Return to TOC Curtis 1232E/34E/36E/38E & 1232SE/34SE/36SE/38SE Manual, os 31 – May 2017

11 — DIAGNOSTICS AND TROUBLESHOOTING

These controllers detect a wide variety of faults or error conditions. Faults can be detected by the
operating system or by the VCL code. This chapter describes the faults detected by the operating system
Faults detected by VCL code (faults 51–67 in Table 6) cannot be defined here as they will vary from
application to application. Refer to the appropriate OEM documentation for information on these faults.

DIAGNOSTICS
Diagnostics information can be obtained in either of two ways: (1) by reading the display on a 1313
handheld or 1314 PC programmer or (2) by observing the fault codes issued by the Status LEDs. See
Table 5 for a summary of LED display formats.
The 1313 /1314 programmer will display all faults that are currently set as well as a history of the
faults that have been set since the history log was last cleared. The 1313/1314 displays the faults by
name.
The pair of LEDs built into the controller (one red, one yellow) produce flash codes displaying all the
currently set faults in a repeating cycle. Each code consists of two digits. The red LED flashes once
to indicate that the first digit of the code will follow; the yellow LED then flashes the appropriate
number of times for the first digit. The red LED flashes twice to indicate that the second digit of the
code will follow; the yellow LED flashes the appropriate number of times for the second digit.

Example:
B+ Undervoltage Cutback (code 23).
In the Fault menu of the 1313/1314 programmer, the words B+ Undervoltage Cutback will be
displayed; the real-time battery voltage is displayed in the Monitor menu (“Capacitor Voltage”).
The controller’s two LEDs will display this repeating pattern:

Red Yellow Red Yellow

(first digit) (2) (second digit) (3)

The numerical codes used by the yellow LED are listed in the troubleshooting chart (Table 6), which
also lists possible fault causes and describes the conditions that set and clear each fault.

11 — DIAGNOSTICS AND TROUBLESHOOTING pg. 129

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Summary of LED Display Formats

The two LEDs have four different display modes, indicating the type of information they are providing.
Table 5 Types of LED Display
Display Status
Neither LED illuminated Controller is not powered on; or vehicle has dead battery; or severe damage.
Yellow LED flashing Controller is operating normally.
Yellow and red LEDs both
Controller is in Flash program mode.
on solid
Red LED on solid Internal hardware fault detected by the Supervisor or Primary microprocessor.
Missing or corrupt software. Interrupting a software download may cause
corruption of the software. Cycle KSI to clear. Reload software or replace
controller if necessary.
Red LED and yellow LED Controller has detected a fault. 2-digit code flashed by yellow LED identifies the
flashing alternately specific fault; one or two flashes by red LED indicate whether first or second code
digit will follow.

TROUBLESHOOTING
The troubleshooting chart, Table 6, provides the following information on all the controller faults:

• fault code
• fault name as displayed on the programmer’s LCD
• the effect of the fault
• possible causes of the fault
• fault set conditions
• fault clear conditions.

Whenever a fault is encountered and no wiring or vehicle fault can be found, shut off KSI and turn it
back on to see if the fault clears. If it does not, shut off KSI and remove the 35-pin connector. Check
the connector for corrosion or damage, clean it if necessary, and re-insert it.

