BYD PMW20 - Page 63

PMW20
125
PMW20
124
SM-PMW202020001-EN
SM-PMW202020001-EN
02A54 LOGIC FAILURE#1
It is a fault caused by low-voltage or over-voltage protection. Under a 24V system, the controller
de-tects that the voltage is over 45V or below 9V; while under a 45V system, it is over 65V or
below 11V.
Possible causes:
1. Check whether a short circuit appears in the circuit system, such as DC-DC, brake coil, or check
whether the input power of the controller is connected well.
2. Check whether the battery voltage is too low or too high.
3. Detect B+ and B, and check whether the power cable over the binding post of the master
contactor is tightened well.
4. Check whether calibration parameters of controller voltage are consistent with those of actual
voltage.
5.For the hardware circuit fault with overvoltage protection on the logic card, replace the controller.
02A55 LOGIC FAILURE#2
For it is a fault on the phase-voltage feedback hardware circuit of the logic card, replace the
controller.
TILLER ERROR
Replace the controller.
02A65 MOTOR TEMPERAT
1.The fault appears when the temperature digital switch of the motor turns on or when the analog
sig-nal exceeds the switch-off value.
2.When the temperature of the motor reaches 120℃, the controller will alarm. By this time, the
forklift still can move, but the maximum current is cut and the performance of the forklift is reduced.
When the temperature of the motor reaches 125℃, the motor stalls working where it should be
cooled down.
3.If the fault still exists when the motor cools down, check the circuit. If necessary, replace the con-
troller.
The output signal of temperature sensor of the controller exceeds what is allowed.
Check the value of the sensor and the connection of cables. Otherwise, it should be blamed for
the inside of the controller.
NO CAN MSG
It is a fault about CAN communication between the steering and traction.
Check the setting of CAN connection and the software, and version information.
02A68
SMARTDRIVER KO
Check whether there is a short circuit between the high-end driver of the electromagnetic brake
(CNB#1) and B-.
Otherwise, the internal drive model may be damaged.
If a controller connected to another controller can’t communicate smoothly under the CAN commu-
nication network, it will be always in a waiting state until all the CAN communication network works
smoothly. Find out the reason why those model connection can’t communicate smoothly, and
check whether the version of the software or set of parameters is correct.
02A70 ENCODER ERROR
Check the encoder of the motor.
02A71 EEPROM KO
If a fault is found in the storage area of parameters, the forklift will stop moving. If the fault still
exists after the electric lock is closed repeatedly, the logic card shall be replaced. If the fault
disappears, parameters stored previously will be replaced by wrong ones and thereby being reset.
CAPACITOR
CHARGE
THERMIC SENS. KO
HIGH TEMPERATURE
TH. PROTECTION
SENS MOT TE
WAITING FOR NODE
When the electric lock is turned on, the controller will charge the capacitance through a power
resistor and detect whether the capacitance is overcharged in the regulated time.
If the capacitance is in insufficient power and voltage thereof is still 20% lower than that of the
battery, the controller will alarm and thereby the master contactor will not closed down.
Possible causes:
1、If peripheral devices such as DC-DC and motor, or other devices interfere with the charging of
the controller, interference on these devices should be eliminated.
2、If the charging resistance disconnects and faults are found in the charging circuit and power
models, the controller should be replaced.
The output signal of temperature sensor of the controller exceeds what is allowed.
Since the fault is irrelevant with peripheral components, just replace the controller.
Measure the temperature of the controller board.
Drop the temperature of the controller below 85°. If the fault still exists, it may be blamed for the
temperature sensor or the logic board of the controller itself. Replace the controller at this time.
02A72 VMN LOW
Causes: when starting, the high-end voltage of MOS transistor is 66% lower than that of the
capacitance or it is lower than what is required during the operation of the motor.
Possible causes:
1. The connection or circuit of the motor is incorrect; check the threephase connection of the motor
is correct; check whether there is electric leakage in the motor connecting to the ground or the coil
of the motor disconnects.
2. Check whether the suction of the master contactor is firm and whether the contact is worn.
3. Replace the controller.
02A74
sens-Motor temn ko02A73
Check wire harness of the temperature sensor of the motor.
DRIVER SHORTED
02A75
CONTACTOR CLOSED
CONTACTOR CLOSED
02A76
1.Check whether the output and load of the controller are too high.
2.Replace the controller.
COIL SHOR EV
If there is a fault in a coil driven by PEV, check whether the connection between the coil driven by
PEV and the coil itself is good.
Check whether a short circuit appears in the coils of the master contactor and oil pump contactor.
02A77
coil shorted
1. The coil of the master contactor disconnects.
2. The master contactor is broken.
02A78 VACC NOT OK
Detecting time: the standby state
The alarm displays that the voltage of the accelerator is at least 1V higher than the minimum value
set in the accelerator sinal(PROGRAM VACC).
Possible causes:
1. The upper and lower voltage limits of the accelerator are not collected. Enter the
PROGRAM VACC menu and Recollect again.
2. Error occurs in the accelerator wherein its pedal doesn’t return, or error occurs inside the
accelerator.
3. A fault occurs in the controller.
In the starting phase, a fault will appear when the controller detects that a low logic level signal
is found in disconnecting the key switch.
Fault analysis: it is likely that the voltage is too low.
Recommend to check the following items:
-The key switch is based on external load. (For example, DC-DC converter starts, and the input
signal of the relay or contactor is lower than starting voltage.)
-Check the connection among the power cable and positive and negative terminals of battery, and
that among the power cable and –BATT and +BATT of the master contactor and controller. Use
screws to con-nect with a torque range of 13NM÷15NM.
-Voltage drop will be detected on the power supply cable when the key switch is turned ON every
time.
Fault signal: The fault may occur in the hardware of the controller and thereby it is necessary to
replace the controller.
Replace the controller
When the electric lock is closed down, microcontroller will detect whether a short circuit appears in
the driver of the main contactor. If any, it will alarm. Check whether a short circuit appears when
the positive pole of the main contactor coil connects to A16 or the negative pole of power supply .
If the outer part is normal, replace the controller.
Check whether a short circuit appears in the coil output by the controller. If any, replace the
controller.
Check whether the connection between B1 and B5 is correct. If yes, replace the controller.
AUX BATT. SHORT.
DRV. SHOR. EV
CONT. DRV. EV
KEY OFF SHORTED
COIL SHOR MC-EB
COIL SHORTED
Check whether a short circuit appears between the low-end of EV1/EV2/EV3 and B-.
If yes, replace the controller.
Before closing down the coil of the master contactor, the controller detects whether contacts of the
master contactor adhere at first. Try to discharge the capacitor. If the capacitor voltage reduces the
battery voltage by 20%, a fault may occur. Recommend to check whether contacts of the contactor
adhere or to replace the controller.
02A67
02A60
02A61
02A62
02A64
02A56
PUMP I NO ZERO
Replace the controller.
FORW+BACK02A80
The controller will always detect and alarm when requests from two directions
run signals at the same time.
Possible causes are as follows:
1. The wire is broken.
2. A fault appears in the direction switch.
3. The operation is improper.
4. If a fault cannot be eliminated, the controller shall be replaced.