Troubleshooting - Motor Controller
24
3A9034B
NOTE: When a fault is encountered, shut off the Power Switch and turn it back on to see if the fault clears. If
it does not, shut off the Power Switch and remove the 35-pin connector. Check the connector for corrosion
or damage, clean if necessary, and re-insert connector. If the fault persists, follow the instructions below.
When inspecting a cable, always check for a loose terminal fastener, a loose crimp, corrosion, and
connector or insulation damage. Repair or replace components as needed.
Table 2
CODE
DESCRIPTION
POSSIBLE CAUSE
SET / CLEAR CONDITIONS
SOLUTION
12
Controller
Overcurrent
1. External short of phase
U, V, or W motor
connections.
2. Controller defective.
Set:
Phase current exceeded the
current measurement limit.
Clear:
Cycle Power Switch.
1. Inspect motor cables U,V,W.
Visually inspect motor terminal
block for external short circuit.
2. Measure resistance between U,
V, W cables and frame of
motor. If resistance is less than
1 megohm, replace motor or
controller.
13
Current Sensor Fault
1. Leakage to vehicle
frame from phase U, V,
or W (short in motor
stator).
2. Controller defective.
Set:
Controller current sensors
have invalid offset reading.
Clear:
Cycle Power Switch.
1. Inspect motor cables U,V,W.
Visually inspect motor terminal
block for external short circuit.
2. Measure resistance between U,
V, W cables and frame of
motor. If resistance is less than
1 megohm, replace motor or
controller.
14
Pre-charge Failed
1. External load on battery
pack (B+ connection
terminal) that prevents
the controller from
charging.
Set:
The pre-charge failed to
charge the capacitor bank.
Clear:
Cycle Power Switch.
1. Inspect all cables and
connectors from batteries to
controller.
2. Remove any after market
devices that could draw power
during system power up. Only
use designated auxiliary ports
for after market devices.
15
Controller Severe
Undertemp
1. Controller is operating in
an extreme environ
-
ment.
Set:
Heatsink temperature below
-40°C.
Clear:
Bring heatsink temperature
above -40°C, and cycle Power
Switch.
1. Move the unit to a warmer area.
16
Controller Severe
Overtemp
1. Controller is operating in
an extreme
environment.
2. Excessive load on
vehicle.
3. Improper mounting of
controller.
Set:
Heatsink temperature above
+95°C.
Clear:
Bring heatsink temperature
below +95°C, and cycle Power
Switch.
1. Move the unit to a cooler area.
2. Reduce operating load on
vehicle.
3. Inspect controller heatsink
mounting for air gaps and
tighten fasteners.