pg. 130 11 — DIAGNOSTICS AND TROUBLESHOOTING

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The fault actions (effect of fault) in Table 6 use the same bit-structure as the User_Fault_Action_xx
listed in the OEM-defined User Faults on page 113. The variable System_Action (available in WinVCL
Monitor or TACT) returns the decimal number corresponding to the active fault action bit(s). The
Dual Drive fault actions, Bits 12–15, are listed in the supplemental Dual Drive Operation manual.
System_Action Bit Action
No defined System_Action Effect of fault as noted in Table 6
Bit0 = ShutdownMotor Disable the motor.
Bit1 = ShutdownMainContactor Shut down the main contactor (only if Main Enable = On)
Bit2 = ShutdownEMBrake Shut down the EM brake (only if EM Brake Disable Upon Fault = On).
Bit3 = ShutdownThrottle Set the Throttle_Command = 0%.
Bit4 = ShutdownInterlock Set the Interlock_State = Off.
Bit5 = ShutdownDriverl Shut down Driver1.
Bit6 = ShutdownDriver2 Shut down Driver2.
Bit7 = ShutdownDriver3 Shut down Driver3.
Bit8 = ShutdownDriver4 Shut down Driver4.
Bit9 = ShutdownPD Shut down Proportional Driver
Bit10 = FullBrake Set the Brake_Command = 100%.
Bit11 = [reserved] N/A (for 1232–1238E/SE, and 1239E controllers)
Bit12 = TrimDisable Disable Dual Drive trim calculation.
For Dual Drive system, one controller has a severe fault but the main
Bit13 = SevereDual
contactor must stay closed so the other controller can continue to operate.
Bit14 = ShutdownSteer Steer angle = 0° (DD applicable).
For Dual Drive system, set the max speed to Dual_LOS_Max_Speed
Bit15 = LOSDual
parameter for operation in Limited Operating Strategy.

Example:
HPD/Sequencing Fault, Flash Code 47.
Effect of fault = Shutdown Throttle.
System_Action = 8 (equates to Bit3 set: 0000 0000 0000 1000)

11 — DIAGNOSTICS AND TROUBLESHOOTING pg. 131

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Table 6 TROUBLESHOOTING CHART

PROGRAMMER LCD DISPLAY

CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
12 Controller Overcurrent 1. External short of phase U,V, or W motor Set: Phase current exceeded the current
ShutdownMotor; connections. measurement limit.
ShutdownMainContactor; 2. Motor parameters are mis-tuned. Clear: Cycle KSI.
ShutdownEMBrake; 3. Controller defective.
ShutdownThrottle;
FullBrake. 4. Speed encoder noise problems.
13 Current Sensor Fault 1. Leakage to vehicle frame from phase U, Set: Controller current sensors have invalid offset
ShutdownMotor; V, or W (short in motor stator). reading.
ShutdownMainContactor; 2. Controller defective. Clear: Cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
FullBrake.
14 Precharge Failed 1. See Monitor menu » Battery: Capacitor Set: The precharge failed to charge the capacitor
ShutdownMotor; Voltage. bank.
ShutdownMainContactor; 2. External load on capacitor bank (B+ Clear: Cycle Interlock input or use VCL function
ShutdownEMBrake; connection terminal) that prevents the Enable_Precharge().
ShutdownThrottle; capacitor bank from charging.
FullBrake.
15 Controller Severe Undertemp 1. See Monitor menu » Controller: Set: Heatsink temperature below -40°C.
ShutdownMotor; Temperature. Clear: Bring heatsink temperature above -40°C,
ShutdownMainContactor; 2. Controller is operating in an extreme and cycle interlock or KSI.
ShutdownEMBrake; environment.
ShutdownThrottle;
FullBrake.
16 Controller Severe Overtemp 1. See Monitor menu » Controller: Set: Heatsink temperature above +95°C.
ShutdownMotor; Temperature. Clear: Bring heatsink temperature below +95°C,
ShutdownMainContactor; 2. Controller is operating in an extreme and cycle interlock or KSI.
ShutdownEMBrake; environment.
ShutdownThrottle; 3. Excessive load on vehicle.
FullBrake.
4. Improper mounting of controller.
17 Severe B+ Undervoltage 1. Battery parameters are misadjusted. Set: Capacitor bank voltage dropped below the
No drive torque. 2. Non-controller system drain on battery. Severe Undervoltage limit (see page 25) with FET
3. Battery resistance too high. bridge enabled.
4. Battery disconnected while driving. Clear: Bring capacitor voltage above Severe
5. See Monitor menu » Battery: Capacitor Undervoltage limit.
Voltage.
6. Blown B+ fuse or main contactor did not
close.
17 Severe KSI Undervoltage 1. See Monitor menu » Battery: Keyswitch Set: When below Brownout Voltage for 2 seconds
No action. Voltage. (see Table D-1).
2. Non-controller system drain on battery/ Clear: Bring KSI voltage above Brownout Voltage.
KSI circuit wiring.
3. KSI disconnected while driving.
4. Blown KSI fuse.
18 Severe B+ Overvoltage 1. See Monitor menu » Battery: Capacitor Set: Capacitor bank voltage exceeded the Severe
ShutdownMotor; Voltage. Overvoltage limit (see page 25) with FET bridge
ShutdownMainContactor; 2. Battery parameters are misadjusted. enabled.
ShutdownEMBrake; 3. Battery resistance too high for given Clear: Bring capacitor voltage below Severe
ShutdownThrottle; regen current. Overvoltage limit, and then cycle KSI.
FullBrake.
4. Battery disconnected while regen
braking.

