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Batteries
1 Alarm codes
This chapter explains the meaning of the various alarms that the different controllers may produce. Refer to Chapter 2 for information on using the console and accessing the Alarms submenu.
1.1 Traction motor controller (Combi Ac1) Mode:2
Before you start to troubleshoot, make sure all power supplies, fuses and connections are in order.
The fault diagnostic system of controller is divided into two main groups:
Alarms: These are the faults which open the power bridge and when possible also the main contactor is opened and magnetic brake is activated. Failures in the motor, controller or in the safety functions cause alarms.
Warnings: These are faults which not stop the truck or stop the truck by using regeneration braking. Controller is working well, but it has detected conditions to reduce the performances or to stop the truck without opening the power devices. Wrong operation sequences or conditions which needs performance reduction, like high temperatures etc. cause warnings.
“Stored” text means that alarm or warning is stored in the controller logbook.
Code: Console and display description:
0 NONE No alarms
8 WATCHDOG (Alarm) Stored
This is a safety related test. It is a self diagnosis test within the logic between Master and Slave microcontrollers.
If fault persist replace the Combiac1 controller.
13 EEPROM KO (Warning) Stored
It’s due to a hardware or software defect of the non-volatile embedded memory supporting the controller parameters. This alarm does not inhibit the truck operations, but the truck will work with the default values.
Try to execute a CLEAR EEPROM operation. Switch the key off and on to check the result. If the alarm occurs permanently, it is necessary to replace the Combiac1 controller. If the alarm disappears, the previously stored parameters will have been replaced by the default.
17 LOGIC FAILURE #3 (Alarm) Stored
It’s due to a hardware problem in the logic card circuit for high current protection.
18 LOGIC FAILURE #2 (Alarm) Stored
It’s due to a fault in the logic board which manages the phase’s voltage feedback.
19 LOGIC FAILURE #1 (Alarm) Stored
This fault is displayed when the controller detects an overvoltage or undervoltage condition. Overvoltage threshold is 45V; undervoltage threshold is 9V in the 24V controller.
If fault displayed at startup or in standby; in this case it is due to an undervoltage, so it is important to check following:
a) Key input signal down going pulses (below undervoltage threshold) due external loads, like DC/DC converters starting up, relays or contactors energizing/ denergizing.
b) If no voltage transient is detected on the supply line and the alarm is present every time the key is switched ON, the fault is in the Combiac1 controller.
If fault is displayed during motor driving; in this case due to an undervoltage or an overvoltage condition.
a) If the alarm happens during traction acceleration or driving hydraulic functions, the fault is an undervoltage condition; check battery charge level and power cable connections.
b) If the alarm happens during release braking, the fault is an overvoltage condition; check line contactor tips and battery power cable connections.
30 VMN LOW (Alarm) Stored
Cause 1: startup test. Before switching the main contactor on, the software checks the power bridge; it turns on alternatingly the high side power mosfets and expects the phase’s voltage to increase toward the rail capacitor value. If the phase’s voltage does not increase, this alarm occurs.
Cause 2: motor running test. When the motor is running, power bridge is on, the motor voltage feedback is tested; if it is lower than commanded value, this alarm occurs. a) If the alarm happens during startup (the main contactor does not close at all), check following: - motor internal connections (ohmic continuity) - motor power connections - motor leakage to truck frame - if the motor connections are OK, the fault is in the Combiac1 controller.
b) If the alarm happens during motor running, check following: - motor connections - if motor phases windings/cables have leakages towards truck frame - that the main contactor closes properly, with a good contact - if no faults are found, the fault is in the Combiac1 controller.
