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• Troubleshooting – Motor Controllers

Troubleshooting Guide – Motor Controllers

Control Solutions Motor Controllers have a digital microcontroller, which performs diagnostics during power up. If an error is detected, the controller outputs an error code. The error code is displayed either by an LED on the controller or integrated on the user/throttle interface. When an error is detected, the LED/user/throttle interface will flash a 2 digit sequence of numbers indicating the diagnostic code. The flashing occurs in this order:

Example 2-1 of error code

 

1. The LED/user/throttle interface will flash a number of times indicating the first number of the code
2. A 1 second pause.
3. The LED/user/throttle interface will flash a number of times indicating the second number of the code
4. A pause for 2-3 seconds and then the flash sequence will repeat the error code.

To troubleshoot the problem follow these steps.

1. Write down the error code as determined from the procedure above.
2. Find the error code in the table below.
3. Follow the Corrective Steps in the table to resolve the problem
4. If the Corrective Steps does not solve your problem, contact Control Solutions Technical Support for next steps to resolve this problem.

Error Codes	Problem	Possible Causes	Corrective Steps
1-1	Brake Short	Loose/broken connection between brake and motor controller or shorted with bad brake.	1. Inspect wire between brake and controller for damage or loose connections. Replace wire if needed.
1-2	Brake Open	Brake shorted to case, Missing/open brake, Loose/broken connection to brake, DC motor controller	1. Inspect wire between brake and controller for damage or loose connections. Replace wire if needed. 2. Brake is missing from unit.3. Brake broken.
1-3	Quick Stop/Drive Inhibit	A safety sensing device such as a seat switch, proximity sensor, emergency stop button has been activated.	1. Clear the condition that is activating the safety device.2. The safety device could be faulty and needs to be replaced.
1-4	Deadband Start Error	1. The throttle was engaged during vehicle power up.2. The throttle is automatically returning to neutral when released.	1. Make sure the throttle is in the neutral position prior to turning on the vehicle. 2. The throttle is faulty and not automatically returning to the neutral position when released. Contact your local service center to have it re-centered.
2-1	Motor Short	1. Loose/broken connection to brake or motor controller 2. Broken Motor	1. Inspect wire between brake and controller for damage or loose connections. Replace wire if needed. 2. The drive motor is faulty and should be replaced.
2-2	Motor Open	1. Loose/broken connection to brake or motor controller 2. Broken Motor 3. The drive motor was disengaged (such as in a free wheel mode).	1. Inspect wire between brake and controller for damage or loose connections. Replace wire if needed. 2. The drive motor is faulty and should be replaced. 3. Re-engage the drive motor
2-3	Power Relay Short	The power relay on the controller has developed a short.	Contact your OEM or representative for service of the motor controller.
2-4	PSL Motor Short	1. Loose/broken connection to PSL motor 2. Bad PSL motor	1. Inspect wire between PSL motor and controller for damage or loose connections. Replace wire if needed. 2. Replace PSL motor
3-1	Over Temperature	1. Operating in extreme environment (heat/terrain) 2. Brake is engaged while driving 3. Excessive load on vehicle A slow down in vehicle speed may accompany this error code.	1. Operate the vehicle in accordance with OEM specifications. 2. Check brake for faulty operation. 3. Reduce load on vehicle If a slow down has occurred then stop, turn off the unit and wait for it to cool down. The unit will return to full operating range.
4-1	Over Voltage Condition During Charge	The battery voltage is too high during charge charge cycle.	1. The batteries should be inspected for problems by a qualified technician. 2. Check the battery charger and its connections for problems.
4-2	Charge Mode Time Out	The charge cycle did not complete within 24 hours.	1. Check the battery charger and its connections for problems. 2. The batteries should be inspected for problems by a qualified technician.
4-3	Charger Over Temperature Condition	The charger overheated during the charge cycle (valid for CS1204 charger only). Check the battery and charger for problems.	1. The batteries should be inspected for problems by a qualified technician. 2. Battery charger is faulty.
5-1 5-2	Internal Failure	An internal component of the motor controller.	Contact your OEM or representative for service of the motor controller.
5-3 5-4	Throttle Failband	Throttle control is off center or open.	1. Broken throttle 2. Loose/broken connection/cable to throttle. Generally this is caused by a short to ground, 5V in throttle, or a broken throttle wire.
5-5 5-6 5-7 5-8 5-9 5-10	Intenal Failure	An internal component on the CS1108 has failed.	Contact your OEM or representative for service of the motor controller.
6-1	Internal Failure	The software revision of the programmer is the wrong version for the software in the controller.	The hand held programmer is not compatible with the motor controller. Contact the vehicle OEM or Control Solutions for advice.
6-2 6-3	Internal Failure	An internal component on the CS1108 has failed.	Contact your OEM or representative for service of the motor controller.