pg. 132 11 — DIAGNOSTICS AND TROUBLESHOOTING

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Table 6 TROUBLESHOOTING CHART cont’d

PROGRAMMER LCD DISPLAY

CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
18 Severe KSI Overvoltage 1. Incorrect (to high) battery-voltage Set: KSI voltage exceeded Severe Overvoltage limiit
ShutdownMotor; applied to KSI (pin 1) Clear: Bring KSI voltage below the Severe
ShutdownMainContactor; 2. See Monitor menu » Battery: Keyswitch Overvoltage limit
ShutdownEMBrake; Voltage.
ShutdownThrottle; (see page 25, Severe Overvoltage)
Note: Prevents the Main Contactor closure if
FullBrake. KSI is greater than the Severe Overvoltage
limit.

22 Controller Overtemp Cutback 1. See Monitor menu » Controller: Set: Heatsink temperature exceeded 85°C.
Reduced drive and brake torque. Temperature. Clear: Bring heatsink temperature below 85°C.
2. Controller is performance-limited at this
temperature.
3. Controller is operating in an extreme
environment.
4. Excessive load on vehicle.
5. Improper mounting of controller.
23 B+ Undervoltage Cutback 1. Normal operation. Fault indicates the Set: Capacitor bank voltage dropped below the
Reduced drive torque. batteries need recharging. Controller is Undervoltage limit (see page 25) with the FET
performance limited at this voltage. bridge enabled.
2. Battery parameters are misadjusted. Clear: Bring capacitor voltage above the
3. Non-controller system drain on battery. Undervoltage limit.
4. Battery resistance too high.
5. Battery disconnected while driving.
6. See Monitor menu » Battery: Capacitor
Voltage.
7. Blown B+ fuse or main contactor did not
close.
24 B+ Overvoltage Cutback 1. Normal operation. Fault shows that regen Set: Capacitor bank voltage exceeded the
Reduced brake torque. Note: This braking currents elevated the battery Overvoltage limit (see page 25) with the FET bridge
fault is declared only when the voltage during regen braking. Controller enabled.
controller is running in regen. is performance limited at this voltage. Clear: Bring capacitor voltage below the
2. Battery parameters are misadjusted. Overvoltage limit.
3. Battery resistance too high for given
regen current.
4. Battery disconnected while regen
braking.
5. See Monitor menu » Battery: Capacitor
Voltage.
25 +5V Supply Failure 1. External load impedance on the +5V Set: +5V supply (pin 26) outside the 5 V±10%
None, unless a fault action is supply (pin 26) is too low. range.
programmed in VCL. 2. See Monitor menu » outputs: 5 Volts and Clear: Bring voltage within range.
Ext Supply Current.

