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WATCHDOG
EEPROM KO
LOGIC FAILURE #3
LOGIC FAILURE #2
message
sicos
CALL
SERVICE
description
effect
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Error
detected
in The control device
EEPROM or in EEPROM works using the default Continuous
management.
parameters.
Re-start procedure:
None.
CALL
SERVICE
Hardware protection cir- MC not closed, EB accuit failure due to high tivated, traction/pump Start up
current.
stationary.
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
MC open, EB activated, Switch-on (imMotor phase voltage feedtraction/pump station- mediately after the
back circuit failure.
ary.
MC closes)
Re-start procedure:
Make a traction or hydraulic request.
LOGIC FAILURE #1
Vmn low
Vmn HIGH
CONTACTOR
CLOSED
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
MC open, EB activated,
Motor output voltage low Start up
traction/pump stationer than expected.
During traction
ary.
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
13
programmer
message
CONTACTOR
OPEN
message
sicos
CALL
SERVICE
description
effect
SERVICE
state of the truck
Switch-on (imThe MC coil has been ac- MC open, EB activated, mediately after the
tivated, but the MC fails to traction/pump station- MC closes)
close.
ary.
Stand-by
During traction
Re-start procedure:
Make a traction or hydraulic request.
STBY I HIGH
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
CAPACITOR
CHARGE
TH. PROTECTION
CALL
SERVICE
The voltage of the power MC not closed, EB accapacitors fails to in- tivated, traction/pump Start up
crease.
stationary.
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
The traction control device reduces the maximum current linearly Continuous
from IMAX (85C) to 0A
(105C).
Re-start procedure:
None.
MOTOR
TEMPERAT.
CALL
SERVICE
Re-start procedure:
None.
CALL
SERVICE
BATTERY LOW
DRIVER SHORTED
Re-start procedure:
Recharge the battery.
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
14
SERVICE
programmer
message
CONTACTOR
DRIVER
VACC NOT OK
message
sicos
CALL
SERVICE
description
effect
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
The
value
of
the
accelerator/lifting
potentiometer is greater
Start up
The traction/pump mothan
the
minimum
Stand-by
tor is stationary.
recorded
value
and
During traction
the
direction/activation
switches are off.
Re-start procedure:
Make a traction or hydraulic request.
INCORRECT
START
FORW + BACK
ENCODER ERROR
VDC OFF
SHORTED
WRONG SLAVE
VER.
CALL
SERVICE
Incorrect
quences.
starting
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
Start up
Stand-by
During traction
Re-start procedure:
Make a traction request.
CALL
SERVICE
MC open, EB activated,
Problem in reading the
traction/pump station- During traction
encoder.
ary.
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
MC open, EB activated,
A condition of overvoltage
Stand-by
traction/pump stationhas been detected.
During traction
ary.
Re-start procedure:
Make a valve or traction or hydraulic request.
15
programmer
message
TILLER MISMATCH
message
sicos
CALL
SERVICE
description
effect
SERVICE
state of the truck
Start up
Stand-by
During traction
Re-start procedure:
Make a traction request.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
Start up
Stand-by
During traction
Re-start procedure:
Make a traction request.
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
EEPROM KO
PARAM RESTORE
CALL
SERVICE
it is impossible to
recover the data from the No effect.
memory.
Start up
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
Partial/complete
parameter reset has been
No effect.
performed since the last
shutdown.
Start up
Re-start procedure:
Make a traction or hydraulic request.
WRONG RAM
MEM.
16
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
SERVICE
programmer
message
STALL ROTOR
message
sicos
CALL
SERVICE
description
The traction
blocked.
rotor
effect
Start up
is The traction/pump is
Stand-by
stationary.
During traction
Re-start procedure:
Re-start up of the key.
WAITING SLAVE
HARDWARE
FAULT
CALL
SERVICE
MC open, EB activated,
No activation message
traction/pump station- Start up
from the Slave.
ary.
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
The drivers fail to switch MC not closed, EB acoff with the Watchdog sig- tivated, traction/pump Start up
nal in an alarm state.
stationary.
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
There is a discrepancy
Start up
between Master and The traction/pump is
Stand-by
Slave on the accelerator stationary.
During traction
signal.
Re-start procedure:
Re-start up of the key.
PEV NOT OK
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
None.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic or valve request.
