Fault Level |
LED Flashes |
UID |
Fault ID (HEX) |
Fault ID(DEC) |
Fault Type (level description) |
Fault Message |
Description / Fault Cause |
Recommended Action |
1 |
2 |
1 |
0x4481 |
17537 |
Warning |
Handbrake Fault (warn) |
Handbrake is active when a direction selected |
Warning to release the handbrake before driving |
1 |
5 |
1 |
0x4541 |
17729 |
Warning |
Fan Fault |
No speed feedback from external heatsink fans |
Check operation of heatsink fans |
1 |
5 |
2 |
0x4542 |
17730 |
Warning |
Device test waiting |
Device test waiting |
Ensure nothing is stopping startup tests from completing |
1 |
5 |
2 |
0x4542 |
17730 |
Warning |
Low Oil |
Oil level is low |
Check oil level |
1 |
5 |
3 |
0x4543 |
17731 |
Warning |
Hydraulic Filter |
Hydraulic Filter |
Check hydraulic filter |
1 |
5 |
4 |
0x4544 |
17732 |
Warning |
Pump Current Low |
Pump motor is not drawing sufficient current |
Check pump motor wiring and operation. Ensure an internal cutback is not stopping operation. |
1 |
5 |
5 |
0x4545 |
17733 |
Warning |
Isolation Fault |
Isolation failure detected between logic and power frame |
Check isolation between low and high voltage circuits on controller and vehicle systems |
1 |
5 |
6 |
0x4546 |
17734 |
Warning |
No Motor Speed Signal |
No speed feedback from motor sensor |
Check encoder wiring and speed measurement signal |
1 |
5 |
7 |
0x4547 |
17735 |
Warning |
Tow Mode Active |
Tow mode has been activated |
Disable tow mode if not required |
1 |
5 |
8 |
0x4548 |
17736 |
Warning |
Steer Sensor warning |
Invalid steer sensor state |
Check steer sensor wiring and configuration |
1 |
5 |
9 |
0x4549 |
17737 |
Warning |
Pulsed Enable signal not received |
Pulsed enable 1kHz signal not present on appropriate IO connector pin, unable to enable PowerFrame |
Check 1kHz pulsed enable signal is being sent to controller, or if using controller generated signal check loop is not broken |
1 |
5 |
10 |
0x454A |
17738 |
Warning |
Bridge Enable delayed warn |
Unable to complete power on checks before enabling PowerFrame. Typically caused by: DClink not charged, spinning PM motor or motor not connected |
Check motor wiring, wait for motor to slow down or change configuration to skip tests (if available + required) |
1 |
5 |
11 |
0x454B |
17739 |
Warning |
MOSFET s/c tests waiting |
MOSFET / IGBT short circuit tests cannot be completed due DClink not charged or spinning PM motor |
Check motor wiring, wait for motor to slow down or change configuration to skip tests (if available + required) |
1 |
5 |
12 |
0x454C |
17740 |
Warning |
Electrolyte Low Level |
Battery Electrolyte low level detected |
Check battery electrolyte level |
1 |
5 |
13 |
0x454D |
17741 |
Warning |
Electrolyte Cutout Level |
Battery Electrolyte low level detected and cutback |
Check battery electrolyte level |
1 |
5 |
14 |
0x454E |
17742 |
Warning |
Power Limit cutback (warning) |
For Gen5 DCDC current limit is being reduced so power limit is not exceeded |
Reduce requested voltage or current target or decrease output power draw |
1 |
6 |
1 |
0x4581 |
17793 |
Warning |
Throttle Fault (warning) |
Warning level throttle fault |
Check throttle wiring and installation |
1 |
6 |
2 |
0x4582 |
17794 |
Warning |
Safety Case 1 |
Throttle appears to be stuck. This fault will clear if throttle starts to work again. |
Check throttle wiring and installation |
1 |
6 |
3 |
0x4583 |
17795 |
Warning |
Safety Case 2 |
Throttle appears to be stuck. This fault will latch and can only be cleared by repairing the throttle and recycling power. |
Check throttle wiring and installation |
1 |
6 |
4 |
0x4584 |
17796 |
Warning |
Analogue Output Over Current (warn) |
Contactor driver current limit exceeded |
Ensure contactor doesn't exceed maximum current and check contactor wiring |
1 |
6 |
5 |
0x4585 |
17797 |
Warning |
Analogue Output Off with Failsafe (warn) |
Contactor driver not working |
Internal hardware fault |
1 |
6 |
6 |
0x4586 |
17798 |
Warning |
Analogue Output Over Temperature (warn) |
Contactor driver over temperature |
Ensure contactor doesn't exceed maximum current and check contactor wiring |
1 |
6 |
7 |
0x4587 |
17799 |
Warning |
Analogue Output Under Current (warn) |
Contactor driver unable to achieve current target in current mode |
