Troubleshooting - Motor Controller
3A6623C
21
22
Controller Overtemp Cut-
back
1.
Controller is performance-lim-
ited at this temperature.
2.
Controller is operating in an
extreme environment.
3.
Excessive load on vehicle.
4.
Improper mounting of control-
ler.
Set:
Heatsink temperature exceeded 85°C.
Clear:
Bring heatsink temperature below
85°C.
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.
23
B+ Undervoltage Cutback
1.
Normal operation. Fault indi-
cates the batteries need
recharging. Controller is per-
formance limited at this volt-
age.
2.
Battery resistance too high.
3.
Battery disconnected while
driving.
4.
Open 300 amp fuse or main
contactor did not close.
5.
Non-controller system drain
on battery.
Set:
Battery pack voltage dropped below
the Undervoltage limit with the FET bridge
enabled.
Clear:
Bring battery pack voltage above
the Undervoltage limit (19V).
1.
Charge batteries.
2.
Let battery cool then fully recharge bat-
tery. If error happens again, load test
batteries and replace if needed.
3.
Inspect all cables and connectors from
batteries to controller.
4.
Inspect 300 amp fuse and replace if
needed.
5.
Inspect contactor for damaged, cor-
roded or contaminated contacts.
Repair or replace as needed.
24
B+ Overvoltage Cutback
1.
Normal operation. Fault
shows that regen braking cur-
rents elevated the battery
voltage during regen braking.
Controller is performance lim-
ited at this voltage.
2.
Battery disconnected while
regen braking.
Set:
Battery pack voltage exceeded the
Overvoltage limit.
Clear:
Bring battery pack voltage below the
Overvoltage limit (30V).
1.
Continue using the unit.
2.
Inspect all cables and connectors from
batteries to controller.
25
+5V Supply Failure
1.
Bad crimps or faulty wiring.
2.
Shorted motor encoder.
3.
Shorted throttle.
4.
Shorted ExactMil potentiome-
ter.
Set:
+5V supply (pin 26) outside the 5
V±10% range.
Clear:
Bring voltage within range.
1.
Inspect motor encoder/thermistor cable
and connector. Disconnect motor
encoder and cycle unit power. If the 5V
supply fault clears, replace the motor.
If the 5V supply fault persists, recon-
nect encoder and repeat this process
for the throttle assembly and ExactMil
potentiometer.
28
Motor Temp Hot Cutback
1.
Motor temperature is at or
above the programmed Tem-
perature Hot setting, and the
current is being cut back.
Set:
Motor temperature is at or above the
Temperature Hot parameter setting.
Clear:
Bring the motor temperature within
range.
1.
Move to cooler area, reduce operating
load.
29
Motor Temp Sensor Fault
1.
Motor thermistor is not con-
nected properly.
Set:
Motor thermistor input (pin 8) is at the
voltage rail (0V or 10 V).
Clear:
Bring the motor thermistor input
voltage within range.
1.
Inspect motor encoder/thermistor cable
and connector.
31
Main Contactor
Open/Short
1.
Open or short across contrac-
tor coil.
2.
Dirty connector pins.
3.
Bad crimps or faulty wiring.
Set:
Main contactor driver (pin 6) is either
open or shorted. This fault can be set only
when Main Enable = ON.
Clear:
Correct open or short, and cycle
power switch.
1.
Inspect contactor coil cables and con-
nectors.
2.
Test the contactor coil and replace
contactor if needed.
36
Encoder Fault
1.
Motor encoder failure.
2.
Bad crimps or faulty wiring.
Set:
Motor encoder phase failure detected.
Clear:
Cycle power switch.
1.
Inspect motor encoder/thermistor cable
and connector.
2.
Replace motor.
37
Motor Open
1.
Motor phase is open.
2.
Bad crimps or faulty wiring.
Set:
Motor phase U, V, or W detected
open.
Clear:
Cycle power switch.
1.
Inspect U, V, W cables.
2.
Replace motor.
38
Main Contactor Welded
1.
Main contactor tips are
welded closed.
2.
Motor phase U or V is discon-
nected or open.
3.
An alternate voltage path is
bypassing the contractor
between battery and B+ on
the controller before the con-
tractor engages.
Set:
Just prior to the main contactor clos-
ing, the battery pack voltage (B+ connec-
tion terminal) was loaded for a short time
and the voltage did not discharge.
Clear:
Cycle power switch.
1.
Inspect contactor for welded contacts
and replace if necessary.
2.
Inspect all cables from the battery pack
to controller looking for insulation dam-
age.
3.
Inspect U, V, W cables.
CODE
DESCRIPTION
POSSIBLE CAUSE
SET / CLEAR CONDITIONS
SOLUTION
