Wa0025.

ELFA2 ®
First aid
Failure description and remedial action
Last edition: 15 Nov 2013

First edition: 14.10.1999
Table of Contents
List of Tables and Figures .................................................................................................... 5
Introduction ............................................................................................................................ 6
Failure description and remedial action .............................................................................. 7
1. General failures (DICO / Inverter) ...........................................................................................7
1 ms_overflow (EID 79) ............................................................................................................................ 7
10 ms_overflow (EID 80) .......................................................................................................................... 7
100 ms_overflow (EID 81) ........................................................................................................................ 7
Watchdog (EID 48).................................................................................................................................... 7
FlashChecksum (EID 51) .......................................................................................................................... 8
RAM int (EID 53) ....................................................................................................................................... 8
RAM ext (EID 54) ...................................................................................................................................... 8
ALU (EID 68) ............................................................................................................................................ 8
Ignition off (EID 65) ................................................................................................................................... 9
Error_Buffer (EID 69) .............................................................................................................................. 10
Checksum_Para (EID 71)........................................................................................................................ 11
EEPROM_HW (EID 72) .......................................................................................................................... 12
EEPROM_Read (EID 73) ........................................................................................................................ 13
EEPROM_Write (EID 74) ........................................................................................................................ 13
EEPROM_not_ready (EID 75) ................................................................................................................. 14
EEPROM_Book_Err (EID 76) .................................................................................................................. 15
24V supply (EID 63) ................................................................................................................................ 16
2. Inverter failures CSW ............................................................................................................ 17
Mot1_Sens_Bottom (EID 1)..................................................................................................................... 17
Mot1_Sens_Top (EID 2) .......................................................................................................................... 17
Mot2_Sens_Bottom (EID 3)..................................................................................................................... 17
Mot2_Sens_Top (EID 4) .......................................................................................................................... 17
HS1_Sens_Bottom (EID 5)...................................................................................................................... 18
HS1_Sens_Top (EID 6)........................................................................................................................... 18
OverTemp Motor (EID 9) ......................................................................................................................... 19
OverTempHeatsink (EID 10) ................................................................................................................... 20
OverTemp Junction (EID 12) ................................................................................................................... 21
ExtTempSensBottom (EID 13) ................................................................................................................ 22
ExtTempSensTop (EID 14) ..................................................................................................................... 22
ExtTempSens2Bottom (EID 31) ............................................................................................................. 22
ExtTempSens2Top (EID 32) .................................................................................................................. 22
Speedsensor (EID 15) ............................................................................................................................. 23
Overrule (EID 16) .................................................................................................................................... 24
OverTemp1 MCB (EID 17) ...................................................................................................................... 25
OverTemp2 MCB (EID 18) ...................................................................................................................... 25
Mot1_SensQuiver (EID 21) .................................................................................................................... 26
Mot2_SensQuiver (EID 22) ..................................................................................................................... 26
HS1_SensQuiver (EID 23) ...................................................................................................................... 27
ExtTempSensQuiver (EID 24) ................................................................................................................. 28
ExtTempSens2Quiver (EID 25) ............................................................................................................... 28
SpeedTrackImplaus (EID 26) .................................................................................................................. 29
BR n. c. (EID 30) ..................................................................................................................................... 30
SpeedDirChange (EID 33)....................................................................................................................... 31
short Gen (EID 34) .................................................................................................................................. 32
short DCDC (EID 35) .............................................................................................................................. 33
short IBC (EID 36) ................................................................................................................................... 34
Overvolt (EID 42) .................................................................................................................................... 35
Undervolt (EID 43) .................................................................................................................................. 36
Overspeed (EID 46) ................................................................................................................................ 37
LCA config (EID 44) ................................................................................................................................ 38
LCA Err Load (EID 45) ............................................................................................................................ 38
SafeTorqDirection (EID 56) ..................................................................................................................... 39
ELFA2 first aid
SafeTorqPermit (EID 57) ......................................................................................................................... 40

Slave 1 (EID 58)...................................................................................................................................... 41
Slave 2 (EID 59)...................................................................................................................................... 41
Offset X (EID 60) ..................................................................................................................................... 42
Offset Y (EID 61) ..................................................................................................................................... 42
15V off range (SW) (EID 64) .................................................................................................................. 43
SpeedPulse (EID 78) ............................................................................................................................. 44
AC wire off (EID 82) ............................................................................................................................... 45
current sum (EID 83) ............................................................................................................................... 46
SDC (EID 84) .......................................................................................................................................... 47
SpeedTrackMissed (EID 85) .................................................................................................................. 48
SpeedTracksReversed (EID 86) .............................................................................................................. 49
IGBT I lower (EID 87) .............................................................................................................................. 50
IGBT I upper (EID 88) ............................................................................................................................. 50
IGBT II lower (EID 89) ............................................................................................................................. 50
IGBT II upper (EID 90) ............................................................................................................................ 50
IGBT III lower (EID 91) ............................................................................................................................ 50
IGBT III upper (EID 92) ........................................................................................................................... 50
IGBT IV lower (EID 93)............................................................................................................................ 50
IGBT IV upper (EID 94) ........................................................................................................................... 50
OverCurrent WR (EID 47) ....................................................................................................................... 51
Overcurrent I H (EID 95) ......................................................................................................................... 52
overcurrent II H (EID 96) ......................................................................................................................... 52
overcurrent III H (EID 97) ........................................................................................................................ 52
Overcurrent sum H (EID 99) .................................................................................................................... 53
OverCurrent IV (EID 29) .......................................................................................................................... 54
Overcurrent IV H (EID 98) ....................................................................................................................... 55
3. Inverter failures VCSW .......................................................................................................... 56
PreChg too long (EID 105) ...................................................................................................................... 56
No reset (EID 106) .................................................................................................................................. 57
LOS enabled (EID 107) ........................................................................................................................... 58
false rotation (EID 108) ........................................................................................................................... 59
BR overtemp (EID 109) ........................................................................................................................... 60
SafeRefFbDiff (EID 110) ......................................................................................................................... 61
SafeCreepage (EID 114) ......................................................................................................................... 62
CAN IBC control (EID 115) ...................................................................................................................... 63
DCAN Bus off (EID 116) .......................................................................................................................... 64
DCAN no message (EID 117).................................................................................................................. 65
false quadrant (EID 119) ......................................................................................................................... 66
DIH6 (EID 126) ....................................................................................................................................... 67
Synchronization (EID 127)...................................................................................................................... 68
DIH5 (EID 128) ....................................................................................................................................... 69
4. DICO failures ......................................................................................................................... 70
auto start (EID 131) ................................................................................................................................. 70
Injection off (EID 135) ............................................................................................................................. 71
grave AESEL (EID 132) .......................................................................................................................... 72
PreChg too long (EID 133) ...................................................................................................................... 73
Volt difference (EID 134) ........................................................................................................................ 74
Undervolt (EID 136) ................................................................................................................................ 75
SAE no reference (EID 137) .................................................................................................................... 76
SAE not toggled (EID 138) ...................................................................................................................... 76
SAE bus off (EID 139) ............................................................................................................................. 77
SAE no Msg EVCU1 (EID 141) ............................................................................................................... 78
SAE no Msg EEC1 (EID 143) .................................................................................................................. 78
SAE no Msg EEC2 (EID 144) .................................................................................................................. 78
SAE no Msg BMU (EID 145) ................................................................................................................... 78
SAE no Msg TC1 (EID 146) .................................................................................................................... 78
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SAE no Msg MsgObj7 (EID 147) ............................................................................................................. 78

DNR input (EID 152) ............................................................................................................................... 79
acc switch (EID 153) ............................................................................................................................... 80
brake switch (EID 154) ............................................................................................................................ 81
DCU creepage (EID 155) ........................................................................................................................ 82
DCU dir.motors (EID 156) ...................................................................................................................... 83
DCU DNR plaus. (EID 157) ..................................................................................................................... 84
GW DCAN bus off (EID 158) ................................................................................................................... 85
GW DCAN no message (EID 159) ........................................................................................................... 86
DCAN no Mot1Fb, DCAN no Mot2Fb, (EID 161-162) ............................................................................. 87
DCAN no Aux1Fb, (EID 165) .................................................................................................................. 87
DCAN no Gen1Fb, (EID 167) .................................................................................................................. 87
DCAN no ES_fb, DCAN no ES2_fb (EID 168-169) .................................................................................. 87
short PC (EID 175) .................................................................................................................................. 88
10V out of range (EID 176)...................................................................................................................... 89
12V out of range (EID 177)...................................................................................................................... 90
speed limit (EID 179) ............................................................................................................................... 91
F2 safetyLineLOW (EID 180) .................................................................................................................. 92
F2 DNR Outp.plaus (EID 181) ................................................................................................................. 93
F2 DNR IO-compair (EID 182)................................................................................................................. 94
F2 DNR transition (EID 183) .................................................................................................................... 95
F2 DNR clone (EID 184) ......................................................................................................................... 96
F2 /brake D M<0 (EID 185) ..................................................................................................................... 97
F2 /brake R M>0 (EID 186) ..................................................................................................................... 98
F2 /acc D M>0 (EID 187)......................................................................................................................... 99
F2 /acc R M<0 (EID 188)........................................................................................................................100
F2 pulse motors (EID 191) .....................................................................................................................101
F2 SCU not alive (EID 192) ....................................................................................................................102
VCSW safety (EID 193)..........................................................................................................................103
F2 false quadrant (EID 194) ...................................................................................................................104
F2 warn s.LineHI (EID 195) ....................................................................................................................105
F2 warn no safety (EID 196) ...................................................................................................................106
autoPara off (EID 200) ...........................................................................................................................106
autoPara parity (EID 201) .......................................................................................................................107
autoPara no finish (EID 202) ..................................................................................................................108
autoPara download (EID 203) ................................................................................................................109
autoPara upload (EID 204) .....................................................................................................................110
autoPara array (EID 205) .......................................................................................................................111
autoPara timeout (EID 206) ....................................................................................................................112
autoPara DIL code (EID 207) .................................................................................................................113
discharge IBC (EID 209) ........................................................................................................................114
MC opened (EID 210) ............................................................................................................................114
Low Insulation (EID 230) ........................................................................................................................115
VPM Voltage (EID 236) ..........................................................................................................................116
VPM not ready (EID 237) .......................................................................................................................117
VPM no trigger (EID 238) .......................................................................................................................117
VPM ignited (EID 239)............................................................................................................................118
VPM triggered (EID 240) ........................................................................................................................118
Abbreviations ..................................................................................................................... 121
Error Identification (EID) ................................................................................................... 122
Failure thresholds.............................................................................................................. 123
Appendix ............................................................................................................................ 124
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List of Tables and Figures