Ensure configured contactor driver current target is within range |
1 |
6 |
8 |
0x4588 |
17800 |
Warning |
Analogue Output Short Circuit (warn) |
Contactor driver MOSFET short circuit detected |
Internal hardware fault |
1 |
6 |
9 |
0x4589 |
17801 |
Warning |
Analogue supply (warn) |
Analogue supply is more than 10% out of range |
Check wiring, remove short circuit and check output voltage is correct |
1 |
6 |
10 |
0x458A |
17802 |
Warning |
Seat (warning) |
Seat switch open so configured regen settings in 0x2928 are being applied |
Close the seat switch and recycle the selected direction |
1 |
6 |
11 |
0x458B |
17803 |
Warning |
Footbrake (warning) |
Customer specific fault. Raised when analogue footbrake voltage does not match digital footbrake switch state |
Check footbrake wiring and installation |
1 |
7 |
1 |
0x45C1 |
17857 |
Warning |
BDI (battery discharge) warning |
BDI remaining charge (0x2790,1) is less than configured BDI Warning level (0x2C30,5). No action is taken by the controller. For information only. |
Charge battery (or if commissioning controller and battery is charged check BDI configuration in 0x2C30) |
1 |
7 |
2 |
0x45C2 |
17858 |
Warning |
BDI (battery discharge) cutout |
BDI remaining charge (0x2790,1) is less than configured BDI Cutout level (0x2C30,4). The low BDI drivability profile is applied if configured in 0x2931. |
Charge battery (or if commissioning controller and battery is charged check BDI configuration in 0x2C30) |
1 |
7 |
3 |
0x45C3 |
17859 |
Warning |
Low Battery cutout |
Battery voltage is less than the configured Under Voltage limit (0x2C02,2) for longer than the protection delay (0x2C03,0) |
Charge battery (or if commissioning controller and battery is charged check BattApp configuration in 0x2C01, 0x2C02, 0x2C03) |
1 |
7 |
4 |
0x45C4 |
17860 |
Warning |
High Battery cutout |
Battery voltage is greater than the configured Over Voltage limit (0x2C01,2) for longer than the protection delay (0x2C03,0) |
Charge battery (or if commissioning controller and battery is charged check BattApp configuration in 0x2C01, 0x2C02, 0x2C03) |
1 |
7 |
5 |
0x45C5 |
17861 |
Warning |
High Capacitor cutout |
Capacitor voltage is greater than the configured Over Voltage limit (0x2C01,2) for longer than the protection delay (0x2C03,0) |
Charge battery (or if commissioning controller and battery is charged check BattApp configuration in 0x2C01, 0x2C02, 0x2C03) |
1 |
7 |
6 |
0x45C6 |
17862 |
Warning |
Vbat below rated min |
Battery voltage is less than rated minimum voltage for controller for longer than 1sec |
Charge battery or check DC link voltage is within controller operating range (NOTE: This fault is sometimes seen at power down) |
1 |
7 |
7 |
0x45C7 |
17863 |
Warning |
Vbat above rated max |
Battery voltage is greater than rated maximum voltage for controller for longer than 1sec |
Charge battery or check DC link voltage is within controller operating range |
1 |
7 |
8 |
0x45C8 |
17864 |
Warning |
Vcap above rated max |
Capacitor voltage is greater than rated maximum voltage for controller for longer than 1sec |
Charge battery or check DC link voltage is within controller operating range |
1 |
7 |
9 |
0x45C9 |
17865 |
Warning |
Vcap cutback for motoring torque |
Capacitor voltage is in low voltage cutback region configured in 0x4612 for motor control / torque conditioner drive voltage cutback map |
Charge battery and DC link voltage is within configured range (if commissioning controller check drive torque cutback map 0x4612 is correct) |
1 |
7 |
10 |
0x45CA |
17866 |
Warning |
Vcap cutback for regen torque |
Capacitor voltage is in high voltage cutback region configured in 0x4619 (or 0x4612 if 0x4619 not present) for motor control / torque conditioner regen voltage cutback map |
Charge battery and DC link voltage is within configured range (if commissioning controller check regen torque cutback map 0x4619 is correct, use 0x4612 if 0x4619 not present) |
1 |
7 |
11 |
0x45CB |
17867 |
Warning |
Mains Under Voltage |
Mains voltage is below minimum |
Check mains supply is within controller limits |
1 |
7 |
12 |
0x45CC |
17868 |
Warning |
Mains Over Voltage |
Mains voltage is above maximum |
Check mains supply is within controller limits |
