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Faults

A fault may occurs when an abnormal diagnostic condition is detected. A fault inhibits motion, and requires a keyswitch off/on cycle to clear.

Depending on the Controller model, fault codes may be reported using

  • A flashing LED on the controller. The controller blinks the first digit of the fault, followed by a short pause, then blinks the second digit.
  • Via diagnostic software
  • As a CANBUS fault status message.

Fault codes are 2 character codes. Chore type controllers have different fault codes than Traction type controllers. Note that some fault codes may not be applicable to all models.

A non-volatile fault log is maintained by the controller. This log contains the most recent faults experienced by the controller.

CS8101 Fault Codes

Code Meaning Comments
0 No Fault Controller is operating normally
0x21-0x27 Motor Open/Short Fault Indicates a problem with the motor, or high-current motor connections. Correct the condition and cycle the controller off, then on again.
0x51 Incorrect Motor Sensor Pattern Indicates incorrect or faulty wiring to the motor’s rotor position sensors. Correct the condition and cycle the controller off, then on again.
0x52 Throttle Failband Fault Indicates a throttle input that is out of the expected range. Indicates faulty throttle wiring or improperly adjusted throttle. Correct the condition and cycle the controller off, then on again.
0x61 Input Voltage or Temperature Out of Range The input (VBAT) voltage or temperature was measured outside the established limits when the controller was turned on. Correct the voltage or temperature condition, or replace controller.
0x71 BEMF Gate Fault Indicates a problem with hardware used for sensorless BLDC operation. Replace controller.

Traction Drive Fault Codes

Code Meaning Result Comments
0x00 No Fault Controller is operating normally
0x08 Battery Voltage out of range Motion Inhibited Battery Voltage is too low or too high. Check the battery voltage and connections.
After the condition is corrected, cycle the keyswitch to clear the fault.
0x11 Brake Short Motion Inhibited Check for
- A loose or broken connection between brake and motor controller
- Faulty brake.
After the condition is corrected, cycle the keyswitch to clear the fault.
0x12 Brake Open Motion Inhibited Check for
-Brake is missing when one is expected
- Brake shorted to case
-A loose or broken connection between brake and motor controller
After the condition is corrected, cycle the keyswitch to reset the fault.
0x13 Quickstop/Drive Inhibit Motion Inhibited A safety sensing device such as a seat switch, proximity sensor, emergency stop button has been activated and Quickstop is configured to generate a fault. Check for
- A device connected to the Quickstop input indicating a stop condition
- Loose or broken connection to the Quickstop input
- Incorrect configuration of the Quickstop input
After the condition is corrected, cycle the keyswitch to reset the fault.
0x14 Deadband Inhibit Motion Inhibited If configured to do so (Fault Deadband Start), this fault will be declared when the controller is switched on and the throttle is not in the neutral position. To clear the fault, return the throttle to neutral and cycle keyswitch.
0x21 Motor Short Motion Inhibited Check for
-Faulty motor
-Loose/broken connection to motor on large motor leads.
After the condition is corrected, cycle the keyswitch to clear the fault.
0x22 Motor Open Motion Inhibited Check for
-Faulty motor
-Loose/broken connection to motor on large motor leads.
After the condition is corrected, cycle the keyswitch to clear the fault.
0x23 Power Relay Short Motion Inhibited Depending on application, the Power Relay may be onboard the Motor Controller, or an exteral contactor controlled by the motor controller. This fault indicates that the power relay is not operating properly. Check for
-Faulty Power Relay
-Faulty connection to external Power Relay.
After the condition is corrected, cycle the keyswitch to clear the fault.
0x24 PSL Motor Short Motion Inhibited Loose/broken connection to Power Seat Lift motor
0x28 Motor Sensor Fault Motion Inhibited An invalid condition was detected for the motor position sensors. Check for
- Correct wiring to the motor and motor sensors.
- Correct configuration of the motor sensor(s)
After the condition is corrected, cycle the keyswitch to clear the fault. Check the motor sensor and the wiring connections
- Replace or reconnect the motor temperature sensor
After the condition is corrected, cycle the keyswitch to clear the fault.
0x29 External Temperature Sensor Motion Inhibited A problem was detected with the external temperature sensor.
0x2A High Voltage Protect Error Motion Inhibited High voltage was detected on the motor outputs. Check for disconnected power cables.
- Reconnect cables.
After the condition is corrected, returning the throttle to neutral will clear the fault.
0x31 FET Over Temperature Power cutback or Motion Inhibited The FET (Field Effect Transistor) temperature sensor on-board has indicated a temperature above the allowable limit. Check for
-Operating in extreme environment,
-excessive load,
-faulty or disconnected brake engaged while driving. Allowing controller to cool will restore full power and/or allow motion
0x32 Motor Over Temperature Power cutback or Motion Inhibited The temperature sensor on the motor has indicated a temperature above the allowable limit. Check for
-Operating in extreme environment,
-excessive load,
-faulty or disconnected brake engaged while driving. Allowing the motor to cool will restore full power and/or allow motion
0x41 Over Voltage Condition During Charge Motion Inhibited The battery voltage is too high during charge charge cycle
0x42 Charge Mode Time Out Motion Inhibited The charge cycle did not complete within the expected time.
0x43 Charger Over Temperature Condition Motion Inhibited The charger overheated during the charge cycle
0x51 Low FET Error Motion Inhibited Power up test on high side FET detected a problem.
-Check battery voltage
-Check motor wiring
After the condition is corrected, cycle the keyswitch to clear the fault.
0x52 High FET Error Motion Inhibited Power up test on low side FET detected a problem.
-Check battery voltage
-Check motor wiring
After the condition is corrected, cycle the keyswitch to clear the fault.
0x53 Throttle Failband Motion Inhibited Check for
-shorted or off-center throttle input
Correct configuration of Throttle Failband
0x54 Throttle 2 Failband Motion Inhibited Check for
-shorted or off-center throttle input
Correct configuration of Throttle Failband
0x71 Controller Temperature Error Motion Inhibited The on-board temperature sensor is indicating an out of range condition. Check for
-Operating in extreme environment,
-excessive load,
-faulty or disconnected brake engaged while driving. Allowing controller to cool will may restore full power and/or allow motion. If the problem persist the controller PCB may be damaged.
Other Internal Failure Motion Inhibited Motor Controller problem detected.
Replace controller