VKEY OFF
SHORTED
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
17
programmer
message
FLASH
CHECKSUM
MC COIL SHOR.
message
sicos
CALL
SERVICE
description
effect
SERVICE
state of the truck
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
WAITING FOR
NODE
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
TILLER OPEN
OUTPUT
MISMATCH
WD SYNCRO
NO SLAVE
ENABLE
18
CALL
SERVICE
Stand-by
Re-start procedure:
Make a traction or hydraulic or valve request.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
MC open, EB activated,
No activation message
traction/pump station- During traction
from the Slave.
ary.
Re-start procedure:
Re-start up of the key.
SERVICE
programmer
message
DIR SEL OUT
RANG
POWER MOS
SHORT
COIL SHOR. EB
message
sicos
CALL
SERVICE
description
effect
Start up
The selected direction sig- Traction/pump station Stand-by
nal is outside the limits.
ary.
During traction
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
Current Gain
CALL
SERVICE
Re-start procedure:
None.
Analog input
CALL
SERVICE
MC open, EB activated,
The analogue channel traction/pump station- Start up
reading is not up-to-date. ary.
During traction
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
TILLER ERROR
Tiller failure.
Re-start procedure:
Re-synchronisation of the system:
release all requests (traction and hydraulic)
make a traction or hydraulic request or both.
19
programmer
message
INPUT MISMATCH
PARAM
TRANSFER
SP MISMATCH
Throttle prog.
Iq mismatched
20
message
sicos
CALL
SERVICE
description
effect
SERVICE
state of the truck
Re-start procedure:
Make an EVP request.
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
Re-start procedure:
Re-start up of the key.
CALL
SERVICE
During traction
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
SERVICE
programmer
message
DATA
ACQUISITION
message
sicos
CALL
SERVICE
description
effect
Stand-by
Re-start procedure:
Make a traction request.
NO CAN MSG.
CHECK UP
NEEDED
THERMIC SENS.
KO
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic or valve request.
CALL
SERVICE
Start up
it is time to carry out Traction is reduced or
Stand-by
maintenance work.
stationary.
During traction
Re-start procedure:
Switch the key back on, after performing maintenance.
CALL
SERVICE
Re-start procedure:
None.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
Wrong zero
Field orient. KO
aux driv.shrt.
CALL
SERVICE
The motor phase voltage MC not closed, EB acfeedback is outside the tivated, traction/pump Start up
permissible limits.
stationary.
Re-start procedure:
Make a traction or hydraulic request.
CALL
SERVICE
The error between the ld MC not closed, EB acset point and the estimat- tivated, traction/pump During traction
ed ld is outside the limits. stationary.
Re-start procedure:
Make a traction or hydraulic or valve request.
CALL
SERVICE
Re-start procedure:
Make a traction or hydraulic request.
21
SERVICE
breakdown search
Watchdog
This alarm could be caused by a malfunctioning of the
Cause:
canbus shutting off Master-Slave communication.
This is a safety test. it is a self-diagnosis test within the
logic between the Master and Slave micro-controllers.
Eeprom ko
Logic failure #3
Logic failure #2
Logic failure #1
Cause:
This alarm appears when the control device detects over
or under voltage conditions. The overvoltage threshold is
45V, the undervoltage threshold is 9V on the 24V control
device. On the 48V control device, the overvoltage threshold is 65V and the undervoltage threshold is 11V.
22
SERVICE
ALARM
breakdown search
Vmn low
Vmn high
Cause 1:
Before switching on the LC, the software checks the power
bridge: it turns on the bottom side power MOSFETs alternately and waits until the phase voltage decreases down
to -BATT. If the voltage of the phases is under 10% of the
nominal voltage of the battery, this alarm appears.
Cause 2:
This alarm may appear even once the start-up diagnosis
has been passed and therefore the LC has closed. In
this situation, the phase voltage should be less than 1/2
Vbatt. Should it exceed this value, an error status would
appear.
Contactor closed
Cause:
Before activating the MC coil, the control device verifies
Please check the LC power contacts and replace it if
whether the contactor is blocked. The control device acnecessary.
tivates the bridge for a few tens of milliseconds, trying to
discharge the bank of capacitors If the capacitor voltage
fails to decrease by 20% of the key voltage, an alarm is
generated.
Contactor open
Stby I high
23
ALARM
SERVICE
breakdown search
Capacitor charge
The charging capacitor diagram is shown below:
Cause:
When the key is turned on, the inverter tries to charge
the power capacitors through a series of PTC and the
power resistance and it checks whether the capacitors
have charged within a short time frame. If the measured
capacitor voltage is less than 20% of the nominal voltage
of the battery, an alarm is signalled; the main contactor is
not closed.