1 Figure 1: KTY84 sensor resistance as a function of ambient temperature; average values .............. 125
2
3
4 Table 1: temperature sensor check: pin assignment on 1FV5/1PV5 motor/generator and INV ........ 124
5 Table 2: temperature sensor check : pin assignment on 1DB PEM motor/generator and INV .......... 124
6 Table 3: PT1000 resistance as a function of ambient temperature ................................................... 124
7 Table 4: temperature sensor check: pin assignment on braking resistor and INV ............................ 124
8 Table 5: temperature sensor check: pin assignment on inductor box and INV ................................. 124
9 Table 6: speed sensor interface: pin assignment on 1FV5/1PV5 motor/generator and INV ............. 124
10 Table 7: speed sensor interface: pin assignment on 1DB PEM motor/generator and INV ................ 125
11 Table 8: inverter variable „speedSensor“ ......................................................................................... 125
12 Table 9: DICO PIN’s ........................................................................................................................ 126
13 Table 10: ELFA2 Inverter X1............................................................................................................ 127
14
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Introduction
1 The First Aid document describes the failure types and effects of the ELFA components. The
2 document is intended for trained specialists, which have experience with troubleshooting of the
3 vehicle and the ELFA system.
4
5 The document describes the following failure groups.
6  General failures which can occur in the DICO and also in the Inverter.
7  Inverter failures are split into VCSW (Vehicle Control Software) and CSW (Control Software)
8 failures.
9  DICO failures are specific failures of the DICO.
10
11 The failure description has the following structure.
12
Failure name reserved Definition:
(EID - Error ID) The definition explains the meaning of the failure.
Reaction:
 The reaction describes the system behavior if the failure is
registered in the error buffer.
Potential cause:
 Potential causes are reasons and conditions which trigger the
failure.
Remedial action:
 Remedial actions are possible actions to correct the cause for the
failure.
Acknowledge:
 Acknowledge means the reset condition of the failure. The
following reset conditions are possible.
o Reset with Key Off / Key On - The error is only reset by
restart of the vehicle.
o Automatically reset - The error is automatically reset if the
error condition isn’t present anymore.
Possible Side Effects:

 Possible side effects are additional failures as a consequence of
this failure.
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Failure description and remedial action
1. General failures (DICO / Inverter)
Definition:
Failures during operation of microcontroller system.
1 ms_overflow Failure in operating system (time slice overload).
(EID 79)
Reaction:
 DICO: pulse inhibition of drive motors.
 Inverter: pulse inhibition.
10 ms_overflow Potential cause:
(EID 80)  Failure in software or calibration.
Remedial action:
 Check software version with diagnostic tool (e.g. Siadis).
100 ms_overflow  Compare the original parameter settings with the current settings.
(EID 81) Reload original parameter settings if necessary.
 Does failure occur only sporadically?
 Reset error and contact Siemens Service, if error happens again.
Watchdog Acknowledge:
(EID 48)  Reset with Key Off / Key On.

 None
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Definition:
FlashChecksum Hardware failure on microcontroller board.
(EID 51)
Reaction:
 DICO: pulse inhibition of drive motors.
RAM int  Inverter: pulse inhibition.
(EID 53)
Potential cause:
 Hardware failure in inverter/DICO (microcontroller board).
RAM ext Remedial action:
(EID 54)  Check software version with diagnostic tool (e.g. Siadis).
 Compare the original parameter settings with the current
settings. Reload original parameter settings if necessary.
ALU  Does failure occur only sporadically?
(EID 68)  Replace inverter/DICO if failure occurs regularly after the Key-
Off / Key-On sequence.
Acknowledge:
 Reset with Key Off / Key On.

 None
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Definition:
Ignition off Short interruption of the ignition (key on).
(EID 65)
Reaction:
 Pulse inhibition.
Potential cause:
 Loose connection of ignition (key on).
Remedial action:
 Check wiring/connection of the ignition (key on).
Acknowledge:
 Automatically reset.

 None
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Definition:
Error_Buffer Read of the internal errorbuffer isn’t possible. Errorbuffer is shown as
(EID 69) empty.
Reaction:
 None
Potential cause:
 Read of EEPROM could not be performed.
Remedial action:
 Replace inverter/DICO if failure occurs regularly after the Key-
Acknowledge:

 None
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Definition:
Checksum_Para Checksum Error by reading parameter.
(EID 71)
Reaction:
 Load of Default Parameter from FLASH.
Potential cause:
 Read of EEPROM could not be performed.
Remedial action:
Acknowledge:

 EOL parameter will be lost.
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Definition:
EEPROM_HW Hardware Connection of EEPROM is defect.
(EID 72)
Reaction:
 Errors aren’t permanently saved in EEPROM.
Potential cause:
 Read/write of EEPROM could not be performed.
Remedial action:
Acknowledge:

 None
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Definition:
Transfer between EEPROM and Software is not ok.
EEPROM_Read
(EID 73) Reaction:
 Entry in Errorbuffer.
 Errors aren’t permanently saved in EEPROM.
Potential cause:
EEPROM_Write
 Read/Write to EEPROM could not be performed.
(EID 74)
Remedial action:
Acknowledge:

 None
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Definition:
EEPROM_not_ready EEPROM don’t get ready for communication.
(EID 75)
Reaction:
Potential cause:
 No Operation with EEPROM could be performed.
Remedial action:
Acknowledge:

 None
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Definition:
EEPROM_Book_Err EEPROM is reserved by another task.
(EID 76)
Reaction:
Potential cause:
 Too many EEPROM read/write orders in progress.
Remedial action:
 Check for presence of other failures in error-buffer and apply
corresponding remedial actions first if present.
 If failure remains, update Software of DICO/Inverter.
 If failure still remains, replace DICO/Inverter.
Acknowledge:

 Some errors would not appear in errorbuffer.
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Definition:
24V supply 24 V supply of the component is out of range.
(EID 63)
Reaction:
 No reaction.
Potential cause:
 24 V supply is too low.
Remedial action:
 Check 24V supply of the vehicle with a voltmeter.
Acknowledge:

 None
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2. Inverter failures CSW
Definition:
Analogue motor/generator winding temperature beyond specified
Mot1_Sens_Bottom limits (see Failure thresholds).
(EID 1)
Mot1: sensor 1 at motor/generator
Mot2: sensor 2 at motor/generator
Top: measured value exceeds limit
Bottom: measured value below limit
Mot1_Sens_Top
(EID 2) Reaction:
 Power reduction, rated-current operation.
In case of 2 sensors connected only power reduction and
rated-current operation, if error occurs on both sensors.
Mot2_Sens_Bottom
(EID 3) Potential cause:
 Unreliable connection of the signal cable X2 between inverter
and motor/generator.
 Contact or sensor problem in motor/generator or inverter.
Mot2_Sens_Top  Wrong sensor type.
(EID 4)  MotX_Sens_Bottom: Probably short circuit in sensor circuit.
 MotX_Sens_Top: Probably open wire in sensor circuit.
Remedial action:
 Check motor temperature actual values (Inv.) “T_MotSens1”
and (Inv.) “T_MotSens2”.
 Check correct state and fit of X2 connecting signal cable.
 Check correct state of connector pins on motor/generator and
inverter (X2).
 Check connector inside terminal box on motor/generator.
 Check temperature sensor in motor/generator (Table 1 /

Figure 1, Table 2 / Table 3).
 Check supply voltage for temperature sensor on inverter
connector X2 (Table 1, Table 2).
 In two motor applications, check the suspicious motor by
switching signal cables and check if error entry moves to the
other inverter.
Acknowledge:

 None
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Definition:
Analogue heat sink temperature in inverter beyond specified limits (see
HS1_Sens_Bottom Failure thresholds).
(EID 5)
Top: measured value exceed limit: short circuit possible
Bottom: measured value below limit: open circuit possible
HS1_Sens_Top Reaction:
(EID 6)  Power reduction, rated-current operation.
Potential cause:
 Sensor or connector problem in inverter.
Remedial action:
 Check heat sink temperature actual value (T_HS_sens1).
This value should show a realistic temperature
(e.g. -50°C…100°C). In case of unrealistic temperature replace
inverter.
Acknowledge:

 None
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Definition:
OverTemp Motor Winding temperature of motor/generator exceeds specified limit (INV
(EID 9) Par. 148 Mot_Tmp_EPO) despite temperature limitation (see Failure
thresholds).
Reaction:
Potential cause:
 Problem in cooling circuit.
 Wrong sensor type.
 Wrong calibration of motor temperature limitation.
Remedial action:
 Check motor temperature actual values (T_MotSens1 /
T_MotSens2).
 Check calibration of motor temperature limitation (INV Par. 148
Mot_Tmp_EPO and INV Par. 141 Mot_Tmp_Lim).
 Check cooling circuit (flow rate – pressure – air bubble).
 Check temperature sensor in motor/generator (Table 1, Table 2,
Table 3 and Figure 1).
Acknowledge:
 Has to be reset by external control unit.

 None
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Definition:
OverTempHeatsink Heat sink temperature exceeds 85 °C despite heat sink temperature
(EID 10) limitation (see Failure thresholds).
Reaction:
Potential cause:
 Wrong parameter settings.
Remedial action:
 Check heat sink temperature actual value under operation
(T_HS_sens1) and compare with the temperatures of other
inverters to establish if the problem affects only one inverter
(big temperature differences) or the whole cooling circuit (all
temperatures are high).
 Check cooling circuit: enough coolant present, cooling
pump/fans works, absence of air bubbles, and flow rate
according to specification…
 Fast temperature increase may indicate not enough
coolant present in the circuit, cooling pump not working
or air bubbles.
 Very slow temperature reduction when inverter under
low load or inactive may indicate low flow rate, cooling
pump or cooling fan not working.
 Check calibration of heatsink temperature current limitation:
 HS_Tmp_Lim (INV Par. 140) <= approx. 55°C.
 Check if gains of heat sink temperature limitation controller
are greater than zero (INV Par. 144 & 145).
Acknowledge:

 OverTemp Junction
(EID 12)
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Definition:
OverTemp Temperature of IGBT junction (transistor or diode) exceeds 145°C.
Junction Power semiconductor over temperature (see Failure thresholds).
(EID 12)
Reaction:
Potential cause:
 Wrong calibration of junction temperature limitation.
 Switching frequency reduction of the IGBT is disabled.
Remedial action:
 Check for presence of “OverTempHeatsink” (EID 10) in error-
buffer and apply corresponding remedial actions first if present.
If error appears again apply below actions.
 Check calibration of junction temperature current limitation:
 Ju_Tmp_Lim (INV Par. 142) > approx. 130 °C.
 Check if gains of junction temperature limitation controller
are greater than zero (INV Pars. 149 & 150).
 Compare parameters to original set.
Acknowledge:

 None
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Definition:
External temperature sensor at the X1 connector (braking resistor,
ExtTempSensBottom inductor box beyond specified limits (see Failure thresholds).
(EID 13)
Top: measured value exceed limit: short circuit possible.
Bottom: measured value below limit: open circuit possible.
Reaction:
ExtTempSensTop  Power reduction during braking.
(EID 14)  Power reduction DCDC.
Potential cause:
ExtTempSens2Bottom and external component.
(EID 31)  Contact or sensor problem in external component or inverter.
 Wrong parameter settings.
ExtTempSens2Top Remedial action:

(EID 32)  Check actual value of temperature external component
(T_extern).
 Check correct state of connector pins on external component
and inverter (X1).
 Check supply voltage at external component connector (see
operating instructions).
 Check external temperature sensor (PT1000 – Table 3, Table
4 and Table 5).
 Check voltage at inverter connector X1 (Table 4 and Table 5).
 In case of defect/wrong sensor in braking resistance, replace
brake resistor.
 In case of defect/wrong sensor in inductor box, replace
inductor box.
Acknowledge:

 None
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Definition:
Speedsensor Speed encoder signals at X2 connector are not plausible (speed
(EID 15) information is jumping by too many rpm).
Investigation is necessary if failure occurs regularly.
Reaction:
 None
Potential cause:
 Noise or defect on the wiring.
 Power supply problem of the encoder.
 Encoder hardware failure.
 Wrong calibration.
Remedial action:
 Check motor speed actual value (n_input).
 Compare parameters to original set (INV Par. 162
n_incMaxSens).
 Check wiring (grounding, shield).
inverter (X2).
 Check supply voltage of encoder at the X2 connector side
(Table 6 and Table 7).
 Contact Siemens Service, if error happens again.
Acknowledge:

 None
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Definition:
Overrule Indication that the overrule function is activated by user.
(EID 16)
Reaction:
 Inverter can be activated without safety checks.
Potential cause:
 Activation by user.
Remedial action:
 Check, why the user used the function (latest error entries, talk
to driver).
Acknowledge:

 None
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Definition:
Internal temperature of inverter (air temperature) exceeds specified limit
OverTemp1 MCB measured on main control board (MCB) by two sensors (see Failure
(EID 17) thresholds).
Reaction:
 None
OverTemp2 MCB Potential cause:
(EID 18)  Temperature of cooling water too high (midsummer, heavy duty).
Problem in cooling circuit.
 Contact or sensor problem in inverter.
 Wrong setting of MCB temperature limit.
Remedial action:
 Check MCB temperature current value (T_MCB - this value
represents the maximum of both temperature sensors). Switch off
the system and check after cool down if the temperature is still too
high. If the temperature is too high replace the inverter.
 Check for presence of “OverTempHeatsink” (EID 10) in error-buffer
and apply corresponding remedial actions first if present.
 Check that heatsink temperature (T_HS_sens1) is higher than 55°C.
If higher check the cooling system.
 Check parameter settings of MCB temperature limitation (Par. 143
Hw_Tmp_Lim).
Acknowledge:

 None
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Definition:
Analogue motor and generator winding temperature alteration is too high
Mot1_SensQuiver (no reliable value).
(EID 21)
Mot1: sensor 1 on motor/generator
Mot2: sensor 2 on motor/generator
Reaction:
Mot2_SensQuiver  Power reduction, rated-current operation.
(EID 22) In case of 2 sensors connected only power reduction and rated-
current operation if error occurs on both sensors.
Potential cause:
 Contact or sensor problem in motor/generator or inverter.
Remedial action:
 Check motor temperature actual value (T_MotSens1,
T_MotSens2).
inverter.
 Check temperature sensor in motor/generator (Table 1, Table 2,
Table 3 and Figure 1).
 Check supply voltage for temperature sensor on inverter
connector X2 (Table 1, Table 2). In case of problem with supply
voltage for temperature sensor, replace inverter.
 In two motor applications, check the suspicious motor by
switching signal cables and check if error entry moves to the
other inverter.
Acknowledge:

 None
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ELFA2 first aid
Definition:
HS1_SensQuiver Analogue heat sink temperature alternation is too fast (no reliable value).
(EID 23)
Reaction:
 Power reduction, rated-current operation.
Potential cause:
 Sensor or connector problem inside inverter.
Remedial action:
 Check heat sink temperature actual value (T_HS_sens1), and
replace inverter if fast alternation can be observered.
Acknowledge:

 None
Page 27 of 128
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ELFA2 first aid
Definition:
External temperature sensor (braking resistor, inductor box changes
ExtTempSensQuiver too fast (no reliable value).
(EID 24)
Reaction:
 Power reduction, rated-current operation during braking.
 Power reduction, rated-current operation DCDC.
ExtTempSens2Quiver Potential cause:
(EID 25)  Unreliable X1 connection inverter and external component.
 Contact or sensor problem in external component or inverter.
Remedial action:
 Check actual value of temperature external component
(T_extern).
 Check correct state of connector pins on external component
and inverter (X1).
 Check external temperature sensor (PT1000 –Table 4 und
Table 5).
 Check supply voltage at external component connector (see
operating instructions). If supply voltage to external
component is not in correct range replace inverter.
 Check voltage at inverter connector X1 (Table 4 und Table 5).
In case of defect/wrong sensor in braking resistance, replace
sensor.
 In case of defect/wrong sensor in inductor box, replace
inductor box.
 In case of damaged connector on inverter/inductor box,
replace inverter/ inductor box.
Acknowledge:

 None
Page 28 of 128
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ELFA2 first aid
Definition:
SpeedTrackImplaus Monitored speed encoder tracks at X2 connector are not plausible.
(EID 26)
Reaction:
 Pulse inhibition
Potential cause:
Remedial action:
 Check drive inverter variable “encoderState” (Table 8)
“ySpurA”, “ySpurB” at low speeds, to consider if encoder
pulses are visible on both tracks.
 Check actual value of speed encoder (n_input).
 Check correct state of connector pins on motor and inverter
(X2).
 Change suspicious cable-connector set with correct working
cable-connector set.
 Prevent EMC problems by correct distance to high voltage
cables.
Acknowledge:
 Reset with DNR set to neutral.

 Speedsensor
(EID 15)
Page 29 of 128
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ELFA2 first aid
Definition:
BR n. c. Brake resistor is not connected or has a loose connection.
(EID 30)
Reaction:
 Deactivation of the brake resistor (pulse inhibition of the phase).
Potential cause:
 Brake resistor is not connected.
 Loose of connection to the brake resistor.
 Defect brake resistor.
 Hardware failure in inverter (current sensor, power supply).
Remedial action:
 Check connection of brake resistor to the dc-link.
 Check resistance of the brake resistor.
 Reset error and contact Siemens Service, if error happens
again.
Acknowledge:

 Overvolt
(EID 42)
 discharge IBC
(EID 209)
Page 30 of 128
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ELFA2 first aid
Implausible direction change in speed signal.

SpeedDirChange
(EID 33)
Reaction:
Potential cause:
Remedial action:
 Check actual value of speed encoder (n_input). No peaks
should be visible.
 Check correct state of connector pins on motor and inverter
(X2).
 Prevent EMC problems by correct distance to high voltage
cables.
 Change Motor/Generator
Acknowledge:
 Reset with DNR set to neutral.

 Speedsensor
(EID 15)
Page 31 of 128
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Definition:
short Gen Not allowed current flows over the diodes of the generator inverter, if the
(EID 34) inverter is off.
Reaction:
 Deactivation of the generator inverter (pulse inhibition).
 Emergency off signal to the engine.
Potential cause:
 Short-circuit of the dc-link.
Remedial action:
 Connect 24V power supply with current limitation to the DC-link
and check DC-link voltage. In case of a short-circuit disconnect
the DC-link power cables of one inverter and check the
disconnected inverter with a 24V power supply. Replace inverter
if short-circuit is measured. If no short-circuit is measured check
the next inverter in the same way. Check every inverter separate
with a 24V power supply.
 Replace inverter if short-circuit is measured.
Acknowledge:

 PreChg too long
(EID 105)
Page 32 of 128
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ELFA2 first aid
Definition:
short DCDC Not allowed current flows over the diodes of the dcdc inverter, if the
(EID 35) inverter is off.
Reaction:
 Deactivation of the dcdc inverter (pulse inhibition).
 Storage Main Contactor open request.
Potential cause:
Remedial action:

Acknowledge:

 None
Page 33 of 128
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ELFA2 first aid
Definition:
short IBC Very fast dc-link voltage reduction.
(EID 36)
Reaction:
 Deactivation of all inverters (pulse inhibition).
 Storage Main Contactor open request.
Potential cause:
Remedial action:
Acknowledge:

 None
Page 34 of 128
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ELFA2 first aid
Definition:
Overvolt Intermediate circuit voltage exceeds defined limit (INV Par. 81
(EID 42) Ubat_Max_CSW).
Reaction:
Potential cause:
This error depends on system hardware configuration:
 Hardware failure in inverter (voltage sensor).
 Wrong calibration of intermediate bus voltage limitation.
 Missing braking resistor.
 System failure which influences the bus voltage control.
Remedial action:
 Compare actual value of intermediate bus voltage of different
components (voltIBC_fbGen1, voltIBC_fbMot1, voltIBC_fbMot2).
 Check calibration of intermediate bus voltage limitation
(INV Par. 81 Ubat_Max_CSW).
 Does failure occur only under special conditions?
again.
Acknowledge:

 Overcurrent IV
(EID 29)
Page 35 of 128
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ELFA2 first aid
Definition:
Undervolt Intermediate circuit voltage falls below defined limit (INV Par. 80
(EID 43) Ubat_Min_CSW).
Reaction:
Potential cause:
This error depends on system hardware configuration:
 Hardware failure in inverter (voltage sensor).
 Wrong calibration of intermediate bus voltage limitation.
 Short-circuit in intermediate circuit.
 System failure which influences the bus voltage control.
Remedial action:
 Compare actual value of intermediate bus voltage of different
components (voltIBC_fbGen1, voltIBC_fbMot1, voltIBC_fbMot2).
 Check calibration of intermediate bus voltage limitation
(INV Par. 80 Ubat_Min_CSW).
 Check if error happened in more than one component.
 Does failure occur only sporadically? (Check documentation in
failure memory.)
 Is failure reproducible?
again.
Acknowledge:

 None
Page 36 of 128
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ELFA2 first aid
Overspeed failure of the drive motors.

Overspeed
(EID 46) Definition:
If speed exceeds the maximum permissible value n_Emerg_PowerOff
(Par. 86) the drive motor is pulse-inhibited.
Reaction:
Potential cause:
 No vehicle acceleration allowed (e.g. downhill driving).
Remedial action:
again.
Acknowledge:
 Automatically reset, if the speed is lower than limit
n_Emerg_PowerOff (Par. 86).
 The motor inverter switches on automatically, if the speed is
lower than n_startMax (Par. 425).

 Overvolt
(EID 42)
Overspeed of the generator.
Definition:
If speed exceeds the maximum permissible value n_Emerg_PowerOff
(Par. 86) an emergency stop will be sent to the engine.
Reaction:
 Emergency stop request to the engine.
Potential cause:
 Problems of the engine/generator control.
Remedial action:
again.
Acknowledge:

 Overvolt
(EID 42)
Page 37 of 128
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Definition:
Hardware failure on microcontroller board.
LCA config
(EID 44) Reaction:
Potential cause:
 Hardware failure in inverter (microcontroller board).
LCA Err Load
(EID 45) Remedial action:
 Check software version with diagnostic tool (e.g. Siadis).
settings.
Reload original parameter settings if necessary.
 Replace inverter/dico if one of these failures occurs regularly
after the Key-Off / Key-On sequence.
Acknowledge:

 None
Page 38 of 128
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ELFA2 first aid
Definition:
SafeTorqDirection Torque reference direction does not fit to the slip frequency reference.
(EID 56)
Reaction:
Potential cause:
 Wrong parameterization of the component.
Remedial action:
again.
Acknowledge:

 VCSW safety
(EID 193)
Page 39 of 128
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ELFA2 first aid
Definition:
SafeTorqPermit Torque isn’t permitted but the slip frequency reference looks like a
(EID 57) torque is demanded.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 VCSW safety
(EID 193)
Page 40 of 128
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Definition:
Failure of slave 1 or 2 when master-slave operation is active.
Slave 1
(EID 58) Reaction:
Potential cause:
 One Slave is not active.
Slave 2
 Check the Errorbuffers of the slave inverters and apply the
corresponding remedial action.
Acknowledge:

 None
Page 41 of 128
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ELFA2 first aid
Definition:
Offset failure in inverter current sensor.
Offset X Failure in current sensor or power supply ( 15 V) of drive motor or
(EID 60) generator.
X: current sensor of phases 1-3
In earlier software Y: current sensor of phase 4
versions it was Reaction:
called “Offset IR”  Pulse inhibition.
and “Offset IS”
Potential cause:
 Hardware failure in inverter (current sensor, power supply).
Remedial action:
Offset Y  Replace inverter if failure occurs regularly after the Key-Off /
(EID 61) Key-On sequence.
Acknowledge:

 None
Page 42 of 128
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Definition:
15V off range Internal 15 V supply of the inverter is out of range.
(SW)
(EID 64) Reaction:
Potential cause:
 Defect main control board (MCB) of the inverter.
Remedial action:
 Replace inverter if failure occurs regularly after the Key-Off /
Key-On sequence.
Acknowledge:

 None
Page 43 of 128
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Definition:
SpeedPulse Form of pulses from speed sensor is wrong. Phase shift between
(EID 78) encoder tracks is out of valid range.
Reaction:
Potential cause:
 Wrong parameterization of the system.
 Hardware problem of the encoder.
 Problem due to vibrations.
Remedial action:
 Change motor/generator.
again.
Acknowledge:
 Reset with DNR set to neutral

 Speedsensor
(EID 15)
 SpeedDirChange
(EID 33)
Page 44 of 128
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Definition:
AC wire off One or more motor/generator phases are not connected.
(EID 82)
Reaction:
 Drive motor inverter - Pulse inhibition, no driving torque.
 Generator inverter - Pulse inhibition, emergency off request to
the engine.
Potential cause:
 Power cable not connected inside terminal box of
inverter/motor/generator.
 Power cable broken/interrupted.
 Inverter/Motor defect.
Remedial action:
 Check the actual values of the motor/generator currents (I_R,
I_S, I_T).
 Check connections of power cable inside terminal box of inverter
(L1/L2/L3) and correct tightening torque (M10 screws = 30 Nm).
 Check connections of external power cables inside terminal box
of motor/generator (U/V/W) and correct tightening torque.
 Check connections of internal power cables inside terminal box
of motor/generator (U/V/W) and correct tightening torque.
 Check connection between cable lug and power cable.
 Check power cables between motor/generator and inverter.
Acknowledge:

 None
Page 45 of 128
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Definition:
current sum Sum of AC currents on the 3 phases to motor/generator is not zero.
(EID 83) One or more phases are making contact to Ground/the chassis.
Reaction:
Potential cause:
 Power cable or cable lug makes contact with the chassis.
 Contact with the chassis inside motor/generator.
 Contact with the chassis inside inverter.
 Cooling water leak in motor/generator.
 Unwanted/foreign material inside motor/generator.
Remedial action:
 Check the actual values of the motor/generator currents (I_R,
I_S, I_T).
 Make an isolation measurement on the suspicious component
(component isolated from ELFA system).
 Check power cables.
 Check power cables (length, state, contact with chassis) inside
terminal box of inverter.
 Check connections inside terminal box of inverter.
 Check cable lugs (state, size, contact with chassis) inside
terminal box of inverter.
 Check power cables (length, state, contact with chassis) inside
terminal box of motor/generator.
 Check connections inside terminal box of motor/generator.
 Check correct state of terminal block inside terminal box of
motor/generator.
 Check cable lugs (state, size, and contact with chassis) inside
terminal box of motor/generator.
Acknowledge:

 None
Page 46 of 128
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ELFA2 first aid
Definition:
SDC The calibration data for voltage measurement are wrong.
(EID 84)
Reaction:
 Default values are taken.
Potential cause:
 EEPROM is defect.
 Calibration data are wrong.
Remedial action:
 Replace inverter if failure occurs regularly after the Key-Off /
Key-On sequence.
Acknowledge:

 None
Page 47 of 128
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ELFA2 first aid
Definition:
SpeedTrackMisse One or more speed encoder signals at X2 connector are missing (track
d A, B and/or C).
(EID 85)
Reaction:
Potential cause:
 Encoder or inverter hardware failure.
Remedial action:
 Check inverter variable “encoderState” (Table 8).
inverter (X2). In case of damaged connector on
inverter/motor/generator, replace inverter/motor/generator.
 Check supply voltage of encoder at the X2 connector side
(Table 6 and Table 7). In case of problem with supply voltage for
speedsensor, replace inverter.
 Check if failure occurs only sporadically.
 Check if failure occurs at certain speeds.
 Replace motor/generator
Acknowledge:
 Reset with DNR set to neutral

 Speedsensor
(EID 15)
 SpeedDirChange
(EID 33)
Page 48 of 128
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ELFA2 first aid
Definition:
SpeedTracksReversed Position encoder signals at X2 connector are swapped.
(EID 86)
Reaction:
Potential cause:
 Wrong pin assignment in connector(s) on cable between
synchron motor/generator and inverter.
Remedial action:
 Check inverter variable “encoderState” (Table 8).
 Check pin assignment in connector(s) on cable between
synchron motor/generator and inverter (Table 6 / Table 7).
Repair or change connector(s).
Acknowledge:
 Reset with pulse disable of inverter

 Speedsensor
(EID 15)
 grave AESEL
(EID 132)
 auto start
(EID 131)
Page 49 of 128
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Definition:
Short circuit failure indication of IGBT’s
IGBT I lower
(EID 87) Reaction:
Potential cause:
 Short circuit to the chassis of motor/inverter phases or power
IGBT I upper cables.
(EID 88)  Short circuit between motor windings.
 Short circuit between the power cables.
 Hardware problem in the inverter.
IGBT II lower Remedial action:
(EID 89)  Check isolation resistance of the motor connected to inverter.
 Check the resistance (see motor manual) of the windings with
disconnected power cables (L1 to L2, L2 to L3 and L1 to L3).
 Check the resistance between the power cables with
IGBT II upper disconnected motor and inverter (L1 to L2, L2 to L3 and L1 to
(EID 90) L3).
 Replace inverter, if the above checks are passed.
Acknowledge:
IGBT III lower  Automatically reset.
(EID 91)
 No reset
(EID 106)
IGBT III upper
(EID 92)
Definition:
Short circuit failure indication of IGBT’s.
IGBT IV lower
(EID 93) Reaction:
 Pulse inhibition of phase IV.
Potential cause:
 Hardware problem of inverter.
IGBT IV upper
 Replace inverter, if failure number increases with the some Key-
Off / Key-On sequences.
Acknowledge:

 short DCDC
(EID 35)
Page 50 of 128
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Definition:
Overcurrent detection (Software), peak current in the phases exceeds
OverCurrent WR the defined limit.
(EID 47)
Reaction:
Potential cause:
 Short circuit of the connected component.
 Short circuit in power cable to connected component.
 Short circuit to the chassis of motor/inverter phases or power
cables..
 No optimum system tuning (prototype phase).
Remedial action:
 Check correct state and fit of power cables to drive motor or
generator.
 Check isolation resistance of the motor connected to inverter.
 Check the resistance (see motor manual) of the windings with
disconnected power cables (L1 to L2, L2 to L3 and L1 to L3).
 Check the resistance between the power cables with
disconnected motor and inverter (L1 to L2, L2 to L3 and L1 to
L3).
Acknowledge:

 No reset
(EID 106)
 current sum
(EID 83)
Page 51 of 128
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ELFA2 first aid
1
Definition:
Overcurrent detection (Hardware), peak current in the phases exceeds
Overcurrent I H the maximum measureable current of the current sensor.
(EID 95)
Reaction / Potential cause / Remedial action / Acknowledge / Possible
Side Effects:
 see Overcurrent (EID 47)
overcurrent II H
(EID 96)
overcurrent III H
(EID 97)
Page 52 of 128
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1
Definition:
Overcurrent detection (Hardware), it’s used if only two sensors are
Overcurrent sum installed.
H  sum peak current of the phase 1 and phase 2 is used for
(EID 99) calculation current in phase 3
 sum peak current (= phase 3 current) exceeds the maximum
measureable current of the current sensor

Side Effects:
 see Overcurrent (EID 47)
Page 53 of 128
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Phase 4 is used as DCDC converter:

OverCurrent IV th
(EID 29) Current measured on 4 phase on inverter exceeds specified limit.
Specified limit = online calculated limit (depending on INV Par. 87 to 89)
+ delta (INV Par. 100).
Reaction:
 Pulse inhibition of phase IV.
Potential cause:
 Short circuit in power cable to the connected component.
 Short circuit of the connected component.
 No optimum system tuning (prototype phase).
Remedial action:
 Check correct state and fit of power cables to the connected
component.
again.
Acknowledge:

 None
Brake resistor is connected on phase 4:
Calculated brake resistor current exceeds specified limits.
Reaction:
 No reaction.
Potential cause:
 Wrong brake resistor type.
 Overvoltage failure caused full duty of the brake resistor.
Remedial action:
 Check brake resistor resistance (e.g. 6 Ohms).
Acknowledge:

 None
Page 54 of 128
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Overcurrent detection (Hardware), peak current in the phases exceeds

Overcurrent IV H the maximum measureable current of the current sensor.
(EID 98)
Side Effects:
 see Overcurrent IV (EID 29)
Page 55 of 128
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ELFA2 first aid
3. Inverter failures VCSW
Definition:
PreChg too long Failure indicates that the precharging time is longer as the maximum
(EID 105) allowed time of 2 seconds. This means that the DC bus voltage is not in
the parameterized range or changes too fast, before the inverter is
enabled.
Reaction:
 Inverter will not become active.
Potential cause:
 Power Source/Energy Storage phases aren’t connected to the
inverter.
 Engine does not turn the generator, when generator inverter is
enabled.
 Precharge by Energy Storage does not work.
 Bus voltage measurement of inverter not correct.
Remedial action:
 Check bus voltage and alternation (U_IBC_fb) during the system
startup.
 Check wiring and connection of the power cables between
power source and inverter.
 Check engine/generator mechanical connection by comparing
engine speed with generator speed (n_Gen1Fb). The gear ratio
has to be considered.
 Check precharge by Energy Storage.
 Compare measured bus voltage of the failed inverter with other
inverters (voltIBC_fbGen1, voltIBC_fbMot1, voltIBC_fbMot2).
 Check if consumer is active during precharge.
 If it happens also at the generator inverter in diesel electric
mode: Disconnect the DC bus from the generator inverter. If the
error happens still at this inverter, then maybe a DC bus short-
circuit at this inverter. If not, there maybe a DC bus short-circuit
at another inverter or connection.
Acknowledge:

 None
Page 56 of 128
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Definition:
No reset This failure indicates that an “overcurrent” (EID 47, 95, 96, 95, 99) or
(EID 106) “IGBT” error (EID 87-92) occurred directly after the reset of the first
occurrence and an automatic restart. If it fails for the second time, it will
stay in this condition.
Reaction:
 Respective inverter is switched off. It has to be reset.
 Emergency stop request for engine in case of a generator.
Potential cause:
 Individual inverter error is shown in the Error Buffer before this
failure.
Remedial action:
 Follow the instructions of the error which was entered one
position before in the error buffer sequence.
Acknowledge:

 None
Page 57 of 128
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Definition:
LOS enabled Information that the LOS mode (Limited Operation strategy) is active.
(EID 107)
Potential cause:
 CAN disturbed.
 Safety Cut off by VCSW of the drive motors.
 SafeRefFbDiff
(EID 110)
 SafeCreepage
(EID 114)
 false quadrant
(EID 119)
 LOS activated by DICO.
Acknowledge:
Page 58 of 128
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Definition:
false rotation Only possible for generator:
(EID 108) If measured generator speed exceeds -500 rpm, i.e. wrong engine
speed direction (Please note, that the possible speed direction change
of a gearbox is considered).
Reaction:
 Pulse inhibition, no generator operation.
Potential cause:
 2 Phases of the power cables turned.
 Situation happens during engine turn off due to vibration.
 Inverter Problem (e.g. calibration of generator speed direction).
Remedial action:
 Check power cable wiring.
 Check engine turn off behavior and measure the engine speed.
 Check inverter parameter for speed direction of generator.
Acknowledge:

 None
Page 59 of 128
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Definition:
BR overtemp If measured braking resistor temperature exceeds the maximum
(EID 109) permissible value (T_resistMax + T_resistHyst), the chopper of the
braking resistor is pulse-inhibited.
Reaction:
Potential cause:
 Cooling circuit of the brake resistor not working properly.
 Wrong system calibration (e.g. engine speed is too low for the
brake resistor cooling).
Remedial action:
 Check temperature sensor (T_BR) value.
 Check cooling circuit.
again.
Acknowledge:

 Overvolt
(EID 42)
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Definition:
SafeRefFbDiff The torque reference and torque feedback signals do not match within
(EID 110) allowed tolerance limits.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 VCSW safety
(EID 193)
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Definition:
SafeCreepage Speed during creepage is higher than maximum allowed speed.
(EID 114)
Reaction:
Potential cause:
 Wrong parameterization of the creepage function.
Remedial action:
again.
Acknowledge:

 VCSW safety
(EID 193)
Page 62 of 128
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Definition:
CAN IBC control Indicates, that the slave drive motors (drive motor 2 and bigger) do not
(EID 115) receive the bus voltage control value from drive motor 1 on the DCAN
bus within the specified time of at least 20 ms.
Reaction:
 Bus voltage control of the slave drive motors are not
synchronized correct with the master, which might cause bus
system voltage errors.
Potential cause:
 Wrong parameter setting in inverter.
 Hardware wiring problem of DCAN (120 Ohm resistances
missing).
Remedial action
 Check inverter parameter.
 Check wiring of DCAN bus.
 Check 60 Ohm resistance of the DCAN bus as necessary.
Acknowledge:

 None
Page 63 of 128
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Definition:
DCAN Bus off Inverter detects too many error messages.
(EID 116)
Reaction:
 Messages are not received and cannot be sent.
 Torque reference from the DCAN is set to zero via a time ramp.
Potential cause:
missing).
 Unreliable DCAN connection of the inverter.
 Any participant connected to DCAN disturbs the CAN-Bus.
Remedial action:
 Check correct state of connector pins on inverter.
 Check DCAN communication:
o Are error frames on the DCAN bus?
o Disconnect participants and check communication.
Acknowledge:

 DCAN no message
(EID 117)
 CAN IBC control
(EID 115)
Page 64 of 128
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Definition:
DCAN no Inverter does not receive the important reference message for more than
message 200ms.
(EID 117)
Reaction:
 Torque reference from the DCAN is set to zero via a time ramp.
Potential cause:
missing).
 Unreliable DCAN connection of the inverter.
Remedial action:
 Check wiring of DCAN bus / Measure the total 60 Ohm
resistance of the DCAN bus
 Check correct state of connector pins on inverter.
o Is the necessary message sent?
o Is the timing of the messages constant and has no
fluctuation?
Acknowledge:

 None
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Definition:
false quadrant The check whether the torque demand is in the right quadrant by
(EID 119) considering the DNR information failed.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 VCSW safety
(EID 193)
Page 66 of 128
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Definition:
DIH6 Indicates that the motor phases are disabled by the DIH6 hardware input
(EID 126) when the inverter is on.
Reaction:
 Yellow lamp.
Potential cause:
 Safety controller switched off the DIH6.
 DIH6 was intentionally cut.
Remedial action:
 Check other errors in the error buffer.
 Actuator Test (if available): Switching of Safety Line.
 Check DIH6 hardware wiring (see Table 10: ELFA2 Inverter X1).
Acknowledge:

 None
Page 67 of 128
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Definition:
Synchronization The synchronization of the generator to the running engine failed.
(EID 127)
Reaction:
Potential cause:
 Engine speed for synchronization too low or high.
Remedial action:
 Check engine speed during the synchronization procedure.
 Service Routine (if available): Generator operation in DE mode.
Acknowledge:

 None
Page 68 of 128
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Definition:
DIH5 Indicates that the 4th phase is disabled by the DIH5 hardware input
(EID 128) when the inverter is on.
Reaction:
Potential cause:
 DIH5 was cut.
Remedial action:
 Check DIH5 hardware wiring (Table 10: ELFA2 Inverter X1).
Acknowledge:

 BR n. c.
(EID 30)
Page 69 of 128
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ELFA2 first aid
4. DICO failures
Definition:
auto start Failure indicates that the generator is not able to accelerate the engine
(EID 131) to the idle speed reference within the specified time.
Reaction:
 Generator repeats the start two times.
 After the two attempts a 24V start will be requested.
Potential cause:
 Hardware wiring problem of generator (power and signal cable).
 No Fuel or problems with the fuel injection.
 Engine load too big (incl. Coupling).
 Generator control issue (inverter, generator).
Remedial action:
Remedy is only necessary if failure happens often or leads to failure
“grave AESEL”.
 Service Routine (if available): Engine start over generator and
emergency stop.
 Check power and signal cable to the generator, Compare
generator speed (n_input of Inverter) with the engine speed. The
gear ratio has to be considered.
 Check errors on ICE
Acknowledge:

 “Speedsensor” (EID 15)
Page 70 of 128
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Definition
Injection off Failure indicates problems with the fuel injection of the engine.
(EID 135)
Reaction:
 Generator repeats the start two times.
 After the two attempts a 24V start will be requested.
Potential cause:
 No Fuel or problems with the fuel injection.
 Engine load too big (incl. Coupling).
Remedial action:
Remedy is only necessary if failure happens often or leads to failure
“grave AESEL”.
 Service Routine (if available): Engine start over generator and
emergency stop.
 Check Error of ICE.
Acknowledge:

 grave AESEL
(EID 132)
Page 71 of 128
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Definition:
grave AESEL Failure indicates that the generator is not able to accelerate the engine
(EID 132) to the idle speed reference within the specified time and it already
repeated this for two times. (AESEL: Automatic engine start enable
logic)
Reaction:
 External engine start (24V engine start) will be requested.
Potential cause/Remedial action:

For error analysis see:
 auto start
(EID 131)
 Injection off
(EID 135)
Acknowledge:

 Automatic Engine Start/Stop is disabled.
Page 72 of 128
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Definition:
PreChg too long Failure indicates that the precharging time is longer as the maximum
(EID 133) defined time (Par. 52 / z_PCMx).
Reaction:
 System will stop the precharge function and stay in this mode,
i.e. the system will not become active.
Potential cause:
 Precharge contactor not switched on.
 Hardware wiring problem or wrong Precharge Resistor.
 Wrong calibration in the DICO (Par. 423 / U_batStartMin and
Par. 424 / U_batStartMax).
Remedial action:
 Check precharge contactor turned on / Check storage error
buffer.
 Check precharge circuit (measure resistance).
 Check calibration.
Acknowledge:

 None
Page 73 of 128
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Definition:
Volt difference DC bus (intermediate bus circuit = IBC) voltage feedback of the inverters
(EID 134) does not fit together.
Reaction:
 Wrong dc-voltage feedback from one inverter.
Potential cause:
 Loss of dc-link connection.
 Problems with the voltage sensor.
Remedial action:
 Check which component acquires the wrong value. Compare
the dc-link voltage of the components (voltIBC_fbMot1,
voltIBC_fbMot2, voltIBC_fbGen1).
 Check dc-link connection.
Acknowledge:

 None
Page 74 of 128
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Definition:
Undervolt Average dc-link voltage of the components falls under 150 V during
(EID 136) operation.
Reaction:
 Deactivation of all inverters (pulse inhibition).
 Storage main contactor open request.
Potential cause:
 Short-circuit in dc-link.
 Dc-link control problem.
Remedial action:
again.
Acknowledge:
 Reset with Key On/Off.

 None
Page 75 of 128
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Definition:
SAE no reference DICO does not receive the important reference messages (EVCU1) for
(EID 137) more than 200 ms. The error happens together with (EID 141).
Reaction:
 Loss of traction torque.
Potential cause / Remedial action:

 see “SAE no Msg EVCU1 (EID 141)”
Acknowledge:

 None
Definition:
SAE not toggled The EVCU life sign counter is not transmitted to the DICO as specified
(EID 138)
Reaction:

 Check counting bits (“toggle bits”)
Acknowledge:

 None
Page 76 of 128
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Definition:
SAE bus off DICO detects too many error messages.
(EID 139)
Reaction:
Potential cause:
 Hardware wiring problem of SAE-CAN (120 Ohm resistances
missing).
 Unreliable SAE-CAN connection of the DICO.
 Any participant connected to SAE-CAN disturbs the CAN-Bus.
Remedial action:
 Check wiring of SAE-CAN bus.
 Check correct state of connector pins.
 Check SAE-CAN communication:
o Are error frames on the SAE-CAN bus?
Acknowledge:

 SAE no reference
(EID 137)
 SAE no Msg EVCU1
(EID 141)
 SAE no Msg EVCU2
(EID 142)
 SAE no Msg EEC1
(EID 143)
 SAE no Msg EEC2
(EID 144)
 SAE no Msg BMU
(EID 145)
 SAE no Msg TC1
(EID 146)
 SAE no Msg MsgObj7
(EID 147)
Page 77 of 128
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Definition:
SAE no Msg EVCU1 DICO does not receive the message.
(EID 141)
Reaction:
 System takes defined safety values. The reaction depends on
SAE no Msg EVCU2 the safety values.
(EID 142)  Loss of traction torque is possible.
 Switching to diesel-electric mode is possible.
Potential cause:
SAE no Msg EVCU3
 Single message is missed:
(EID 245) o Unit which transmits the SAE-CAN message is not in
operation.
 All messages (141-147) aren’t received :
SAE no Msg EVCU5 o Unit which transmits the SAE-CAN messages is not in
(EID 244)SAE no Msg operation.
EEC1 o Unreliable SAE-CAN connection of the DICO.
(EID 143) o Hardware wiring problem of DCAN (120 Ohm resistances
missing).
Remedial action:
SAE no Msg EEC2  Single message is missed:
(EID 144) o Check unit which sends the message.
 All messages (141-147) aren’t received :
o Check unit which sends the messages.
o Check correct state of connector pins.
o Check wiring of SAE-CAN bus.
SAE no Msg BMU o Check SAE-CAN communication (see “DICO Interface
(EID 145) Specification”):
o Are all necessary messages sent?
o Is the timing of the messages correct?
o Are error frames on the SAE-CAN bus?
SAE no Msg TC1
(EID 146) Acknowledge:
SAE no Msg MsgObj7 Possible Side Effects:

(EID 147)  SAE no reference
(EID 137)
SAE no Msg EBC1
(EID 148)
SAE no Msg TSC1_DR

(EID 149)
SAE no Msg TSC1_E

(EID 150)
Page 78 of 128
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Definition:
DNR input The Drive-Neutral-Reverse gear selection does not show a plausible
(EID 152) status for longer time than 500ms.
Reaction:
 Loss of gear, switch to Neutral (N).
Potential cause:
 Redundant DNR signals don’t fit together (e.g. “D” and “N”
Signal are active at the same time).
Remedial action:
 If transferred on SAE-CAN, check DNR-Signal on SAE-CAN.
Acknowledge:

 None
Page 79 of 128
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Definition:
acc switch Throttle pedal analog value does not fit to the throttle pedal switch
(EID 153) (analog value > 10% received, but switch not active) for more than
1000ms.
Reaction:
 Red Lamp Failure, Safety Cut-Off and if enabled LOS-Mode.
Potential cause:
 Hardware wiring problem of the throttle pedal switch or of the
analog sensor.
 Failure in SAE-CAN reference message if transmitted by SAE-
CAN.
 Wrong calibration of analog sensor value and the switch
position.
Remedial action:
 Check SAE-CAN information send to the DICO.
 Check hardware wiring to the throttle pedal switch.
Acknowledge:

 None
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Definition:
brake switch Brake pedal analog value does not fit to the Brake pedal switch (analog
(EID 154) value > 10% received, but switch not active) for more than 1000ms.
Reaction:
 No braking torque applied and yellow lamp indication.
Potential cause:
 Hardware wiring problem of the brake pedal switch or of the
analog sensor.
 Failure in SAE-CAN reference message if transmitted by SAE-
CAN.
 Wrong calibration of analog sensor value and the switch
position.
Remedial action:
 Check SAE-CAN information send to the DICO.
 Check hardware wiring for the brake pedal switch.
Acknowledge:

 None
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Definition:
DCU creepage Creepage function is active, even if the speed is higher than two times
(EID 155) reference speed.
Reaction:
Potential cause:
 Drive Motor Control issue.
 Wrong calibration of the creepage controller.
Remedial action:
 Check creepage parameter values.
 Check basic drive motor control behavior.
 Check speedsensor of drive motors.
again.
Acknowledge:

 DIH6
(EID 126)
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Definition:
DCU dir.motors Drive Motors torque reference don’t fit to drive motor speed direction
(EID 156) feedback
Reaction:
 Drive Motor Torque to zero.
Potential cause:
 Drive Motor Control issue.
 Acceleration at very steep hills with rollback.
Remedial action:
 Check basic drive motor control behavior.
 Check speedsensor of drive motors.
again.
Acknowledge:

 None
Page 83 of 128
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Definition:
DCU DNR plaus. DCU has implausible direction request depending on the DNR selection.
(EID 157)
Reaction:
 Drive Motor Torque to zero.
Potential cause:
 Drive Control Unit software issue.
 DICO Hardware issue.
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
Page 84 of 128
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Definition:
GW DCAN bus DICO detects too many error messages on the DCAN.
off
(EID 158) Reaction:
Potential cause:
missing).
 Inverter and DICO connectors are not plugged in, unreliable
DCAN-CAN connection of the DICO.
 Any participant connected to D-CAN disturbs the CAN-Bus.
Remedial action:
 Check correct state of connector pins.
 Measure the total 60 Ohm resistance of the DCAN bus
Acknowledge:

 GW DCAN no message
(EID 159)
 DCAN no Mot1Fb,
DCAN no Mot2Fb,
(EID 161-162)
 DCAN no Aux1Fb,
(EID 165)
 DCAN no Gen1Fb,
(EID 167)
 DCAN no ES_fb,
DCAN no ES2_fb
(EID 168-169)
Page 85 of 128
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Definition:
GW DCAN no DCAN module does not receive one of the feedback messages from the
message inverter of the drive motors or auxiliary’s inverters for more than 200ms.
(EID 159)
Reaction:
 Datas are not renewed, last values will be held and used.

 See DCAN no Mot1Fb,
DCAN no Mot2Fb,
(EID 161-162)
 See DCAN no Aux1Fb,
(EID 165)
Acknowledge:

 None
Page 86 of 128
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Definition:
DICO does not receive the message.
DCAN no
Mot1Fb, Reaction:
DCAN no  Datas are not renewed, last values will be held and used.
Mot2Fb,
Potential cause:
(EID 161-162)  Inverter which transmits the message is not in operation
 Unreliable DCAN connection with the DICO.
missing).
DCAN no
Aux1Fb,
 Check if inverter which should send the missing message is in
operation.
 Check correct state of connector pins (see Table 10: ELFA2
DCAN no Inverter X1).
Gen1Fb,  Check wiring of DCAN bus.
(EID 167)  Check DCAN communication:
Is the timing of the messages constant and has no fluctuation?
Are error frames on the DCAN bus?
Acknowledge:
DCAN no ES_fb,
DCAN no ES2_fb
(EID 168-169) Possible Side Effects:
 GW DCAN no message
(EID 159)
Page 87 of 128
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Definition:
short PC Short-circuit detected during connection (pre-charge) of the energy
(EID 175) storage to the dc-link.
Reaction:
 Interruption pre-charge.
 Disable use of the storage.
Potential cause:
 Wrong pre-charge resistor used.
Remedial action:
 Check correct size of pre-charge resistor.
Acknowledge:
 Reset with Key On/Off

 None
Page 88 of 128
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Definition:
10V out of range Internal 10 V supply of the DICO is out of range.
(EID 176)
Reaction:
 Failure entry.
Potential cause:
 DICO Hardware defect.
Remedial action:
 Replace DICO.
Acknowledge:

 None
Page 89 of 128
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Definition:
12V out of range Internal 12 V supply of the DICO is out of range.
(EID 177)
Reaction:
 Failure entry.
Potential cause:
 DICO Hardware defect.
Remedial action:
 Replace DICO.
Acknowledge:

 None
Page 90 of 128
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Definition:
speed limit Speed limit of the drive system is exceeded.
(EID 179)
Reaction:
 Failure entry.
Potential cause:
 Automatic electrical brake torque was not sufficient to prevent
overspeed condition.
 Mechanical brake was not sufficient to prevent overspeed
condition.
Remedial action:
 Driver should be trained to prevent overspeed condition by using
mechanical brakes.
Acknowledge:

 Overspeed
(EID 46)
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Definition:
F2 Error indicates failure of Safety Cut-Off line between the DICO and the
safetyLineLOW drive motor inverters. It indicates that the test during the system power-
(EID 180) up failed and that at least one of the drive motor inverters do not indicate
the high state of the Safety Cut-Off line, i.e. they do not have their
External Enable.
Reaction:
Potential cause:
 Hardware wiring problem of Safety Cut-Off line between DICO
and drive motor inverters.
Remedial action:
 Actuator Test (if available): Switching of Safety Line
 Check wiring Safety Cut-Off line.
Acknowledge:

 DIH6
(EID 126)
Page 92 of 128
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Definition:
F2 DNR Error indicates failure of Drive Control Unit (DCU) respective to the
Outp.plaus Drive-Neutral-Reverse (DNR) Determination. The DCU outputs do not
(EID 181) have a plausible DNR status.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
Page 93 of 128
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Definition:
F2 DNR IO- Error indicates failure of Drive Control Unit (DCU) respective to the
compair Drive-Neutral-Reverse (DNR) Determination. The DCU outputs, Drive or
(EID 182) Reverse, do not fit into their stationary input commands.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
Page 94 of 128
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Definition:
F2 DNR transition The change from Neutral to Drive or from Neutral to Reverse requires
(EID 183) special conditions. Generally the plausibility of the DNR switch, the
brake pedal and the vehicle speed is considered. The error indicates
failure of Drive Control Unit (DCU) respective to the Drive-Neutral-
Reverse (DNR) determination.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
Page 95 of 128
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Definition:
F2 DNR clone Error indicates failure of Drive Control Unit (DCU) respective to the
(EID 184) Drive-Neutral-Reverse (DNR) Determination. The DCU received the
external DNR commands, intermediately stored in two individual
addresses, with a difference.
Reaction:
Potential cause:
Remedial action:
 Replace DICO Hardware.
Acknowledge:

 DIH6
(EID 126)
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Definition:
F2 /brake D M<0 Error indicates failure of DCU drive motor torque reference
(EID 185) determination. In case of Drive, i.e. forward direction command and no
braking torque allowed, the drive motor torque reference was negative.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
Page 97 of 128
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Definition:
F2 /brake R M>0 Error indicates failure of DCU drive motor torque reference
(EID 186) determination. In case of Reverse, i.e. reverse direction command and
no braking torque allowed, the drive motor torque reference was
positive.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
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Definition:
F2 /acc D M>0 Error indicates failure of DCU drive motor torque reference
(EID 187) determination. In case of Drive, i.e. forward direction command and no
accelerating torque allowed, the drive motor torque reference was
positive.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
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Definition:
F2 /acc R M<0 Error indicates failure of DCU drive motor torque reference
(EID 188) determination. In case of Reverse, i.e. reverse direction command and
no accelerating torque allowed, the drive motor torque reference was
negative.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
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Definition:
F2 pulse motors Error indicates failure of drive motor feedback signals. At least one drive
(EID 191) motor feedback is active without an active reference command or there
is an active pulse enable feedback of any drive motor during the
“Neutral” condition at speed low speed.
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
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Definition:
F2 SCU not alive Error indicates that the Safety Software within the DICO is not performed
(EID 192) within the correct timing.
Reaction:
Potential cause:
 DICO Software issue.
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
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Definition:
VCSW safety This entry indicates that the Safety Function within the Inverter Software
(EID 193) detected a failure preventing the safe driving of the vehicle and inhibited
traction.
Reaction:
 Red Lamp Failure, Pulse inhibition of drive motors.
Potential cause:
 Respective drive motor software has indicated a safety issue.
 The following inverter failures can be the reason for this failure.
 SafeTorqDirection
(EID 56)
 SafeTorqPermit
(EID 57)
 SafeRefFbDiff
(EID 110)
 SafeCreepage
(EID 114)
 false quadrant
(EID 119)
Remedial action:
 Identify inverter failure and affected inverter by checking the
error-buffers of the drive motor inverters. Look for the above
listed inverter failures.
 Apply the remedial action described under the identified inverter
failure.
Acknowledge:

 None
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Definition:
F2 false quadrant The operation of the system according to the allowed quadrants will be
(EID 194) checked versus the instantaneous directions of the speed feedback and
the torque reference values. Error indicates failure of DCU drive motor
torque reference depending on the direction of the speed feedback and
the DNR status.
Reaction:
Potential cause:
 Drive Control Unit Software issue.
Remedial action:
again.
Acknowledge:

 DIH6
(EID 126)
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Definition:
F2 warn s.LineHI Error indicates failure of Safety Cut-Off line between the DICO and the
(EID 195) drive motor inverters. It indicates, that the test during the system power-
up failed and that at least one of the drive motor inverters does not
indicate the low state of the Safety Cut-Off line, i.e. they do not indicate
that their External Enable is deactivated.
Reaction:
 Vehicle operation with Yellow Lamp Failure possible (Note:
Safety Cut-Off Line is not working). Problem should be solved as
soon as possible.
Potential cause:
 Hardware wiring problem of Safety Cut-Off line between DICO
and inverters.
Remedial action:
 Actuator Test (if available): Switching of Safety Line.
 Check wiring Safety Cut-Off line.
Acknowledge:
 Reset with Key Off/On.

