buzzer buzzer - replace replace the controller b) Horn - rrepla eplace ce the contro controller ller
EMERGENCY:
Emergency pushbutton pressed (an input of the t he CANIO) when the keyswitch was turned on. Reset the emergency pushbutton
NOTES:
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Date: Mar. 2002
Part No.: 524162546
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SERVICE
Section: DIAGNOSTIC
5. 5.0 0
DESC DESCRI RIPT PTIO ION N OF OF MHYR MHYRIO IO ALA ALARM RMS S
EEPROM KO:
Fault in memory area where the parameter settings are stored. This alarm inhibits operation of the machine. Turn the keyswitch of and then on again; if the alarm disappears, remember that all the previously programmed parameter settings will have been deleted and replaced with the default values. If the fault persists after turning the keyswitch back on - replace the controller.
CAN BUS KO:
There is a problem with the CAN BUS. This alarm is signalled if the MHYRIO does not receive any message from the SICOS via the CAN. First check the wiring. If the wiring is OK, then the problem is in the logic board - replace the controller
FF VALVES:
Flip flop circuit that signals that the driver of the ON/OFF valves is disabled. This alarm refers to the inputs of the auxiliary valves (referred to CNF pin 4/9F - 3/10F - 2/5F) The cause could be a high current at the shunt - replace the control
DRIVER OPEN:
The MOS that pilots the positive of the forks f orks down solenoid valve EV1 (pin 3 CNB) is open when it should be closed. Replace the controller controller
C I T S O N G A I D
DRIVER EPV GR1:
The MOS that pilots the positive of the forks up solenoid valve EV2 (pin 10 CNG) is open when it should should be closed. Replace the controller. controller.
DRIVER EPV GR2:
The MOS that pilots the positive of the carriage translation solenoid valves EV3-4 (pins 11-16 11-16 CNG) is open when it should should be closed. Replace the controller.
DRIVER EPV GR3:
The MOS that pilots the positive of the forks up/down tilting solenoid valves EV5-6 (pin 9-13 CNG), right/left fork translation solenoids EV 7-8 (pins 1215 CNG) is open when it should be closed. Replace the controller
DRIVER SHORTED:
The MOS that pilots the positive to the solenoid valves is closed when it should be open. Replace the controller.
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Part No.: 524162546
Date: Mar. 2002
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SERVICE
Section: DIAGNOSTIC
NOTES:
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