26 Digital Out 6 Open/Short 1. External load impedance on Digital Set: Digital Output 6 (pin 19) current exceeded 1
Digital Output 6 driver will not Output 6 driver (pin 19) is too low. Amp.
turn on. Clear: Remedy the overcurrent cause and use the
VCL function Set_DigOut() to turn the driver on
again.
27 Digital Out 7 Open/Short 1. External load impedance on Digital Set: Digital Output 7 (pin 20) current exceeded 1
Digital Output 7 driver will not Output 7 driver (pin 20) is too low. Amp.
turn on. Clear: Remedy the overcurrent cause and use the
VCL function Set_DigOut() to turn the driver on
again.

11 — DIAGNOSTICS AND TROUBLESHOOTING pg. 133

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Table 6 TROUBLESHOOTING CHART cont’d

PROGRAMMER LCD DISPLAY

CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
28 Motor Temp Hot Cutback 1. Motor temperature is at or above the Set: Motor temperature is at or above the
Reduced drive torque. programmed Temperature Hot setting, Temperature Hot parameter setting.
and the current is being cut back. Clear: Bring the motor temperature within range.
2. Motor Temperature Control Menu
parameters are mis-tuned.
3. See Monitor menu » Motor: Temperature
and » Inputs: Analog2.
4. If the application doesn’t use a motor
thermistor, Temp Compensation and Temp
Cutback should be programmed Off.
29 Motor Temp Sensor Fault 1. Motor thermistor is not connected Set: Motor thermistor input (pin 8) is at the voltage
MaxSpeed reduced (LOS, Limited properly. rail (0 V or 10 V).
Operating Strategy), and motor 2. If the application doesn’t use a motor Clear: Bring the motor thermistor input voltage
temperature cutback disabled. thermistor, Motor Temp Sensor Enable within range.
should be programmed Off.
3. See Monitor menu » Motor: Temperature
and » Inputs: Analog2.
31 Coil1 Driver Open/Short 1. Open or short on driver load. Set: Driver 1 (pin 6) is either open or shorted. This
ShutdownDriver1. 2. Dirty connector pins. fault can be set only when Main Enable = Off.
3. Bad crimps or faulty wiring. Clear: Correct open or short, and cycle driver.
31 Main Open/Short 1. Open or short on driver load. Set: Main contactor driver (pin 6) is either open
ShutdownMotor; 2. Dirty connector pins. or shorted. This fault can be set only when Main
ShutdownMainContactor; 3. Bad crimps or faulty wiring. Enable = On.
ShutdownEMBrake; Clear: Correct open or short, and cycle driver
ShutdownThrottle;
FullBrake.
32 Coil2 Driver Open/Short 1. Open or short on driver load. Set: Driver 2 (pin 5) is either open or shorted. This
ShutdownDriver2. 2. Dirty connector pins. fault can be set only when EM Brake Type = 0.
3. Bad crimps or faulty wiring. Clear: Correct open or short, and cycle driver.
32 EMBrake Open/Short 1. Open or short on driver load. Set: Electromagnetic brake driver (pin 5) is either
ShutdownEMBrake; 2. Dirty connector pins. open or shorted. This fault can be set only when EM
ShutdownThrottle; 3. Bad crimps or faulty wiring. Brake Type >0.
FullBrake. Clear: Correct open or short, and cycle driver.
33 Coil3 Driver Open/Short 1. Open or short on driver load. Set: Driver 3 (pin 4) is either open or shorted.
ShutdownDriver3. 2. Dirty connector pins. Clear: Correct open or short, and cycle driver.
3. Bad crimps or faulty wiring.
34 Coil4 Driver Open/Short 1. Open or short on driver load. Set: Driver 4 (pin 3) is either open or shorted.
ShutdownDriver4. 2. Dirty connector pins. Clear: Correct open or short, and cycle driver.
3. Bad crimps or faulty wiring.
35 PD Open/Short 1. Open or short on driver load. Set: Proportional driver (pin 2) is either open or
ShutdownPD. 2. Dirty connector pins. shorted.
3. Bad crimps or faulty wiring. Clear: Correct open or short, and cycle driver.
36 Encoder Fault 1. Motor encoder failure. Set: Motor encoder phase failure detected.
ShutdownEMBrake; 2. Bad crimps or faulty wiring. Clear: Either cycle KSI, or if parameter LOS Upon
Motor disabled. 3. See Monitor menu » Motor: Motor RPM. Encoder Fault= On and Interlock has been cycled,
then the Encoder Fault is cleared and Encoder LOS
fault (code 93) is set, allowing limited motor control.
36 Sin/Cos Sensor Fault 1. Sin/Cos sensor failure. Set: Greater than Sin_Cos_Fault_Threshold %
ShutdownEMBrake; 2. Bad crimps or faulty wiring. difference from expected value between two phases
Motor disabled. 3. See Monitor menu » Motor: Motor RPM. seen 5 times within one second.
Clear: Cycle KSI, or VCL reset, or Entry into LOS
mode if enabled, (or entry into an ACIM auto-
characterization).

pg. 134 11 — DIAGNOSTICS AND TROUBLESHOOTING

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Table 6 TROUBLESHOOTING CHART cont’d

PROGRAMMER LCD DISPLAY

CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
37 Motor Open 1. Motor phase is open. Set: Motor phase U, V, or W detected open.
ShutdownMotor; 2. Bad crimps or faulty wiring. Clear: Cycle KSI.
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
FullBrake.
38 Main Contactor Welded 1. Main contactor tips are welded closed. Set: Just prior to the main contactor closing, the
ShutdownMotor; 2. Motor phase U or V is disconnected or capacitor bank voltage (B+ connection terminal)
ShutdownMainContactor; open. was loaded for a short time and the voltage did not
ShutdownEMBrake; 3. An alternate voltage path (such as an discharge.
ShutdownThrottle; external precharge resistor) is providing Clear: Cycle KSI
FullBrake. a current to the capacitor bank (B+
connection terminal).
39 Main Contactor Did Not Close 1. Main contactor did not close. Set: With the main contactor commanded closed,
ShutdownMotor; 2. Main contactor tips are oxidized, burned, the capacitor bank voltage (B+ connection terminal)
ShutdownMainContactor; or not making good contact.* did not charge to B+.
ShutdownEMBrake; 3. External load on capacitor bank (B+ Clear: Cycle KSI.
ShutdownThrottle; connection terminal) that prevents
FullBrake. *New contactors may need to be cycled electrically &
capacitor bank from charging.
mechanically to remove any non-conductive material on
4. Blown B+ fuse. the tips. Use reduced voltage (e.g., 12V) to prevent tip
damage through excessive arcing.
41 Throttle Wiper High 1. See Monitor menu » Inputs: Throttle Pot. Set: Throttle pot wiper (pin 16) voltage is higher
ShutdownThrottle. 2. Throttle pot wiper voltage too high. than the high fault threshold (can be changed with
the VCL function Setup_Pot_Faults()).
Clear: Bring throttle pot wiper voltage below the
fault threshold.
42 Throttle Wiper Low 1. See Monitor menu » Inputs: Throttle Pot. Set: Throttle pot wiper (pin 16) voltage is lower than
ShutdownThrottle. 2. Throttle pot wiper voltage too low. the low fault threshold (can be changed with the
VCL function Setup_Pot_Faults()).
Clear: Bring throttle pot wiper voltage above the
fault threshold.
43 Pot2 Wiper High 1. See Monitor menu » Inputs: Pot2 Raw. Set: Pot2 wiper (pin 17) voltage is higher than the
FullBrake. 2. Pot2 wiper voltage too high. high fault threshold (can be changed with the VCL
function Setup_Pot_Faults()).
Clear: Bring Pot2 wiper voltage below the fault
threshold.
44 Pot2 Wiper Low 1. See Monitor menu » Inputs: Pot2 Raw. Set: Pot2 wiper (pin 17) voltage is lower than the
FullBrake. 2. Pot2 wiper voltage too low. low fault threshold (can be changed with the VCL
function Setup_Pot_Faults()).
Clear: Bring Pot2 wiper voltage above the fault
threshold.
45 Pot Low OverCurrent 1. See Monitor menu » Outputs: Pot Low. Set: Pot low (pin 18) current exceeds 10 mA.
ShutdownThrottle; 2. Combined pot resistance connected to Clear: Clear pot low overcurrent condition and cycle
FullBrake. pot low is too low. KSI.
46 EEPROM Failure 1. Failure to write to EEPROM memory. Set: Controller operating system tried to write to
ShutdownMotor; This can be caused by EEPROM memory EEPROM memory and failed.
ShutdownMainContactor; writes initiated by VCL, by the CAN Clear: Download the correct software (OS) and
ShutdownEMBrake; bus, by adjusting parameters with the matching parameter default settings into the
ShutdownThrottle; programmer, or by loading new software controller and cycle KSI.
ShutdownInterlock; into the controller.
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.

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Table 6 TROUBLESHOOTING CHART cont’d

PROGRAMMER LCD DISPLAY

CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
47 HPD/Sequencing Fault 1. KSI, interlock, direction, and throttle Set: HPD (High Pedal Disable) or sequencing fault
ShutdownThrottle. inputs applied in incorrect sequence. caused by incorrect sequence of KSI, interlock,
2. Faulty wiring, crimps, or switches at KSI, direction, and throttle inputs.
interlock, direction, or throttle inputs. Clear: Reapply inputs in correct sequence.
3. See Monitor menu » Inputs.
47 Emer Rev HPD 4. Emergency Reverse operation has Set: At the conclusion of Emergency Reverse, the
ShutdownThrottle; concluded, but the throttle, forward and fault was set because various inputs were not
ShutdownEMBrake. reverse inputs, and interlock have not returned to neutral.
been returned to neutral. Clear: If EMR_Interlock = On, clear the interlock,
throttle, and direction inputs. If EMR_Interlock = Off,
clear the throttle and direction inputs.
49 Parameter Change Fault 1. This is a safety fault caused by a change Set: Adjustment of a parameter setting that requires
ShutdownMotor; in certain parameter settings so that the cycling of KSI.
ShutdownMainContactor; vehicle will not operate until KSI is cycled. Clear: Cycle KSI.
ShutdownEMBrake; For example, if a user changes the Throttle
ShutdownThrottle; Type this fault will appear and require
FullBrake. cycling KSI before the vehicle can operate.
51-67 OEM Faults 1. These faults can be defined by the Set: See OEM documentation.
(See OEM documentation.) OEM and are implemented in the Clear: See OEM documentation.
application-specific VCL code. See OEM
documentation.
68 VCL Run Time Error 1. VCL code encountered a runtime VCL Set: Runtime VCL code error condition.
ShutdownMotor; error. Clear: Edit VCL application software to fix this error
ShutdownMainContactor; 2. See Monitor menu » Controller: VCL Error condition; flash the new compiled software and
ShutdownEMBrake; Module and VCL Error. This error can then matching parameter defaults; cycle KSI.
ShutdownThrottle; be compared to the runtime VCL module
ShutdownInterlock; ID and error code definitions found in the
ShutdownDriver1; specific OS system information file.
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
69 External Supply Out of Range 1. External load on the 5V and 12V supplies Set: The external supply current (combined current
None, unless a fault action is draws either too much or too little used by the 5V supply [pin 26] and 12V supply
programmed in VCL. current. [pin 25]) is either greater than the upper current
2. Fault Checking Menu parameters Ext threshold or lower than the lower current threshold.
Supply Max and Ext Supply Min are The two thresholds are defined by the External
mis-tuned. Supply Max and External Supply Min parameter
3. See Monitor menu » Outputs: Ext Supply settings (page 54).
Current. Clear: Bring the external supply current within range.
71 OS General 1. Internal controller fault. Set: Internal controller fault detected.
ShutdownMotor; Clear: Cycle KSI.
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
72 PDO Timeout 1. Time between CAN PDO messages Set: Time between CAN PDO messages received
ShutdownThrottle; received exceeded the PDO Timeout exceeded the PDO Timeout Period.
CAN NMT State set to Period. Clear: Cycle KSI or receive CAN NMT message.
Pre-operational.