 None
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Definition:
F2 warn no safety Error indicates that the Safety Software within the DICO and at least
(EID 196) from one drive motor inverter is not correctly enabled, i.e. at least one
unit has the safety software differently calibrated as the other controllers.
Reaction:
 Yellow Lamp Failure
Potential cause:
 Wrong calibration in DICO.
 Wrong calibration of at least one drive motor inverter.
Remedial action:
 Check parameter modeSelector Bit 7 (has to be set if the safety
controller shall be active) of the DICO and the drive motor
inverters.
 Update the calibration of the unit with the wrong parameter
settings.
 If parameter correction is not possible, replace the respective
unit.
Acknowledge:

 None
Definition:
autoPara off Warning when AUTOPARA is disabled within DICO parameter.
(EID 200)
Reaction:
Potential cause:
Remedial action:
again.
Acknowledge:
 None

 None
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Definition:
autoPara parity Failure indicates that the auto parameterization parity bit (most
(EID 201) significant bit in the DIL code) is wrong. The parity bit doesn’t fit to the
other bits of the DIL code.
The system is not switched on.
Reaction:
 no system start-up, hybrid mode won’t accept.
Potential cause:
 The parity bit doesn’t fit to the other bits of the DIL code.
Remedial action:
 The DIL code can be checked in inverter variable inputBin.
Compare the bits in this variable to the specification (24V
Harness).
 Wire the DIL code correctly.
Acknowledge:

 autoPara no finish
(EID 202)
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Definition:
autoPara no Failure indicates that the auto parameterization procedure was not
finish completed correctly. The autoparameterization procedure takes place
(EID 202) whenever the ELFA is restarted.
Reaction:
 No system start-up, hybrid mode won’t be accepted.
Potential cause:
 Another “autoPara..” error has happened just before.
 autoPara parity
(EID 201)
 autoPara array
(EID 205)
 autoPara timeout
(EID 206)
 autoPara DIL code
(EID 207)
 The inverters were not restarted together with the DICO in the
right way. DICO and Inverter have to start at the same time.
 Too high DCAN bus load.
 DCAN interruption due to hardware failure.
Remedial action:
 Check whether another autoparameterization error was entered
before.
 Repeat the autoparameterization procedure by restart the
whole ELFA system and check whether this error or another
autoparameterization error is entered again (pay attention to
the keep alive time and ignition delays).
 Check the bus load.
 Check the DCAN bus wiring.
Acknowledge:

 None
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Definition:
autoPara Failure indicates that the auto parameterization procedure was not
download completed, because the check of the parameter download was not
(EID 203) passed.
Reaction:
 No system start-up, hybrid mode won’t be accepted.
Potential cause:
 Two inverters have the same DIL code.
 Wrong inverter software.
Remedial action:
 Repeat the autoparameterization procedure by restarting the
autoparameterization error is entered again.
 Check the DIL codes. The DIL code can be checked in inverter
variable inputBin. Compare the bits in this variable to the
specification (24V Harness).
 Update inverter software.
Acknowledge:

(EID 202)
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Definition:
autoPara upload Information that the inverter has saved another parameter value than the
(EID 204) DICO.
Reaction:
 No reaction.
Potential cause:
 The inverter was replaced just before.
 The DICO software was updated just before.
 The inverter has lost his parameters (minor).
Remedial action:
Acknowledge:
 Automatically reset after upload is finished.

 None
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Definition:
autoPara array Failure indicates that the parameter list in the DICO is wrong (ID list
(EID 205) doesn't fit to contents list).
Reaction:
 no system start-up, hybrid mode won’t be accepted.
Potential cause:
 Wrong DICO software.
Remedial action:
 Repeat the autoparameterization procedure by resetting the
 Update the DICO software.
Acknowledge:

(EID 202)
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Definition:
autoPara timeout Failure indicates that the inverter has exceeded the maximum response
(EID 206) time on the DCAN when the autoparameterization was in progress.
Reaction:
Potential cause:
 The DCAN was overloaded.
 The inverter has a CAN hardware defect.
 The inverter was replaced just before.
 The DICO software was updated just before
Remedial action:
 Check the bus load.
Acknowledge:

(EID 202)
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Definition:
autoPara DIL Failure indicates that an undefined DIL code was detected at one of the
code inverters.
(EID 207)
Reaction:
Potential cause:
 DIL code wiring is not correct.
Remedial action:
 Check the DIL codes. The DIL code can be checked in inverter
variable inputBin. Compare the bits in this variable to the
specification (24V Harness).
 Wire the DIL code correctly.
Acknowledge:

(EID 202)
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Definition:
discharge IBC Failure indicates that the discharge of the dc-link at start-up is failed.
(EID 209)
Reaction:
 The energy storage can’t be used, because it isn’t possible to
connect it with the dc-link.
Potential cause:
 Brake Resistor not connected - see “BR n. c.
(EID 30)”.
 Power Source (e.g. Generator) active during discharge.
Remedial action:
 Check Brake Resistor - see “BR n. c.
(EID 30)”.
 Check Start-up procedure of the system.
Acknowledge:

 None
Definition:
MC opened Failure indicates that the BMU has opened the MC unexpected. Hence,
(EID 210) the MC was still requested by DICO.
Reaction:
 The energy storage can’t be used anymore.
 Pulse inhibition of DCDC
 Yellow lamp
Potential cause:
 BMU failure
Remedial action:
 Check error buffer of the BMU
Acknowledge:

 OverCurrent IV
(EID 29)
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Definition:
Low Insulation Failure indicates that the insulation monitoring device has detected a
(EID 230) low insulation resistance or special device errors.
Reaction:
 The energy storage will be discharged (Ucap) and
disconnected. If error is still present, the system will be switched
of at the next stop
 Red lamp
 Yellow lamp (while the discharge logic is in progress)
Potential cause:
 Insulation resistance is below the specific value
 Device error has been detected (see specification of Bender-
Isometer)
Remedial action:
 Check high voltage wiring
 Check Isometer low voltage wiring
 Check Dico variable “resistance_isolation” (Table 11).
Acknowledge:
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Definition:
VPM Voltage High deviation of the VPM voltage measurement at the PEM power
(EID 236) terminals. This indicates that the self-ignition function of the VPM may
be impaired.
Reaction:
 None. VPM can still be triggered externally by the DICO if
necessary.
Potential cause:
 Signal wiring problem between DICO and VPM
 Power wiring problem between VPM and motor
 VPM internal hardware problem
Remedial action:
 Check signal wiring between DICO and VPM. Output “Volt_Ok”
from VPM must be connected to the DICO.
 Check power wiring between VPM and motor. The power
terminals of the VPM have to be connected to the power
terminals of the PEM.
 After checking and correcting any signal or wiring problem, drive
to its maximum speed
Acknowledge:

 None
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Definition:
VPM not ready VPM won’t be able to trigger to protect the system in case of overvoltage
(EID 237) caused by the PEM traction motor
Reaction:
 Traction motor speed limited to a safe value
Potential cause:
 VPM temperature > 70 °C
 VPM power supply interruption
Remedial action:
 Check power supply of VPM’s
 Check signal wiring between DICO and VPM
 Replace VPM in case of no wiring issue
Acknowledge:
 Automatically reset if temperature triggered
 Reset with Key Off/On if it appears during start-up

 Overvoltage (EID 42)
Definition:
VPM no trigger VPM can not be triggered by the DICO to protect the system in case of
(EID 238) overvoltage caused by the PEM traction motor
Reaction:
 Traction motor speed limited to a safe value
Potential cause:
Remedial action:
 Check signal wiring between DICO and VPM
 Replace VPM in case of no wiring issue
Acknowledge:

 Overvoltage (EID 42)
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Definition:
VPM ignited VPM ignited by itself
(EID 239)
Reaction:
 Traction loss
Potential cause:
 Pulse inhibition of the PEM drive motor inverters when driving
 VPM power supply surge
Remedial action:
 Read error buffer of the PEM traction motor inverters and solve
any failure causes that lead to a “Pulse inhibition” as reaction
Acknowledge:
 Automatically reset when the PEM motor comes to a halt

 Overcurrent
Definition:
VPM triggered VPM triggered externally by DICO
(EID 240)
Reaction:
 Traction loss
Potential cause:
 Pulse inhibition of the PEM motor inverters when driving
 DICO lost the communication with all the inverters in the system
Remedial action:
 Read error buffer of the PEM traction motor inverters and solve
any failure causes that lead to a “Pulse inhibition” as reaction
 Read the DICO
Acknowledge:
 Automatically reset when the PEM motor comes to a halt

 Overcurrent
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Abbreviations
ABS: Anti slip control
AESEL: Automatic engine start enable logic
ASR: Traction control system
CSW: Control software
D-CAN: ELFA proprietary “Drive CAN”
DCDC: direct voltage converter (step-up converter)
DICO: Digital input controller, i.e. ELFA overhead controller
DIH: Digital input - high active
DIL: Digital input - low active
DNR: Drive-Neutral-Reverse
DCU: Drive Control Unit
EBS: Electronic brake system
EEPROM: Electrically erasable programmable read-only-memory
EID: Error identification
ELFA: Electric Low Floor Axle
EMC: Electromagnetic compliance
EOL: End of line
HS: Heatsink
IGBT: Insulated gate bipolar transistor
IND: Inductor
INV: Inverter
LOS: Limited operation strategy
MCB: Main control board
Par. : Parameter
SAE-CAN: CAN bus at which the ELFA system is connected to the bus environment
Var.: Variable
VCSW: Vehicle control software
VPM: Voltage protection module
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1 Error Identification (EID)