Th. protection
Motor temperat.
Check the heat sensor inside the motor (look for MOTOR TEMPERATURE in the TESTER menu); check the
Cause:
value in ohms of the sensor and the sensor cabling. If
This warning appears when the temperature sensor is the sensor is OK, boost the motor cooling. If the warning
open (if digital) or it has exceeded the 150C threshold is present when the motor is cold, then the problem is
(if analog).
located inside the control device.
Battery low
Driver shorted
Cause:
The driver of the main contactor coil has shorted.
24
SERVICE
ALARM
troubleshooting
Contactor driver
This kind of failure is not connected to external compoCause:
nents; replace the ACE2 logic board.
The MC coil driver is not capable of carrying the load. The
device or its pilot circuit is damaged.
Vacc not ok
Cause:
The test has been performed with the key activated and
immediately after both drive requests have been deactivated. This alarm appears if the ACCELERATOR reading
in the TESTER menu is 1.0V over the min. PROGRAM
VACC acquisition when the throttle is released.
Incorrect start
Cause:
It is a warning for an incorrect start sequence.
Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the
alarm persists, check the mechanical calibration and
the operation of the potentiometer. If the alarm is not
deactivated, the fault is in the ACE logic board, therefore
proceed with replacement.
The possible causes of this alarm are (see the TESTER
items to make troubleshooting easier):
Active drive request with key activated
Active man on board sensor with key activated.
Check the wiring. Check the microswitches. It could also
be an issue of an incorrect error sequence performed by
the operator. a fault in the logic board is another possibility; therefore, after checking all the above conditions and
finding nothing, replace the ACE logic board.
Forw+back
Check the wiring of the inputs of the Fwd and Rev drive
requests (see the TESTER items to make troubleshooting easier). Check for any faults with the microswitches.
Cause:
a fault in the logic board is another possibility. Therefore,
This alarm appears when both the (Fwd and Bwd) motion after checking that the drive request switches work
requests are active at the same time.
properly and the wiring is correct, the ACE-2 logic board
needs replacing.
Encoder error
Cause:
This fault is signalled under the following conditions: the
frequency supplied to the motor is greater than 40 Hz and
the encoder's feedback signal shows leaps of more than
40 Hz in just a few tens of mSec. This behaviour is linked
to an encoder malfunction.
25
ALARM
SERVICE
troubleshooting
it is very likely that the fault is due to overvoltage, therefore you should check:
The connection of the electrical cables to the battery
terminal, positive and negative, to MC and to the control device +Batt and Batt, which must be tightened
Cause:
to a torque of between 13Nm and 15Nm.
This fault is displayed when the control device detects
If no voltage transient is detected on the line +B and
a low logic level of the VDC-off signal during start-up
the alarm is present every time the key is switched
diagnosis.
on, then the fault probably lies with the hardware
of the control device and so the logic board needs
replacing.
Tiller mismatch
26
SERVICE
ALARM
Init vmn high
Cause:
Before switching on the LC, the software checks the voltage of the power bridge without activating it. The software
expects the voltage to have a stationary state value. If
this value is too high, this alarm appears.
troubleshooting
Check:
The internal motor connections
The motor power cable connections
Motor loss to the truck frame
If the motor connections are OK, the problem lies
within the control device.
Check:
The internal motor connections (ohm continuity)
Cause:
The motor power cable connections
Before switching on the LC, the software checks the volt Motor loss to the truck frame
age of the power bridge without activating it. The software
If the motor connections are OK, the problem lies
expects the voltage to have a stationary state value. If
within the control device.
this value is too low, this alarm appears.
Eeprom ko
Cause:
The control device cannot access the memory.
This kind of failure is not connected to external components; replace the ACE2 logic board.
Param restore
Stall rotor
Waiting slave
Try switching the key off and back on again. If the alarm
Cause:
still remains, replace the ACE2 logic board.
When switching on, there is no activation message from
Slave C to Master C.
Hardware fault
27
ALARM
SERVICE
troubleshooting
Check the ohm value of the sensor and the wire harness assembly of the sensor. If the sensor is OK, then
the problem is in the ACE logic board, proceed with
replacement.