1 |
7 |
13 |
0x45CD |
17869 |
Warning |
KL15 / KL30 Too Low |
The voltage applied to the KL15 / KL30 input pins is below the controller rated minimum |
Check KL15 / KL30 supply voltage is within the controller operating range |
1 |
7 |
14 |
0x45CE |
17870 |
Warning |
Vcap to Vkey (Vbat) difference |
Vcap is below 7/8 of Vkey (Vbat) due to DC link pre-charge problems |
Charge battery or check pre-charge |
1 |
8 |
1 |
0x4601 |
17921 |
Warning |
Device too cold |
Low heatsink temperature has reduced available power to motor |
Allow controller to warm up to normal operating temperature |
1 |
8 |
2 |
0x4602 |
17922 |
Warning |
Device too hot |
High heatsink / junction / PCB track / capacitor temperature has reduced available power to motor |
Allow controller to cool down to normal operating temperature. Check coolant flow rate / air flow is sufficient for required motor current |
1 |
8 |
3 |
0x4603 |
17923 |
Warning |
Motor in thermal cutback |
High measured (0x4600,3) or estimated (0x4602,8) motor temperature has reduced available power to motor as configured in 0x4620, 0x4621, 0x461E, 0x461F |
Allow motor to cool down to normal operating temperature. Check motor cooling or motor thermistor configuration and wiring. If not using a thermistor and this fault is set make sure motor estimate is configured correctly (or disabled in 0x4621,1 = 0 and 0x4621,2 = 100) |
1 |
8 |
4 |
0x4604 |
17924 |
Warning |
Motor too cold |
Motor measured temperature is below -30degC |
Check motor thermistor connection or allow motor to warm up. Check motor thermistor configuration and wiring |
1 |
8 |
5 |
0x4605 |
17925 |
Warning |
Motor Thermistor Wiring |
An open or short circuit has been detected in the motor thermisor wiring |
Check motor thermistor and wiring |
1 |
10 |
1 |
0x4681 |
18049 |
Warning |
Unit in pre-operational |
Controller is in pre-operational state |
If configured and ready for use, change state to operational. If controller is slave check master state |
1 |
10 |
2 |
0x4682 |
18050 |
Warning |
IO can't initialise |
Controller has not received all configured RPDOs at power up |
Check PDOs on all other CANbus nodes are configured correctly and match up with controller RPDO configuration. Check CAN wiring. |
1 |
10 |
3 |
0x4683 |
18051 |
Warning |
RPDO Timeout (warning) |
One or more configured RPDOs not received with 3sec at start up or 500ms during normal operation. |
Check status of all nodes on CANbus. Check PDOs on all CANbus nodes are configured correctly and match up with controller RPDO configuration |
1 |
11 |
1 |
0x46C1 |
18113 |
Warning |
Encoder Alignment Warning |
Encoder is not aligned properly with motor |
Ensure encoder offset is configured correctly set or repeat encoder alignment procedure |
1 |
11 |
2 |
0x46C2 |
18114 |
Warning |
SinCos Tracking Warning |
SinCos tracked Min-Max (trough-peak) values are deviating from the configured levels and are heading towards a voltage rail or converging together. Typically due to thermal or mechanical variation |
Check sincos sensor, wiring and encoder configuration |
1 |
11 |
3 |
0x46C3 |
18115 |
Warning |
Fault Ride Through |
A fault ride through event has been encountered, but operation is allowed to continue although the system may be derated |
Investigate cause of the original fault that is activating fault ride through |
1 |
11 |
4 |
0x46C4 |
18116 |
Warning |
Induction Motor Pull-Out Warning |
The open loop V/f induction motor software has detected a pulled-out condition (applied frequency much larger than actual), it will automatically attempt to restart. |
Reduce load torque transients and demanded acceleration rates. Check motor parameters (V/f ratio and current limit/allowed torque may be too low) and control gains. Stall detection can be disabled in 0x4650 |
1 |
11 |
5 |
0x46C5 |
18117 |
Warning |
Stator Resistance Error |
Warning that stator resistance thermal compensation has failed due to the estimated value being too different from the configured value. Motor should still operate but stall torque may be reduced. |
Check the value of Rs (0x4641,6) configured in the controller is correct for the motor and the resistance compensation gains (0x4641,48 and 0x4641,49) are correctly tuned. These 3 parameters can be set to zero to disable Rs compensation if not required (or alternatively only the Rs can be set and the PI gains set to zero to use a fixed value) |
