SERVICE Section: DIAGNOSTIC

DIAGNOSTICS
D DIAGNOSTICS ......................................................................... 68

D DESCRIPTION OF AC2 INVERTER ALARMS -

DRIVE CONTROL .................................................................... 68

D DESCRIPTION OF AC2 INVERTER ALARMS -

PUMP CONTROL .................................................................... 72

D DESCRIPTION OF CAN I/O ALARMS ...................................... 74

D DESCRIPTION OF MHYRIO ALARMS ..................................... 76

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 Section: DIAGNOSTIC SERVICE

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 “Programming”).

1.1 ALARMS

The controllers store the last 5 alarm events in their memory, recording the relative identification code, the
number of times that the same alarm has been activated and the temperature 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 submenu contained in the
MAIN MENU.

2.0 DESCRIPTION OF AC2 INVERTER ALARMS - DRIVE CONTROL

DIAGNOSTIC

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.

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.

LOGIC FAILURE #1: This alarm signals the intervention of an undervoltage/overvoltage protec-
tion. There are two possible causes:
a) A real undervoltage/overvoltage event has occurred; in which case turn
the keyswitch off and then on again.

b) Fault in the hardware section of the logic board that controls overvoltage
protection - replace the controller.

LOGIC FAILURE #2: Fault in the hardware section of the logic board that controls the feedback
of the phase voltages.
Replace the controller

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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 operator presence sensor or the start sensor - Replace the
sensor
b) Operator error in carrying out the starting sequence - Carry out the
correct starting sequence.
c) Incorrect wiring - make sure wiring is connected correctly
d) If the fault persists - replace the controller

FORW + BACK: The test performed continuously. An alarm is signalled whenever a two drive
requests are made simultaneously. Possible causes:
a) Faulty wiring - make sure wiring is connected correctly
b) Check the travel direction sensors - if faulty, replace the sensor
c) Drive request operation incorrect - Repeat the drive request operations
in the correct sequence
e) If the fault persists - replace the controller

HANDBRAKE: The truck fails to start because the contact of the parking brake pushbutton
is open. Possible causes:
a) The parking brake is on - release it
b) Parking brake pushbutton short circuited - replace the pushbutton
c) Operator error - Release the parking brake in correct manner

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 the controller
b) There is a fault in the charging circuit - replace the controller
c) There is a problem in the power module - replace the controller

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 Section: DIAGNOSTIC SERVICE

VMN LOW (24V): This test is performed during the initial diagnostic procedure and in standby.
VMN HIGH (48V) In these conditions, due to the two grid-bias resistors and that all the Mosfets
of the bridge are 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 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 in the motor connections or in the motor power
circuits; check that the three phase are connected correctly; heck for
any dispersion of motor current to earth;
b) Fault in the inverter - replace the controller

STBY I HIGH: Test performed in standby condition. It checks that the current is 0. If the
current is 0, the Hall effect sensor will produce a voltage of 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 unit - replace the controller

MAIN CONTACTOR ALARMS

COIL SHORTED: This driver can take1.5A continuously and is protected against short cir-
cuit.
When the keyswitch is closed, the microprocessor checks the driver of
the main contactor and the protection circuit comprised of the flip flop FF.
DIAGNOSTIC

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. 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 con-
tactor coil is correct. If not, replace the controller.

DRIVER SHORTED: When the keyswitch is closed, the microprocessor checks that the coil of
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 the voltage on the driver 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 unit, but the contactor is not
closed. There are two possible reasons:
a) The coil connections are interrupted or poorly connected -
Make the connections correctly
b) The contacts of the contactor do not work 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) Fault in the logic unit - replace the controller

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 out-
put of 2.73V at 0°C and 3.73V at 100°C; if this output 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 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 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 - re-
place 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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 Section: DIAGNOSTIC SERVICE

3.0 DESCRIPTION OF AC2 INVERTER ALARMS - PUMP CONTROL

WATCH DOG: The test is performed in both running and standby condition. It is an inter-
nal self-diagnostic test of the logic.
If the alarm persists - replace the controller.

EEPROM KO: Fault in memory area where the configured parameters are stored; this
alarm inhibits operation of the truck.
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.