Pev not ok
Cause:
The PEV connector (CNA#17) is not connected to the Check the connector A17.
battery or the voltage is different. The traction is stationary if AUXOUT is used for electrical braking and PEV is
indispensable (AUX OUT FUNCTION = PRESENT).
"Flash checksum"
The problem is in the flash memory of the microcontroller that could be damaged or in the program saved in
Cause:
it that could be corrupted. Try reprogramming the logic,
After switching on the key, the software checks the integrity
if the alarm is still signalled, then the problem is in the
of the program saved in the flash memory. If the outcome
microcontroller. Replace the ACE logic board.
of the test is negative, this alarm is generated.
MC coil shor.
28
SERVICE
ALARM
troubleshooting
Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the alarm
persists, check the mechanical calibration and the operation of the potentiometer. If the alarm remains, the fault
is in the ACE logic board, proceed with replacement.
Tiller open
Cause:
The warning disappears with the next drive request.
This warning appears when the tiller is released, after a set
stand-by time (30 seconds) the main contactor opens.
Output mismatch
Cause:
This is a fault inside the control device, it is necessary
This is a safety test. The Slave C checks the command to proceed with replacement.
output data of the motor of the Master C and finds a
discrepancy.
Wd syncro
This is a fault inside the control device, it is necessary
Cause:
to proceed with replacement.
The Watchdog signal is not received by the Slave's microcontroller.
No slave enable
Try switching the key off and back on again. If the alarm
Cause:
still remains, replace the ACE2 logic board.
There is no activation message from the Slave C to the
Master C while the control device is in operation.
29
ALARM
SERVICE
troubleshooting
Current gain
Request the assistance of a Zapi technician to carry out
Cause:
the correct adjustment procedure for the current gain
The maximum current gain parameters contain default
parameters.
values, which means that the maximum current adjustment
procedure has not yet been performed.
Analog input
Cause:
This alarm appears when the A/D conversion of the analog
If the problem persists, the ACE logic board needs
inputs gives a frozen value, on all the converted signals,
replacing.
for longer than 400msec. The aim of this diagnosis is to
find a fault in the A//D converter or a problem in the stream
of codes that omits resetting the conversion of the analog
signal.
Tiller error
Input mismatch
This is a fault inside the control device, proceed with
Cause:
replacement.
The Slave C has different values to the inputs from the
Master C.
Param transfer
This is a fault inside the control device, proceed with
Cause:
replacement.
The Master cannot transfer the list of parameters to the
Slave.
30
SERVICE
ALARM
troubleshooting
Sp mismatch
This is a fault inside the control device, proceed with
Cause:
replacement.
This is a safety test. The Master C has detected an incorrect set point of the Slave C.
Throttle prog.
Acquire the maximum and minimum value of the potentiometer via the PROGRAM VACC function. If the
alarm persists, check the mechanical calibration and
Cause:
the operation of the potentiometer. If the alarm is not
One of the potentiometers has not been programmed
deactivated, the fault is in the ACE logic board, therefore
correctly.
proceed with replacement.
Iq mismatched
Request the assistance of a Zapi technician to carry out
Cause:
the correct adjustment of the motor parameters.
The error between the lq set point and the estimated lq is
outside the limits.
Aux driv.open
This kind of failure is not connected to external compoCause:
nents; replace the ACE2 logic board.
The EB/AUX coil driver is not capable of carrying the load.
The device or its pilot circuit is damaged.
Data acquisition
Cause:
Acquisition of current gains.
No can msg.
This type of failure is not connected to external compoCause:
nents, so when it persists the ACE logic board needs
This fault is signalled when there is no communication with
replacing.
the supervisor uC.
Check up needed
Cause:
it is sufficient to take the CHECK UP DONE option onto
It is only a warning reminding you to call scheduled main- level ON after maintenance has been performed.
tenance.
Thermic sensor ko
This kind of failure is not connected to external compoCause:
nents; replace the control device.
The control device heat sensor output is outside the limits.
31
ALARM
SERVICE
troubleshooting
Wrong zero
It is recommended to check:
The internal motor connections (ohm continuity)
Cause:
The motor power cable connections
On start up, the high resolution VMN feedback does not Motor loss to the truck frame
come within the range of permissible values around 2.5V. If the motor connections are OK, the problem lies
The circuit is damaged in the control device.
within the control device, so replace it.
Field orient ko
Request the assistance of a Zapi technician to carry out
Cause:
the correct adjustment of the motor parameters.
The error between the ld set point and the estimated ld is
outside the limits.
32