2 EID 1 ............................... 18 51 EID 71 .............................. 12 100 EID 141 ............................77
3 EID 2 ............................... 18 52 EID 72 .............................. 13 101 EID 142 ............................77
4 EID 3 ............................... 18 53 EID 73 .............................. 14 102 EID 143 ............................77
5 EID 4 ............................... 18 54 EID 74 .............................. 14 103 EID 144 ............................77
6 EID 5 ............................... 19 55 EID 75 .............................. 15 104 EID 145 ............................77
7 EID 6 ............................... 19 56 EID 76 .............................. 16 105 EID 146 ............................77
8 EID 9 ............................... 20 57 EID 79 ................................ 7 106 EID 147 ............................77
9 EID 10 ............................. 21 58 EID 80 ................................ 7 107 EID 148 ............................77
10 EID 12 ............................. 22 59 EID 81 ................................ 7 108 EID 149 ............................77
11 EID 13 ............................. 23 60 EID 82 .............................. 44 109 EID 150 ............................77
12 EID 14 ............................. 23 61 EID 83 .............................. 45 110 EID 152 ............................78
13 EID 15 ............................. 24 62 EID 84 .............................. 46 111 EID 153 ............................79
14 EID 16 ............................. 25 63 EID 85 .............................. 47 112 EID 154 ............................80
15 EID 17 ............................. 26 64 EID 86 .............................. 48 113 EID 155 ............................81
16 EID 18 ............................. 26 65 EID 87 .............................. 49 114 EID 156 ............................82
17 EID 21 ............................. 27 66 EID 88 .............................. 49 115 EID 157 ............................83
18 EID 22 ............................. 27 67 EID 89 .............................. 49 116 EID 158 ............................84
19 EID 23 ............................. 28 68 EID 90 .............................. 49 117 EID 159 ............................85
20 EID 24 ............................. 29 69 EID 91 .............................. 49 118 EID 161-162 .....................86
21 EID 25 ............................. 29 70 EID 92 .............................. 49 119 EID 165 ............................86
22 EID 26 ............................. 30 71 EID 93 .............................. 49 120 EID 167 ............................86
23 EID 29 ............................. 53 72 EID 94 .............................. 49 121 EID 168-169 .....................86
24 EID 30 ............................. 31 73 EID 95 .............................. 51 122 EID 175 ............................87
25 EID 31 ............................. 23 74 EID 96 .............................. 51 123 EID 176 ............................88
26 EID 32 ............................. 23 75 EID 97 .............................. 51 124 EID 177 ............................89
27 EID 34 ............................. 32 76 EID 98 .............................. 54 125 EID 180 ............................90
28 EID 35 ............................. 33 77 EID 99 .............................. 52 126 EID 181 ............................91
29 EID 36 ............................. 34 78 EID 105 ............................ 55 127 EID 182 ............................92
30 EID 42 ............................. 35 79 EID 106 ............................ 56 128 EID 183 ............................93
31 EID 43 ............................. 36 80 EID 107 ............................ 57 129 EID 184 ............................94
32 EID 44 ............................. 38 81 EID 108 ............................ 58 130 EID 185 ............................95
33 EID 45 ............................. 38 82 EID 109 ............................ 59 131 EID 186 ............................96
34 EID 46 ............................. 37 83 EID 110 ............................ 60 132 EID 187 ............................97
35 EID 47 ............................. 50 84 EID 114 ............................ 61 133 EID 188 ............................98
36 EID 48 ............................... 7 85 EID 115 ............................ 62 134 EID 191 ............................99
37 EID 51 ............................... 9 86 EID 116 ............................ 63 135 EID 192 .......................... 100
38 EID 53 ............................... 8 87 EID 117 ............................ 64 136 EID 193 .......................... 101
39 EID 54 ............................... 8 88 EID 119 ............................ 65 137 EID 194 .......................... 102
40 EID 56 ............................. 39 89 EID 126 ............................ 66 138 EID 195 .......................... 103
41 EID 57 ............................. 40 90 EID 127 ............................ 67 139 EID 196 .......................... 104
42 EID 58 ............................. 41 91 EID 128 ............................ 68 140 EID 201 .......................... 105
43 EID 59 ............................. 41 92 EID 131 ............................ 69 141 EID 202 .......................... 106
44 EID 60 ............................. 42 93 EID 132 ............................ 71 142 EID 203 .......................... 107
45 EID 61 ............................. 42 94 EID 133 ............................ 72 143 EID 204 .......................... 108
46 EID 63 ............................. 17 95 EID 134 ............................ 73 144 EID 205 .......................... 109
47 EID 64 ............................. 43 96 EID 135 ............................ 70 145 EID 206 .......................... 110
48 EID 65 ............................. 10 97 EID 136 ............................ 74 146 EID 207 .......................... 111
49 EID 68 ............................... 8 98 EID 137 ............................ 75 147 EID 209 .......................... 112
50 EID 69 ............................. 11 99 EID 139 ............................ 76
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Failure thresholds
threshold
threshold
tolerance
reset
error
EID
set
1 Mot1_Sens_Bottom no tolerance Sensor 1 < -50°C > -50°C
2 Mot1_Sens_Top no tolerance Sensor 1 > 250°C < 250°C
3 Mot2_Sens_Bottom no tolerance Sensor 2 < -50°C Sensor 2 > -50°C
4 Mot2_Sens_Top no tolerance Sensor 2 > 250°C Sensor 2 < 250°C
5 HS1_Sens_Bottom no tolerance < -50°C > -50°C
6 HS1_Sens_Top no tolerance > 250°C < 250°C
9 OverTemp Motor no tolerance > Mot_Tmp_EPO (Par. 148) not resetable
10 OverTemp Heatsink no tolerance > 85° not resetable
12 OverTemp Junction no tolerance >145° not resetable
13 ExtTempSensBottom no tolerance < -50°C > -50°C
14 ExtTempSensTop no tolerance > 250°C < 250°C
17 OverTemp1 MCB no tolerance > Hw_Tmp_Lim (Par. 143) Hw_Tmp_Lim (Par. 143) -
10°C
18 OverTemp2 MCB no tolerance > Hw_Tmp_Lim (Par. 143) Hw_Tmp_Lim (Par. 143) -
10°C
1
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Appendix
Table 1: temperature sensor check: pin assignment on 1FV5/1PV5 motor/generator and INV
X2 1FV5/1PV5
Pin Description Pin Description
3 T_MOT1 → 9 KT84+
4 T_MOT2 → 11 KT84+
5 GND_Temp → 10 KT84-
Table 2: temperature sensor check : pin assignment on 1DB PEM motor/generator and INV
X2 PEM motor (Harting)
3 T_MOT1 → 6 Temperature sensor PT1000
4 Not connected 8 Shield temperature sensor PT1000
5 GND_Temp → 7 Ground of temperature sensor PT1000
Table 3: PT1000 resistance as a function of ambient temperature

Temp R Temp R Temp R Temp R
(˚C) (Ω) (˚C) (Ω) (˚C) (Ω) (˚C) (Ω)
-50 803 5 1020 60 1232 130 1498
-45 823 10 1039 65 1252 140 1536
-40 843 15 1059 70 1271 150 1573
-35 862 20 1078 75 1290 160 1610
-30 882 25 1097 80 1309 170 1648
-25 902 30 1117 85 1328 180 1685
-20 922 35 1136 90 1347 190 1722
-15 941 40 1155 95 1366 200 1758
-10 961 45 1175 100 1385 210 1795
-5 980 50 1194 110 1423 220 1832
0 1000 55 1213 120 1461 230 1868
Table 4: temperature sensor check: pin assignment on braking resistor and INV
X1 PT1000
Braking resistance
10 TEMP_EXT1 → 1 PT1000_1
14 TEMP_EXT 2 → (1) PT1000_2
17 GND → 2, (2) TEMP_ GND
Table 5: temperature sensor check: pin assignment on inductor box and INV
X1 PT1000
X2 inductor box
10 TEMP_EXT1 → 3 PT1000_1
14 TEMP_EXT 2 → 4 PT1000_2
17 GND → 2, 5 TEMP_ GND
Table 6: speed sensor interface: pin assignment on 1FV5/1PV5 motor/generator and INV
X2 1FV5/1PV5
1 P15_ENC → 4 Power supply
2 GND_speed → 5 ground
7 ENCA → 2 Signal S
8 ENCB → 1 Signal T
9 ENCC → 3 Signal R
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Table 7: speed sensor interface: pin assignment on 1DB PEM motor/generator and INV
X2 PEM motor (Harting)
1 P15_ENC → 4 Speed sensor power supply “plus”
2 GND_speed → 5 Speed sensor power supply “minus”
3 Shield speed sensor → Cable shield
7 ENCA → 1 Speed sensor track 1
8 ENCB → 2 Speed sensor track 1
Table 8: inverter variable „speedSensor“

Meaning
Position
Bits
0 Track A is missing, momentary value
1 Track B is missing, momentary value
2 Track C is missing, momentary value
3 some Tracks are reversed, can be implemented only for generators.
4 too much noise in the Track-Signals
8 Track A is missing, will be set if Bit 0 is there 100 times (Pulses) at the row
9 Track B is missing, will be set if Bit 1 is there 100 times (Pulses) at the row
10 Track C is missing, will be set if Bit 2 is there 100 times (Pulses) at the row
11 Some Tracks are reversed, will be set if Bit 3 is there 100 times (Pulses) at the row, can be
implemented only for generators
12 to much noise in the Track - Signals, will be set if Bit 4 is there 100 times (Pulses)at the row
Figure 1: KTY84 sensor resistance as a function of ambient temperature; average values
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1 Table 9: DICO PIN’s

PIN Signal Name Function
1 GND Ground Electronic
2 DO25 Reserve
3 DO26 Reserve
4 DO27 Reserve
5 DO28 Reserve
6 PWM24 Reserve
7 PWM23 Reserve
8 PWM22 Reserve
9 PWM21 Reserve
10 DO20 Safety Cut-Off (DOH 2.5A)
11 DO19 Reserve
12 DO18 Reserve
13 DO17 Reserve
14 +UB Voltage Supply 24V for DOH (fuse 20A)
15 AGND Analog ground (Throttle pedal / brake pedal)
16 D+ Key On
17 1CAN_L DCAN Low
18 TxD RS232 TxD (DICO diagnosis)
19 Ident-Pin
20 DIN10 Reserve
21 DIN12 Reserve
22 DIN14 Reserve
23 2CAN_H SAE CAN High
24 ADIN2 Reserve
25 ADIN4 Reserve
26 ADIN6 Reserve
27 ADIN8 Reserve
29 LGND Ground for DOL (fuse 10A)
30 +UE Voltage Supply 24V for electronic (fuse 2A)
31 1CAN_H DCAN High
32 +10Vext 10V reference output (10mA)
33 RxD RS232 RxD (DICO diagnosis)
34 DIN9 Reserve
35 DIN11 Reserve
36 DIN13 Reserve
37 2CAN_L SAE CAN Low
38 ADIN1 Reserve
39 ADIN3 Reserve
40 ADIN5 Reserve
41 ADIN7 Reserve
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1 Table 10: ELFA2 Inverter X1

Pin No. Signal Name Description
Power Supply
1 KL_30 Continuous power supply 24 V
2 KL_31 Power Supply Ground
3 KL_30 Continuous power supply 24 V (Redundancy)
4 KL_31 Power Supply Ground (Redundancy)
CAN Interface
8 CANH1 CAN1 interface High (DCAN)
9 CANL1 CAN1 interface Low (DCAN)
5 CANT1 Activation of termination CAN1
6 GND KL_31 Signal Ground CAN1
12 CANH2 CAN2 interface High (High Speed CAN)
13 CANL2 CAN2 interface Low (High Speed CAN)
16 CANT2 Activation of termination CAN2
15 GND KL_31 Signal Ground CAN2
Outputs
25 DOL_1 Reserve (binary, PWM and Frequency)
29 DOL_2 Reserve
Analog Inputs
7 AINP_1 Reserve
18 AINP_2 Reserve
10 TEMP_EXT1 External temperature sensor Pt1000 analog input
14 TEMP_EXT2 External temperature sensor Pt1000 analog input
17 GND KL_31 Ground TEMP_EXT, AINP
Digital Inputs
24 DIL_1 Reserve
28 DIL_2 Reserve
21 DIL_3 Reserve
32 DIL_4 Reserve
31 DIH_5 External Enable for IGBT Phase L4
20 DIH_6 External Enable for IGBT Phase L1-L3
27 KL_15 Ignition (Key On, Control signal of power supply)
30 GND KL_31 Signal Ground IO’s
Coding
19 BIN0 Input Coding Bit 0
23 GND KL_31 Signal Ground Coding
DOL = Digital output low-active switches according to ground

DIL = Digital input low-active 24 V internal
DIH = Digital input high-active GND internal
AINP = Analog Input 0–5V
Table 11: dico variable „resistance_isolation“

Value Meaning
50000 Undervoltage
51000 Short-circuit to Kl 15
52000 Device error
53000 Speed start measurement “good”
54000 Speed start measurement “bad”
55000 Connection fault earth (Kl 31)
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ELFA2 ®

Last edition: 15 Nov 2013

SafeTorqPermit (EID 57) ......................................................................................................................... 40

SAE no Msg MsgObj7 (EID 147) ............................................................................................................. 78

List of Tables and Figures

Possible Side Effects:

Failure description and remedial action

1. General failures (DICO / Inverter)

Possible Side Effects:

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2. Inverter failures CSW

 Check temperature sensor in motor/generator (Table 1 /

Possible Side Effects:

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ExtTempSens2Top Remedial action:

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Implausible direction change in speed signal.

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 Connect 24V power supply with current limitation to the DC-link

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Overspeed failure of the drive motors.

Possible Side Effects:

Overspeed of the generator.

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Reaction / Potential cause / Remedial action / Acknowledge / Possible

Phase 4 is used as DCDC converter: