T12 Service Information 9009917 (12-12)
4-19
TROUbLESHOOTING
Curtis 1232 Controller Diagnostic Codes, continued
13
14
15
16
17
Severe Undervoltage
Reduced drive torque.
TROUBLESHOOTING CHART
FAULT CONDITION
CODE
EFFECT OF FAULT
POSSIBLE CAUSE
SET/CLEAR CONDITIONS
12
Controller Overcurrent
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
FullBrake;
ShutdownPump.
1. Leakage to vehicle frame from phase
U, V, or W (short in motor stator).
2. Controller defective.
Current Sensor Fault
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
FullBrake;
ShutdownPump.
1. External load on capacitor bank (B+
connection terminal) that prevents
the capacitor bank from charging.
2. See Monitor menu » Battery:
Capacitor Voltage.
Precharge Failed
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
FullBrake;
ShutdownPump.
1. See Monitor menu » Controller:
Temperature.
2. Controller is operating in an extreme
environment.
Controller Severe Undertemp
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
FullBrake;
ShutdownPump.
1. See Monitor menu » Controller:
Temperature.
2. Controller is operating in an extreme
environment.
3. Excessive load on vehicle.
4. Improper mounting of controller.
Controller Severe Overtemp
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
FullBrake;
ShutdownPump.
1. Battery Menu parameters are
misadjusted.
2. Non-controller system drain on
battery.
3. Battery resistance too high.
4. Battery disconnected while driving.
5. See Monitor menu » Battery:
Capacitor Voltage.
6. Blown B+ fuse or main contactor
did not close.
Set:
Controller current sensors have
invalid offset reading.
Clear:
Cycle KSI.
Set:
Phase current exceeded the
current measurement limit.
Clear:
Cycle KSI.
Set:
Precharge failed to charge the
capacitor bank to the KSI voltage.
Clear:
Cycle interlock input or use VCL
function.
Set:
Heatsink temperature below -40˚C.
Clear:
Bring heatsink temperature
above -40˚C, and cycle interlock or KSI.
Set:
Heatsink temperature above +95˚C.
Clear:
Bring heatsink temperature
below +95˚C, and cycle interlock or KSI.
Set:
Capacitor bank voltage dropped
below the severe undervoltage limit
with FET bridge enabled.
Clear:
Bring capacitor voltage above
severe undervoltage limit.
1. External short of phase U, V, or W
motor connections.
2. Motor parameters are mis-tuned.
3. Controller defective.
TROUBLESHOOTING CHART, continued
FAULT CONDITION
CODE
EFFECT OF FAULT
POSSIBLE CAUSE
SET/CLEAR CONDITIONS
68 VCL Run Time Error
1. VCL code encountered a runtime
Set:
Runtime VCL code error condition.
Clear:
Edit VCL application software to
fix this error condition; flash the new
compiled software and matching
parameter defaults; cycle KSI.
VCL error.
2. See Monitor menu » Controller:
VCL Error Module and VCL Error.
This error can then be compared to
the runtime VCL module ID and
error code definitions found in the
specific OS system information file.
69
External Supply Out of Range
1. External load on the 5V and 12V
Set:
The external supply current (com-
bined current used by the 5V supply
[pin 26] and 12V supply [pin 25]) is either
greater than the lower current threshold.
The two thresholds are defined by the
External Supply Max and External Supply
Min parameter settings.
Clear:
Bring the external supply current
within range.
None, unless a fault action
supplies draws either too much or
is programmed in VCL.
too little current.
2. Fault Checking Menu parameters
Ext Supply Max and Ext Supply Min
are mis-tuned.
3. See Monitor menu » Outputs:
Ext Supply Current.
71
OS General
1. Internal controller fault.
Set:
Internal controller fault detected.
Clear:
Cycle KSI
72
PDO Timeout
1. Time between CAN PDO messages
Set:
Time between CAN PDO messages
received exceeded the PDO Timeout
Period.
Clear:
Cycle KSI.
ShutdownInterlock;
received exceeded the PDO
CAN NMT State set
Timeout Period.
to Pre-operational.
73
Stall Detected
1. Stalled motor.
Set:
No motor encoder movement
detected.
Clear:
Either cycle KSI, or
detect valid motor encoder signals
while operating in LOS mode and
return Throttle Command = 0 and
Motor RPM= 0
ShutdownEMBrake.
2. Motor encoder failure.
3. Bad crimps or faulty wiring.
4. Problems with power supply for
the motor encoder.