1 |
11 |
6 |
0x46C6 |
18118 |
Warning |
Encoder PLL Deactivated (warning) |
Encoder PLL has turned off due to poor angle tracking |
Check PLL gains, encoder setup and wiring – especially shielding and routing of encoder cables |
1 |
12 |
1 |
0x4701 |
18177 |
Warning |
CAN warning |
Vehicle is operating in reduced power mode as some CAN messages are not being received (customer specific) |
Check status of nodes on CANbus expected to be transmitting data |
1 |
12 |
2 |
0x4702 |
18178 |
Warning |
Customer specific CAN protocol warning |
Controller has not received required CAN messages |
Check CANBus network, wiring and BMS |
1 |
13 |
1 |
0x4741 |
18241 |
Warning |
Scheduler stack overflow warning |
This warning is set if any task has between 10% and 20% of its stack free. |
Internal software warning. Contact BorgWarner. |
1 |
13 |
2 |
0x4742 |
18242 |
Warning |
Internal supply out of range warning |
An internal logic supply rail has gone out of range |
Internal hardware warning. Contact BorgWarner. |
1 |
13 |
3 |
0x4743 |
18243 |
Warning |
CAN Protocol error warning |
Controller has not received required CAN messages |
Check CANBus network, wiring and BMS |
1 |
14 |
1 |
0x4781 |
18305 |
Warning |
CANopen anon EMCY level 1 |
EMCY message received from non-Sevcon node and anonymous EMCY level (0x2830,0) is set to 1. |
Check status of non-Sevcon nodes on CANbus |
1 |
14 |
2 |
0x4782 |
18306 |
Warning |
24V Supply Low |
24V Supply Low |
Logic supply is below minimum |
1 |
14 |
3 |
0x4783 |
18307 |
Warning |
24V Supply High |
24V Supply High |
Logic supply is above maximum |
1 |
15 |
1 |
0x47C1 |
18369 |
Warning |
Vehicle Service Required |
Vehicle service next due time (0x2850,5) has expired. If supported Service driveability profile (0x2925) will activate. |
Service vehicle and reset service hours counter. Or check service configuation if service indication not required. |
1 |
15 |
2 |
0x47C2 |
18370 |
Warning |
CAN bus off warning |
Warning level version of CAN bus off |
Check CANbus wiring and configuration (no duplicate COB-IDs, correct baud rate). If controller is standalone check configuration in 0x5901,0 |
1 |
15 |
3 |
0x47C3 |
18371 |
Warning |
Protocol CAN off warning |
CAN bus off detected from protocol messages only |
Check CANbus wiring |
1 |
15 |
4 |
0x47C4 |
18372 |
Warning |
CAN HPRX warning |
Warning level CAN High Priority Receive fault |
Check CANbus wiring and configuration |
1 |
15 |
5 |
0x47C5 |
18373 |
Warning |
CAN HPTX warning |
Warning level CAN High Priority Transmit fault |
Check CANbus wiring and configuration |
1 |
15 |
6 |
0x47C6 |
18374 |
Warning |
Interlock loop broken |
Safety interlock loop has been broken |
Reconnect the loop |
1 |
15 |
7 |
0x47C7 |
18375 |
Warning |
Pump oil level low |
Pump oil level is too low |
Add oil to the hydraulic pump |
1 |
15 |
8 |
0x47C8 |
18376 |
Warning |
Pump oil temperature |
Pump temperature is too high |
Check for blockage in oil filter screen and/or oil cooler |
1 |
15 |
9 |
0x47C9 |
18377 |
Warning |
Active Short Circuit |
Motor controller is in active short circuit state |
Powerframe has been unexpectedly disabled at high speed. Configured (0x4658, 0x4659, 0x4660) active short circuit has activated to protect inverter and battery. |
2 |
2 |
1 |
0x4881 |
18561 |
Drive Inhibit |
Seat Fault |
Valid direction selected with operator not seated or operator is not seated for a user configurable time in drive. |
Must be seated with switches inactive |
2 |
2 |
2 |
0x4882 |
18562 |
Drive Inhibit |
Two Direction Fault |
Both the forward and reverse switches have been active simultaneously for greater than 200 ms. |
If both switches are selected then release both, then select required direction. If fault persists check vehicle wiring and configuration of mapping for digital inputs. |
2 |
2 |
3 |
0x4883 |
18563 |
Drive Inhibit |
SRO Fault |
FS1 (foot switch / throttle) active for user configurable delay (0x2914,2) without a direction selected. |
Deselect FS1 (foot switch / throttle) and select direction first |
2 |
2 |
4 |
0x4884 |
18564 |
Drive Inhibit |
Sequence Fault |
Any drive switch active at power up as configured in 0x2918 |
Deselect all drive switches and then reselect required switch. |
2 |
2 |
5 |
0x4885 |
18565 |
Drive Inhibit |
FS1 Recycle Fault |
FS1 (foot switch / throttle) active after a direction change and FS1 recycle function enabled (0x2914,1,bit1) |
Deselect FS1 / throttle pedal |
2 |
2 |
6 |
0x4886 |
18566 |
Drive Inhibit |
Inch Fault |
Inch switch active along with any drive switch active (excluding inch switches), seat switch indicating operator present or handbrake switch active. |
Correct conditions need to be met for inching functionality (drive not selected, operator not present and handbrake released) |
2 |
2 |
7 |
0x4887 |
18567 |
Drive Inhibit |
Overload Fault |
Vehicle overloaded |
Remove overload condition |
2 |
2 |
8 |
0x4888 |
18568 |
Drive Inhibit |
Raised and Tilted Fault |
Scissor lift platform raised and tilted |
Lower platform |
2 |
2 |
9 |
0x4889 |
18569 |
Drive Inhibit |
Pothole Fault |
Scissor lift pothole protection active |
Lower platform to allow moving vehicle out of pot hole. |
2 |
2 |
10 |
0x488A |
18570 |
Drive Inhibit |
Traction Inhibit Fault |
Traction function inhibited using traction inhibit switch (0x2137) |
Deselect traction inhibit switch if vehicle drive is required |
2 |
2 |
11 |
0x488B |
18571 |
Drive Inhibit |
Illegal Mode Change Fault |
Vehicle changed from traction mode to pump mode (or vice versa) when direction selected |
Deselect all drive switches |
2 |
2 |
12 |
0x488C |
18572 |
Drive Inhibit |
Tilt Sensor Fault |
Scissor lift error code (0x3802,0) set to 0x02 |
Check tilt sensor |
2 |
2 |
13 |
0x488D |
18573 |
Drive Inhibit |
Belly fault |
Belly switch function has activated. |
Deselect belly switch |
2 |
2 |
14 |
0x488E |
18574 |
Drive Inhibit |
Momentary direction fault |
Fault with momentary direction selection switch |
Release momentary direction switch |
2 |
2 |
15 |
0x488F |
18575 |
Drive Inhibit |
Sensorless Startup |
Sensorless has failed to start up. |
Check motor parameters are correct for motor |
2 |
5 |
1 |
0x4941 |
18753 |
Drive Inhibit |
Motor Overspeed |
Motor speed is exceeding configured overspeed threshold |
Check motor configuration and ensure motor speed is not too high. |
2 |
5 |
2 |
0x4942 |
18754 |
Drive Inhibit |
PST Fault |
An issue has occurred with the PST unit |
Check PST unit faults |
2 |
5 |
3 |
0x4943 |
18755 |
Drive Inhibit |
PFC Fault |
Fault with the PFC stage |
Replace unit if fault persists |
2 |
5 |
4 |
0x4944 |
18756 |
Drive Inhibit |
Boost Fault |
Fault with the Boost Stage |
Replace unit if fault persists |
2 |
6 |
1 |
0x4981 |
18817 |
Drive Inhibit |
Throttle Fault |
Throttle value (0x2620,0) is greater than 20% at power up. |
Release throttle and re-apply. Check wiring |
2 |
6 |
2 |
0x4982 |
18818 |
Drive Inhibit |
E-Brake Wire off |
Wire-off detected in electrobrake circuit |
Check electrobrake wiring, ensure current flows when energised |
2 |
6 |
3 |
0x4983 |
18819 |
Drive Inhibit |
Direction Change |
Direction is changed and vehicle speed is greated than allowed in 0x2929,2 |
Neutral switch should be selected to clear the fault |
2 |
7 |
1 |
0x49C1 |
18881 |
Drive Inhibit |
ORFET fault |
Measured ORFET voltage differs too much from measured output voltage |
Check vehicle wiring |
2 |
7 |
2 |
0x49C2 |
18882 |
Drive Inhibit |
Entering Cutback |
Controller has entered thermal or voltage cutback region |
Check for temperature or voltage cutback condition and take appropriate action |
2 |
8 |
1 |
0x4A01 |
18945 |
Drive Inhibit |
Cutback |
Thermal or voltage cutback factors have reduced belowed user defined levels. |
Check for temperature or voltage cutback condition and take appropriate action |
2 |
10 |
1 |
0x4A81 |
19073 |
Drive Inhibit |
RPDO Timeout (drive inhibit) |
One or more configured RPDOs not received with 3s at start up or 500ms during normal operation. |
Check status of all nodes on CANbus. Check PDOs on all CANbus nodes are configured correctly and match up. |
2 |
12 |
1 |
0x4B01 |
19201 |
Drive Inhibit |
CAN off bus (drive inhibit) |
CANbus off fault condition detected on multinode system. NOTE: normally this is a Very Severe CAN off fault |