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Table 6 TROUBLESHOOTING CHART cont’d

PROGRAMMER LCD DISPLAY

CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
73 Stall Detected 1. Stalled motor. Set: No motor encoder movement detected.
ShutdownEMBrake; 2. Motor encoder failure. Clear: Either cycle KSI, or if parameter LOS Upon
Motor disabled; 3. Bad crimps or faulty wiring. Encoder Fault = On and Interlock has been cycled,
Control Mode changed to LOS
4. Problems with power supply for the then the Stall Detected fault is cleared and Encoder
(Limited Operating Strategy).
motor encoder. LOS fault (code 93) is set, allowing limited motor
5. See Monitor menu » Motor: Motor RPM. control.

74 Fault On Other Traction 1. Dual Drive fault: see Dual Drive manual.
Controller

75 Dual Severe Fault 1. Dual Drive fault: see Dual Drive manual.

77 Supervisor Fault 1. The Supervisor has detected a mismatch Set: Mismatched redundant readings; damaged
ShutdownMotor; in redundant readings. Supervisor; illegal switch inputs.
ShutdownMainContactor; 2. Internal damage to Supervisor Clear: Check for noise or voltage drift in all switch
ShutdownEMBrake; microprocessor. inputs; check connections; cycle KSI.
ShutdownThrottle; 3. Switch inputs allowed to be within
ShutdownInterlock; upper and lower thresholds for over 100
ShutdownDriver1; milliseconds. (for recurring errors, check
ShutdownDriver2; the switches for moisture).
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
78 Supervisor Incompatible 1. The main OS is not compatible with the Set: Incompatible software.
ShutdownMotor; Supervisor OS. Clear: Load properly matched OS code or update
ShutdownMainContactor; the Supervisor code; cycle KSI.
ShutdownEMBrake;
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
82 Bad Calibrations 1. Internal controller fault. Set: Internal controller fault detection.
ShutdownMotor; Clear: Cycle KSI.
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
FullBrake.
83 Driver Supply 1. Internal controller fault in the voltage Set: Internal controller fault detection.
ShutdownMotor; supply for the driver circuits. Clear: Cycle KSI.
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
FullBrake.

11 — DIAGNOSTICS AND TROUBLESHOOTING pg. 137

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Table 6 TROUBLESHOOTING CHART cont’d

PROGRAMMER LCD DISPLAY

CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
87 Motor Characterization Fault 1. Motor characterization failed during Set: Motor characterization failed during the motor
ShutdownMotor; characterization process. See characterization process.
ShutdownMainContactor; Monitor menu » Controller: Motor Normally caused by turning off
ShutdownEMBrake; Characterization Error for cause: Motor_Characterization_Test_Enable before
ShutdownThrottle; 0 = sequencing error. Normally caused running test. Needs controller reset.
FullBrake. by turning off Motor Characterization Clear: Correct fault; cycle KSI, or VCL reset.
Test Enable before running the test.
1 = encoder signal seen but step size not
auto-detected; set up Encoder Steps
manually
2 = motor temp sensor fault
3 = motor temp hot cutback fault
4 = controller overtemp cutback fault
5 = controller undertemp cutback fault
6 = undervoltage cutback fault
7 = severe overvoltage fault
8 = encoder signal not seen, or one or
both channels missing
9 = motor parameters out of
characterization range
20 = Sin/Cos sensor not found
21 = phasing not detected
22 = Sin/Cos sensor characterization
failure
23 = started characterization procedure
while motor rotating.
88 Encoder Pulse Count Fault 1. Encoder Steps parameter does not Set: Detected wrong setting of the Encoder Steps
ShutdownMotor; match the actual motor encoder. parameter.
ShutdownMainContactor; Clear: Ensure the Encoder Steps parameter
ShutdownEMBrake; matches the actual encoder; cycle KSI.
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
89 Motor Type Fault 2. The Motor_Type parameter value is out Set: Motor_Type parameter is set to an illegal
ShutdownMotor; of range. value.
ShutdownMainContactor; Clear: Set Motor_Type to correct value and cycle
ShutdownEMBrake; KSI.
ShutdownThrottle;
FullBrake.

