Troubleshooting - Motor Controller
20
3A6623C
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 connec-
tor 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 exter-
nal short circuit.
2.
Measure resistance between U, V, W
cables and frame of motor. If resis-
tance is less than 1 megaohm, 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 exter-
nal short circuit.
2.
Measure resistance between U, V, W
cables and frame of motor. If resis-
tance is less than 1 megaohm, replace
motor or controller.
14
Precharge Failed
1.
External load on battery pack
(B+ connection terminal) that
prevents the controller from
charging.
Set:
The precharge failed to charge the
capactior 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 Under-
temp
1.
Controller is operating in an
extreme environment.
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 Over-
temp
1.
Controller is operating in an
extreme environment.
2.
Excessive load on vehicle.
3.
Improper mounting of control-
ler.
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.
17
Severe B+ Undervoltage
1.
Non-controller system drain
on battery.
2.
Battery resistance too high.
3.
Battery disconnected while
driving.
4.
Open B+ fuse or main con-
tractor did not close
Set:
Battery pack voltage dropped below
the Severe Undervoltage limit with FET
bridge enabled.
Clear:
Bring battery pack voltage above
Severe Undervoltage limit.
1.
Inspect all cables and connectors from
batteries to controller.
2.
Let battery cool then fully recharge bat-
tery. If error happens again, load test
battery and replace if needed.
3.
Inspect 300 amp fuse and replace if
open.
4.
Inspect contactor for corroded contacts
and replace if needed.
Severe Power Switch
Undervoltage
1.
Non-controller system drain
on battery/power switch circuit
wiring.
2.
Power switch disconnected
while driving.
3.
Open 20 amp fuse.
Set:
Below Brownout Voltage for 2 sec-
onds.
Clear:
Bring power switch voltage above
Brownout Voltage.
1.
Inspect all power switch cables and
connectors.
2.
Inspect 20 amp fuse and replace if
open.
18
Severe B+ Overvoltage
1.
Battery resistance too high for
given regen current.
2.
Battery disconnected while
regen braking.
Set:
Battery pack voltage exceeded the
Severe Overvoltage limit with FET bridge
enabled.
Clear:
Bring battery pack voltage below
Severe Overvoltage limit, and then cycle
power switch.
1.
Let battery cool then fully recharge bat-
tery. If error happens again, load test
batteries and replace if needed.
2.
Inspect all cables and connectors from
batteries to controller.
Severe Power Switch
Overvoltage
1.
Incorrect (too high) bat-
tery-voltage applied to power
switch (pin 1).
NOTE: Prevents Main Contactor
closure if power switch is greater
than the Severe Overvoltage limit.
Set:
Power switch voltage exceeded
Severe Overvoltage limit.
Clear:
Bring power switch voltage below
the Severe Overvoltage limit.
1.
Check the voltage of each 6V battery
with a digital volt meter. Inspect power
switch and battery wiring for insulation
damage and proper wiring.