Check CANbus wiring and configuration (no duplicate COB-IDs, correct baud rate). If controller is standalone check configuration in 0x5901,0 |
2 |
12 |
2 |
0x4B02 |
19202 |
Drive Inhibit |
Ren Data |
Data missing from CAN (Customer specific) |
Check connection to CANbus, ensure all devices on bus are communicating. |
2 |
12 |
3 |
0x4B03 |
19203 |
Drive Inhibit |
IO Data Error |
Vehicle application subsystem is not receiving control or status information. |
Check CANbus wiring and configuration of J1939 signal mappings. |
2 |
12 |
4 |
0x4B04 |
19204 |
Drive Inhibit |
Customer Protocol Error |
Controller failed to receive required CAN messages |
Check CANbus wiring and CAN network |
2 |
12 |
5 |
0x4B05 |
19205 |
Drive Inhibit |
CAN protocol lost message 1 |
a message has been lost in a CAN protocol |
Check CANbus wiring |
2 |
12 |
6 |
0x4B06 |
19206 |
Drive Inhibit |
CAN protocol lost message 2 |
a message has been lost in a CAN protocol |
Check CANbus wiring |
2 |
12 |
7 |
0x4B07 |
19207 |
Drive Inhibit |
CAN protocol invalid signal 1 |
a signal in a message has been invalid for 5 cycles |
Check CANbus wiring |
2 |
12 |
8 |
0x4B08 |
19208 |
Drive Inhibit |
CAN protocol invalid signal 2 |
a signal in a message has been invalid for 5 cycles |
Check CANbus wiring |
2 |
14 |
1 |
0x4B81 |
19329 |
Drive Inhibit |
CANopen anon EMCY level 2 |
EMCY message received from non-Sevcon node and anonymous EMCY level (0x2830,0) is set to 2. |
Check status of non-Sevcon nodes on CANbus |
2 |
14 |
9 |
0x4B89 |
19337 |
Drive Inhibit |
Motor Overtemp |
Motor thermal cutback has less than 1% remaining. |
Allow motor to cool down, check motor cooling and cutback configuration |
2 |
14 |
10 |
0x4B8A |
19338 |
Drive Inhibit |
Device Undertemperature |
Controller is below it's minimum operating temperature |
Allow controller to warm up to normal operating temperature. |
3 |
1 |
1 |
0x4C41 |
19521 |
Severe |
Too many slaves |
Number of slaves (0x2810,0) set higher than maximum allowed number of slaves (typically 7) |
Check 0x2810,0 setting is correct |
3 |
2 |
1 |
0x4C81 |
19585 |
Severe |
HVIL loop broken |
On a product with an High Voltage InterLock feature where the feature is enabled, the loop has been detected as broken. |
Check product wiring, cycle KL15/power when fault corrected. |
3 |
4 |
1 |
0x4D01 |
19713 |
Severe |
Circuit Breaker Open |
Circuit Breaker Open |
Check breaker |
3 |
4 |
2 |
0x4D02 |
19714 |
Severe |
Circuit Breaker Welded |
Circuit Breaker Welded |
Check breaker |
3 |
4 |
3 |
0x4D03 |
19715 |
Severe |
DC Link Collapsed |
DC Link Collapsed |
|
3 |
4 |
4 |
0x4D04 |
19716 |
Severe |
Circuit Breaker Timeout |
Time to close breaker of GpAC has expired |
Cycle power and restart breaker close sequence |
3 |
5 |
1 |
0x4D41 |
19777 |
Severe |
Motor Isolation Fault |
Motor isolation contactor is open circuit |
Check isolation contactor and wiring |
3 |
5 |
2 |
0x4D42 |
19778 |
Severe |
Motor Open Circuit Fault |
Motor terminal is open circuit or disconnected from controller |
Check motor wiring. Check controller condition |
3 |
5 |
3 |
0x4D43 |
19779 |
Severe |
Motor stalled |
No speed feedback from motor |
Check encoder wiring and speed measurement signal |
3 |
6 |
1 |
0x4D81 |
19841 |
Severe |
Pin strapping failed |
no config matches the digital input states |
Check wiring and configuration |
3 |
7 |
3 |
0x4DC3 |
19907 |
Severe |
Power Supply Critical |
Battery voltage has dropped below critical level |
Check controller voltage supply |
3 |
10 |
1 |
0x4E81 |
20097 |
Severe |
RPDO Timeout (severe) |
One or more configured RPDOs not received with 3s at start up or 500ms during normal operation. |
Check status of all nodes on CANbus. Check PDOs on all CANbus nodes are configured correctly and match up. |
3 |
11 |
1 |
0x4EC1 |
20161 |
Severe |
Can't Establish Field Current |
Controller is unable to control a current in the field winding |
Check motor field is wired to correct terminals. If motor is permanent magnet ensure correct algorithm is configured |
3 |
11 |
2 |
0x4EC2 |
20162 |
Severe |
Pulsing Disabled |
The motor control protection subsystem unexpectedly disabled the PWM |
Check for presence of other faults that may indicate root cause of problem. |
3 |
12 |
1 |
0x4F01 |
20225 |
Severe |
Unexpected slave state |