pg. 138 11 — DIAGNOSTICS AND TROUBLESHOOTING

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Table 6 TROUBLESHOOTING CHART cont’d

PROGRAMMER LCD DISPLAY

CODE POSSIBLE CAUSE SET / CLEAR CONDITIONS
EFFECT OF FAULT
91 VCL/OS Mismatch 1. The VCL software in the controller Set: VCL and OS software do not match; when KSI
ShutdownMotor; does not match the OS software in the cycles, a check is made to verify that they match
ShutdownMainContactor; controller. and a fault is issued when they do not.
ShutdownEMBrake; Clear: Download the correct VCL and OS software
ShutdownThrottle; into the controller.
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake.
92 EM Brake Failed to Set 1. Vehicle movement sensed after the EM Set: After the EM Brake was commanded to set
ShutdownEMBrake; Brake has been commanded to set. and time has elapsed to allow the brake to fully
ShutdownThrottle. 2. EM Brake will not hold the motor from engage, vehicle movement has been sensed.
Position Hold is engaged when rotating. Clear: 1. Activate the Throttle (EM Brake type 2).
Interlock = On.
2. Activate the Interlock (EM Brake type 1).
93 Encoder LOS (Limited 1. Limited Operating Strategy (LOS) control Set: Encoder Fault (code 36) or Stall Detected (code
Operating Strategy) mode has been activated, as a result of 73) was activated, if parameter LOS Upon Encoder
Enter LOS control mode. either an Encoder Fault (Code 36) or a Fault = On and Interlock has been cycled, then the
Stall Detected fault (Code 73). Encoder LOS (code 93) control mode is activated,
2. Motor encoder failure. allowing limited motor control.
3. Bad crimps or faulty wiring. Clear: Cycle KSI or, if LOS mode was activated by
4. Vehicle is stalled. the Stall Detected fault, clear by ensuring encoder
senses proper operation, Motor RPM = 0, and
Throttle Command = 0.
94 Emer Rev Timeout 1. Emergency Reverse was activated and Set: Emergency Reverse was activated and ran
ShutdownEMBrake; concluded because the EMR Timeout until the EMR Timeout timer expired.
ShutdownThrottle. timer has expired. Clear: Turn the emergency reverse input Off.
2. The emergency reverse input is stuck
On.
98 Illegal Model Number 1. Model_Number variable contains illegal Set: Illegal Model_Number variable; when KSI
ShutdownMotor; value. cycles, a check is made to confirm a legal Model_
ShutdownMainContactor; 2. Software and hardware do not match. Number, and a fault is issued if one is not found.
ShutdownEMBrake; 3. Controller defective. Clear: Download appropriate software for your
ShutdownThrottle; controller model.
FullBrake.
99 Parameter Mismatch 1. Dual drive enabled on only one controller. Set: When the Dual Drive software is enabled,
ShutdownMotor; 2. Incorrect position feedback type chosen the controller must be set to either Speed Mode
ShutdownMainContactor; for motor technology in use. Express or Speed Mode; otherwise this fault is set.
ShutdownEMBrake; 3. Dual drive is enabled in torque mode. Motor Techology=0 must be paired with Feedback
ShutdownThrottle; Type=1, and Motor Technology=1 must be paired
FullBrake. with Feedback Type=2; otherwise this fault is set.
Clear: Adjust parameters to appropriate values and
cycle KSI.

11 — DIAGNOSTICS AND TROUBLESHOOTING pg. 139