5. See Monitor menu » Motor:
Motor RPM.
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake;
ShutdownPump.
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake;
ShutdownPump.
87
Motor Characterization Fault
1. Motor characterization failed during
Set:
Motor characterization failed during
the motor characterization process.
Clear:
Correct fault; cycle KSI.
ShutdownMotor;
characterization process. See Monitor
ShutdownMainContactor;
menu » Controller: Motor
ShutdownEMBrake;
Characterization Error for cause:
ShutdownThrottle;
0=none
FullBrake;
1=encoder signal seen, but step size
ShutdownPump.
not determined; set Encoder Step
Size 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 character-
ization range.
89
Motor Type Fault
1. The Motor_Type parameter value
Set: Motor_Type parameter is set to an
illegal value.
Clear: Set Motor_Type to correct value
and cycle KSI.
ShutdownMotor;
is out of range.
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
FullBrake;
ShutdownPump.
91
VCL/OS Mismatch
1. The VCL software in the controller
Set:
VCL and OS software do not match;
when KSI cycles, a check is made to
verify that they match and a fault is
issued when they do not.
Clear:
Download the correct VCL and
OS software into the controller.
does not match the OS software in
the controller.
92
EM Brake Failed to Set
1. Vehicle movement sensed after the
Set:
After the EM Brake was commanded
to set and time has elapsed to allow the
brake to fully engage, vehicle movement
has been sensed.
Clear:
Activate the throttle.
ShutdownEMBrake;
EM Brake has been commanded
ShutdownThrottle.
to set.
2. EM Brake will not hold the motor
from rotating.
93
Encoder LOS (Limited
1. Limited Operating Strategy (LOS)
Set:
Encoder Fault (Code 36) or Stall
Detect Fault (Code 73) was activated,
and Brake or Interlock has been applied
to activate LOS control mode, allowing
limited motor control.
Clear:
Cycle KSI, or if LOS mode was acti-
vated by the Stall Fault, clear by ensuring
encoder senses proper operation, Motor
RPM = 0, and Throttle Command = 0.
Operating Strategy)
control mode has been activated, as
Enter LOS control mode.
a result of either an Encoder Fault
(Code 36) or a Stall Detect Fault
(Code 73).
2. Motor encoder failure.
3. Bad crimps or faulty wiring.
4. Vehicle is stalled.
TROUBLESHOOTING CHART, continued
FAULT CONDITION
CODE
EFFECT OF FAULT
POSSIBLE CAUSE
SET/CLEAR CONDITIONS
ShutdownMotor;
ShutdownMainContactor;
ShutdownEMBrake;
ShutdownThrottle;
ShutdownInterlock;
ShutdownDriver1;
ShutdownDriver2;
ShutdownDriver3;
ShutdownDriver4;
ShutdownPD;
FullBrake;
ShutdownPump.
PMC010
TROUBLESHOOTING CHART, continued
FAULT CONDITION
CODE
EFFECT OF FAULT
POSSIBLE CAUSE
SET/CLEAR CONDITIONS
94 Emer Rev Timeout
1. Emergency Reverse was activated
Set:
Emergency Reverse was activated
and ran until the EMR Timeout timer
expired.
Clear:
Turn the emergency reverse
input Off.
ShutdownEMBrake;
and concluded because the EMR
ShutdownThrottle.
Timeout timer has expired.
2. The emergency reverse input is
stuck On.
98
Illegal Model Number
1. Model_Number variable contains
Set:
Illegal Model_Number variable; when
KSI cycles a check is made to confirm
a legal Model_Number, and a fault is
issued if one is not found.
Clear:
Download appropriate software
for your controller model.
ShutdownMotor;
illegal value (not 1234, 1236, 1238,
ShutdownMainContactor;
or 1298).
ShutdownEMBrake;
2. Software and hardware do not match.
ShutdownThrottle;
3. Controller defective.
FullBrake;
ShutdownPump.
Terms:
kSI = key Switch Interlock
feT = field-effect Transistor
emr = emergency reverse
Summary of Contents for EC-H2O T12
Page 8: ...1 4 T12 Service Information 9009917 12 12 SAFETY PRECAUTIONS...
Page 68: ...3 44 T12 Service Information 9009917 12 12 MAINTENANCE...
Page 132: ...4 64 T12 Service Information 9009917 12 12 TROUBLESHOOTING...
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