7 — DIAGNOSTICS & TROUBLESHOOTING

Table 8 TROUBLESHOOTING CHART

LED PROGRAMMER
EXPLANATION POSSIBLE CAUSE
CODE LCD DISPLAY
HARDWARE F A I L SA F E 2 output fault 1. Short in motor or in motor wiring.
1,1 2. Controller failure.
HARDWARE F A I L SA F E 4 overcurrent fault 1. Short in motor or in motor wiring.
2. Controller failure.
HARDWARE F A I L SA F E 1 EEPROM fault 1. EEPROM failure or fault.
HARDWARE F A I L SA F E 3 main contactor fault 1. Main contactor welded.
2. Main contactor driver fault.
3. Main contactor coil fault.
PRECHARG E F AU L T precharge fault 1. Internal controller fault.
1,2 2. Low battery voltage.
HW F A I L SA F E motor voltage fault 1. Motor voltage does not correspond to
throttle request.
2. M1 or M2 output shorted to B- or B+.
3. Internal motor short.
4. Controller failure.
2,1 SRO SRO fault 1. Improper sequence of KSI, power enable,
and direction inputs.
2. Wrong SRO type selected.
3. Direction switch circuit open.
2,2 HPD HPD fault 1. Improper sequence of KSI, power enable,
and throttle inputs.
2. Misadjusted throttle pot.
2,3 PROC / W I R I NG F AU L T HPD fault present for >5 sec 1. Misadjusted throttle.
2. Broken throttle pot.
3. Broken throttle mechanism.
2,4 S PD L I M I T POT F AU L T speed limit pot fault 1. Speed limit pot wiper wire broken.
2. Broken speed limit pot.
3,1 B B W I R I NG CHECK emerg. reverse wiring fault 1. BB wire open.
2. BB check wire open.
3,2 EM BRAK E DRVR F AU L T electromag. brake driver fault 1. Electromagnetic brake coil shorted or open.
2. Electromagnetic brake wiring open.
3,3 THROT T L E F AU L T 1 throttle fault 1. Throttle input wire open.
2. Throttle input wire shorted to B- or B+.
3. Throttle pot defective.
4. Wrong throttle type selected.
4,1 LOW B A T T ERY VOL T AGE low battery voltage 1. Battery voltage <16 volts (24V models),
<21V (36V models), or <27V (48V models).
2. Corroded or loose battery terminal.
3. Loose controller terminal.
4,2 OVERVOL T AGE overvoltage 1. Battery voltage >36 volts (24V models),
>48V (36V models), or >60V (48V models).
2. Vehicle operating with charger attached.
4,3 THERMA L CU T BACK over-/under-temp. cutback 1. Temperature >95°C or < -25°C.
2. Excessive load on vehicle.
3. Improper mounting of controller.
4. Operation in extreme environments.

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 7 — DIAGNOSTICS & TROUBLESHOOTING

LED DIAGNOSTICS

During normal operation, with no faults present, the Status LED is steadily on. If
the controller detects a fault, the Status LED provides two types of information.
First, it displays a slow flash (2 Hz) or a fast flash (4 Hz) to indicate the severity of
the fault. Slow-flash faults are self-clearing; as soon as the fault is corrected, the
vehicle will operate normally. Fast-flash faults (“❊” in Table 9) are considered to
be more serious in nature and require that the keyswitch (or power enable switch,
if one is used) be cycled to resume operation after the fault is corrected.
Then, after the severity indication has been active for 5 seconds, the Status
LED flashes a 2-digit fault identification code continuously until the fault is
corrected. For example, code “4,1”—low battery voltage—appears as:

¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤ ¤
(4,1) (4,1) (4,1)

The codes are listed in Table 9.

Table 9 STATUS LED FAULT CODES

LED CODES EXPLANATION

LED off no power or defective controller

solid on controller operational; no faults

❊ 1,1 ¤ ¤ output fault or overcurrent fault

❊ 1,2 ¤ ¤¤ EEPROM, main contactor, precharge, or
motor voltage fault
1,3 ¤ ¤¤¤ [not used]
1,4 ¤ ¤¤¤¤ [not used]
2,1 ¤¤ ¤ static return to off (SRO) fault
2,2 ¤¤ ¤¤ high pedal disable (HPD) fault
❊ 2,3 ¤¤ ¤¤¤ HPD latching (HPD fault for >5 sec)
2,4 ¤¤ ¤¤¤¤ speed limit pot fault
3,1 ¤¤¤ ¤ emerg. rev. wiring fault (BB wiring check)
3,2 ¤¤¤ ¤¤ electromagnetic brake driver fault
3,3 ¤¤¤ ¤¤¤ throttle fault
3,4 ¤¤¤ ¤¤¤¤ [not used]
4,1 ¤¤¤¤ ¤ battery undervoltage
4,2 ¤¤¤¤ ¤¤ battery overvoltage
4,3 ¤¤¤¤ ¤¤¤ thermal cutback, due to over/under temp
4,4 ¤¤¤¤ ¤¤¤¤ [not used]
❊ = “Fast-flash” fault—must cycle keyswitch or power enable switch to clear.
NOTE: Only one fault is indicated at a time, and faults are not queued up.

Curtis PMC 1223/33, 1225/35, 1227/37 Manual 64