CANopen slave has changed to unexpected state |
Check status of all nodes on CANbus. |
3 |
12 |
2 |
0x4F02 |
20226 |
Severe |
EMCY send failed |
Unable to transmit EMCY message |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
1 |
0x4F41 |
20289 |
Severe |
Internal Fault |
Internal software fault – typically set in combination with another fault |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
2 |
0x4F42 |
20290 |
Severe |
Out of memory |
Out of memory – internal software fault |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
3 |
0x4F43 |
20291 |
Severe |
General DSP error |
Unknown error raised by motor model code – internal software fault |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
4 |
0x4F44 |
20292 |
Severe |
Timer Failed |
Unable to allocate timer – internal software fault |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
5 |
0x4F45 |
20293 |
Severe |
Queue Error |
Unable to post message to queue – internal software fault |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
6 |
0x4F46 |
20294 |
Severe |
Scheduler Error |
Unable to create task in scheduler – internal software fault |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
7 |
0x4F47 |
20295 |
Severe |
DSP Heartbeat Error |
Communication lost between Host and DSP processors |
Internal hardware fault. Ensure compatible firmware is programmed in both processors |
3 |
13 |
8 |
0x4F48 |
20296 |
Severe |
I/O SS Error |
IO subsytem fault – internal software fault or configuration error |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
9 |
0x4F49 |
20297 |
Severe |
GIO SS Error |
GIO subsystem fault – internal software fault or configuration error |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
10 |
0x4F4A |
20298 |
Severe |
LCM SS Error |
LCM subsystem fault – internal software fault or configuration error |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
11 |
0x4F4B |
20299 |
Severe |
LCP SS Error |
LCP subsystem fault – internal software fault or configuration error |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
12 |
0x4F4C |
20300 |
Severe |
OBD SS Error |
OBD subsystem fault – internal software fault or parameter range error fault |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
13 |
0x4F4D |
20301 |
Severe |
VA SS Error |
VA subsystem fault – internal software fault or configuration error |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
14 |
0x4F4E |
20302 |
Severe |
DMC SS Error |
DMC subsystem fault – internal software fault or configuration error |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
15 |
0x4F4F |
20303 |
Severe |
TracApp SS Error |
TracApp subsystem fault – internal software fault or configuration error |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
16 |
0x4F50 |
20304 |
Severe |
New Powerframe Detected |
New power frame detected. |
Recycle keyswitch |
3 |
13 |
17 |
0x4F51 |
20305 |
Severe |
DSP Not Detected |
Communication lost between Host and DSP processors |
Internal hardware fault. Ensure compatible firmware is programmed in both processors |
3 |
13 |
18 |
0x4F52 |
20306 |
Severe |
DSP / IOP Comms Error |
Communication lost between Host and DSP processors (or IOP and MCP) |
Internal hardware fault. Ensure compatible firmware is programmed in both processors |
3 |
13 |
19 |
0x4F53 |
20307 |
Severe |
App Manager SS Error |
AppMgr subsystem fault – internal software fault or configuration error |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
13 |
20 |
0x4F54 |
20308 |
Severe |
Autozero Range Error |
Current sensor auto-zero value outside of allowed range |
Internal hardware fault or check configuration in 0x4654,0 (if available) |
3 |
13 |
21 |
0x4F55 |
20309 |
Severe |
DSP parameter error |
Internal software fault or configuration object is out of range |
Set configuration object to valid value. Out of range object can be identified using 0x5621 or DVT CLI window (if enabled) |
3 |
13 |
22 |
0x4F56 |
20310 |
Severe |
Motor in wrong direction |
Motor rotation detected as wrong direction |
Check motor wiring and configuration |
3 |
13 |
23 |
0x4F57 |
20311 |
Severe |
Motor stalled |
Motor rotation stalled |
Check motor wiring and configuration |
3 |
13 |
24 |
0x4F58 |
20312 |
Severe |