LOGIC FAILURE #1: This alarm signals the intervention of an undervoltage/overvoltage protec-
tion. There are two possible causes:
a) A real undervoltage/overvoltage event has occurred; turn the keyswitch
off and then on again.
b) Fault in the hardware section of the logic board that controls overvoltage
protection - replace the controller

LOGIC 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:
DIAGNOSTIC

a) Fault in the pump start microswitch - identify the faulty joystick and
replace it.
b) Operator error in carrying out the starting sequence - Carry out the
correct starting sequence.
c) Incorrect wiring - make sure wiring is connected correctly
d) If the fault persists - replace the controller

CAPACITOR CHARGE: When the keyswitch is closed, the inverter attempts to charge the capaci-
tors 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 the controller
b) There is a fault in the charging circuit - replace the controller
c) There is a problem in the power module - replace the controller

VMN LOW (24V): This test is performed during the initial diagnostic procedure and in standby.
VMN HIGH (48V) Possible causes :
a) There is a problem in the motor connections or in the 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 inverter - replace the controller

STBY I HIGH: Test performed in standby. Checks that the current is 0. If not, the resulting
alarm inhibits operation of the truck.
Possible causes:
a) fault in the current sensor- replace the controller
b) Fault in the logic unit - replace the 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 micro-
processor, this alarm is signalled - replace the 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 sig-
nalled - 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) Fault in the logic unit - replace the controller

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 out-
put of 2.73V at 0°C and 3.73V at 100°C; if this output 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 per-
mitted range..
When this alarm is signalled, and the controller temperature does not cor-
respond - 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 ..............:
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 charging station.

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 Section: DIAGNOSTIC SERVICE
4.0 DESCRIPTION OF CAN I/O ALARMS
VACC NOT OK: Throttle high in standby without enabling signal from start microswitch or
accelerator incorrectly programmed
a) Program the potentiometer from the “Program Vacc” option of the “Main
Menu”.
b) Replace the potentiometer if circuit is interrupted

PEDAL WIRE KO: Drive potentiometer above maximum programmed value.

Check the wiring connections; if OK, replace the 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 incor-
rectly programmed
a) Program the potentiometer
b) Replace the joystick

POT #4 NOT OK: Translation potentiometer high in standby without enabling signal or incor-
rectly programmed
a) Program the potentiometer
b) Replace the joystick

CAN BUS KO TR: The periodic messages from the drive control have not arrived before
timeout
DIAGNOSTIC

a) Look for the alarm on the drive control inverter

b) Check the CAN BUS connections

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 inverter
b) Check the CAN BUS connections

CAN BUS KO VALVE: The periodic messages from the Mhyrio have not been received before
timeout
a) Look for the alarm on the Mhyrio module
b) Check the CAN BUS connections of the Mhyrio module

CAN BUS KO JOY: The multifunction joystick does not send its periodic messages before
timeout
a) Check the joystick connections and re-make correctly if necessary
b) If the fault persists - replace the 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 and re-make them if necessary
b) Check for alarms on the EPS 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 the truck serviced.
To reset the alarm, set the CHECK UP DONE parameter in Set Model to
ON and reset the keyswitch.

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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 in-
serted. Lifting is inhibited, but the retractable carriage and slow drive func-
tions remain operational so that the truck can be driven back to the charg-
ing station.
Alternatively the battery position sensor may be incorrectly adjusted or 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 simul-
taneously.

INCORRECT START: Active drive and/or pump request on power up.i.e. request made before
activation of the operator present button. Repeat the correct power up se-
quence main switch, keyswitch, operator present pushbutton, drive re-
quest)

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 truck in motion buzzer - replace the controller
b) Horn - replace the controller

EMERGENCY: Emergency pushbutton pressed (an input of the CANIO)

when the keyswitch was turned on. Reset the emergency pushbutton

NOTES:

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 Section: DIAGNOSTIC SERVICE

5.0 DESCRIPTION OF MHYRIO ALARMS

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, remem-
ber 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 con-
troller.

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 - re-
place the controller

FF VALVES: Flip flop circuit that signals that the driver of the ON/OFF valves is disa-
bled. 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 down solenoid valve EV1 (pin
3 CNB) is open when it should be closed. Replace the controller

DRIVER EPV GR1: The MOS that pilots the positive of the forks up solenoid valve EV2 (pin 10
CNG) is open when it should be closed. Replace the controller.
DIAGNOSTIC

DRIVER EPV GR2: The MOS that pilots the positive of the carriage translation solenoid valves
EV3-4 (pins 11-16 CNG) is open when it 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 12-
15 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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SERVICE Section: DIAGNOSTIC

NOTES:

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