Graco LineDriver ES Series Operation - Repair - Parts page 21

CODE DESCRIPTION
Controller Overtemp Cut-
22
back
23 B+ Undervoltage Cutback
24 B+ Overvoltage Cutback
25 +5V Supply Failure
28 Motor Temp Hot Cutback
29 Motor Temp Sensor Fault
Main Contactor
31
Open/Short
36 Encoder Fault
37 Motor Open
38 Main Contactor Welded
3A6623C
POSSIBLE CAUSE
1. Controller is performance-lim-
ited at this temperature.
2. Controller is operating in an
extreme environment.
3. Excessive load on vehicle.
4. Improper mounting of control-
ler.
1. Normal operation. Fault indi-
cates the batteries need
recharging. Controller is per-
formance limited at this volt-
age.
2. Battery resistance too high.
3. Battery disconnected while
driving.
4. Open 300 amp fuse or main
contactor did not close.
5. Non-controller system drain
on battery.
1. Normal operation. Fault
shows that regen braking cur-
rents elevated the battery
voltage during regen braking.
Controller is performance lim-
ited at this voltage.
2. Battery disconnected while
regen braking.
1. Bad crimps or faulty wiring.
2. Shorted motor encoder.
3. Shorted throttle.
4. Shorted ExactMil potentiome-
ter.
1. Motor temperature is at or
above the programmed Tem-
perature Hot setting, and the
current is being cut back.
1. Motor thermistor is not con-
nected properly.
1. Open or short across contrac-
tor coil.
2. Dirty connector pins.
3. Bad crimps or faulty wiring.
1. Motor encoder failure.
2. Bad crimps or faulty wiring.
1. Motor phase is open.
2. Bad crimps or faulty wiring.
1. Main contactor tips are
welded closed.
2. Motor phase U or V is discon-
nected or open.
3. An alternate voltage path is
bypassing the contractor
between battery and B+ on
the controller before the con-
tractor engages.
SET / CLEAR CONDITIONS
Set: Heatsink temperature exceeded 85°C.
Clear: Bring heatsink temperature below
85°C.
Set: Battery pack voltage dropped below
the Undervoltage limit with the FET bridge
enabled.
Clear: Bring battery pack voltage above
the Undervoltage limit (19V).
Set: Battery pack voltage exceeded the
Overvoltage limit.
Clear: Bring battery pack voltage below the
Overvoltage limit (30V).
Set: +5V supply (pin 26) outside the 5
V±10% range.
Clear: Bring voltage within range.
Set: Motor temperature is at or above the
Temperature Hot parameter setting.
Clear: Bring the motor temperature within
range.
Set: Motor thermistor input (pin 8) is at the
voltage rail (0V or 10 V).
Clear: Bring the motor thermistor input
voltage within range.
Set: Main contactor driver (pin 6) is either
open or shorted. This fault can be set only
when Main Enable = ON.
Clear: Correct open or short, and cycle
power switch.
Set: Motor encoder phase failure detected.
Clear: Cycle power switch.
Set: Motor phase U, V, or W detected
open.
Clear: Cycle power switch.
Set: Just prior to the main contactor clos-
ing, the battery pack voltage (B+ connec-
tion terminal) was loaded for a short time
and the voltage did not discharge.
Clear: Cycle power switch.
Troubleshooting - Motor Controller
SOLUTION
1. Move the unit to a cooler area.
2. Reduce operating load on vehicle.
3. Inspect controller heatsink mounting
for air gaps and tighten fasteners.
1. Charge batteries.
2. Let battery cool then fully recharge bat-
tery. If error happens again, load test
batteries and replace if needed.
3. Inspect all cables and connectors from
batteries to controller.
4. Inspect 300 amp fuse and replace if
needed.
5. Inspect contactor for damaged, cor-
roded or contaminated contacts.
Repair or replace as needed.
1. Continue using the unit.
2. Inspect all cables and connectors from
batteries to controller.
1. Inspect motor encoder/thermistor cable
and connector. Disconnect motor
encoder and cycle unit power. If the 5V
supply fault clears, replace the motor.
If the 5V supply fault persists, recon-
nect encoder and repeat this process
for the throttle assembly and ExactMil
potentiometer.
1. Move to cooler area, reduce operating
load.
1. Inspect motor encoder/thermistor cable
and connector.
1. Inspect contactor coil cables and con-
nectors.
2. Test the contactor coil and replace
contactor if needed.
1. Inspect motor encoder/thermistor cable
and connector.
2. Replace motor.
1. Inspect U, V, W cables.
2. Replace motor.
1. Inspect contactor for welded contacts
and replace if necessary.
2. Inspect all cables from the battery pack
to controller looking for insulation dam-
age.
3. Inspect U, V, W cables.
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