DCDC SS Error |
DCDC subsystem fault – internal software fault |
If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
3 |
14 |
1 |
0x4F81 |
20353 |
Severe |
CANopen anon EMCY level 3 |
EMCY message received from non-Sevcon node and anonymous EMCY level (0x2830,0) is set to 3. |
Check status of non-Sevcon nodes on CANbus |
4 |
1 |
1 |
0x5041 |
20545 |
Very Severe |
Bad NVM Data |
EEPROM or flash configuration data corrupted and data can not be recovered. |
If firmware has recently been updated, revert to previous version. Contact BorgWarner for support. |
4 |
1 |
2 |
0x5042 |
20546 |
Very Severe |
VPDO Out of Range |
VPDO mapped to non-existent or invalid object |
Check all VPDO mappings (0x3000 to 0x3400) |
4 |
1 |
3 |
0x5043 |
20547 |
Very Severe |
Static Range Error |
At least one configuration object is out of range |
Set configuration object to valid value. Our of range object can be identified using 0x5621 or DVT CLI window. |
4 |
1 |
4 |
0x5044 |
20548 |
Very Severe |
Dynamic Range Error |
At least one configuration object is out of dynamic range. This is where one objects range depends on another object or hardware variant specific level. |
Check all dynamic range objects. DVT CLI window indicates type of object which is out of range. |
4 |
1 |
5 |
0x5045 |
20549 |
Very Severe |
Auto-configuration Fault |
Unable to automatically configure I/O and vehicle setup. |
Check auto configuration objects (0x5810 and 0x5811) |
4 |
1 |
6 |
0x5046 |
20550 |
Very Severe |
Voltage autoconfig error |
Unable to set battery voltage |
Check auxillary drives support low voltage configurations |
4 |
2 |
1 |
0x5081 |
20609 |
Very Severe |
Invalid Steer Switches |
Steering switches are in an invalid state |
Check steering switches and wiring. Check steering map 0x2913 is valid |
4 |
4 |
1 |
0x5101 |
20737 |
Very Severe |
Line Contactor o/c |
Line contactor open circuit – contactor did not close when the coil is energized. |
Check line contactor operation and wiring. DC link fuse blown |
4 |
4 |
2 |
0x5102 |
20738 |
Very Severe |
Line Contactor welded |
Line contactor appears to be closed when the coil is NOT energized. |
Check line contactor hasn't welded closed and the wiring is correct. Make sure the line contactor is not mapped if there is not one connected and controlled by the motor inverter |
4 |
4 |
3 |
0x5103 |
20739 |
Very Severe |
Contactor Drive Fault |
Fault with contactor drive |
Check contactor and wiring for short circuits. If fault persists replace the controller |
4 |
5 |
1 |
0x5141 |
20801 |
Very Severe |
Beltloader Fault |
Unable to change between traction and pump motors on beltloader. |
Check change over contactors and motor wiring. |
4 |
5 |
2 |
0x5142 |
20802 |
Very Severe |
Ren Signal |
Fault signalled by vehicle network |
Check peripheral devices |
4 |
5 |
3 |
0x5143 |
20803 |
Very Severe |
VERLOG |
VERLOG signal failure |
Check peripheral devices |
4 |
5 |
14 |
0x514E |
20814 |
Very Severe |
Power Limit Cutback |
Power is being limited |
Reduce output power to within range |
4 |
6 |
1 |
0x5181 |
20865 |
Very Severe |
Digital Input Wire Off |
Digital input wire-off |
Check wiring and configuration |
4 |
6 |
2 |
0x5182 |
20866 |
Very Severe |
Analogue Input Wire Off |
Analogue input voltage outside of configured range (0x46C0 – 0x46C7) |
Check wiring and configuration is correct in 0x46c0 to 0x46c7. If analogue input is not used the range should be set to the minimum and maximum limits |
4 |
6 |
3 |
0x5183 |
20867 |
Very Severe |
Analogue Output Over Current |
Contactor driver over current protection has activated |
Ensure contactor doesn't exceed maximum current and check contactor wiring for short circuits. Make sure contactor or load is NOT capacitive such as contactors with economizer circuits |
4 |
6 |
4 |
0x5184 |
20868 |
Very Severe |
Analogue Output On with No Failsafe |
Internal hardware failsafe circuitry not working |
Contact driver failed startup checks. Internal circuit has failed or external wiring issues with contactor connected to B- / logic ground. For Gen4 DC the contactor output used needs to be configured in 0x46A5, if none are used a resistor needs to be fitted in place of a contactor for the test to complete – see Gen4DC manual / AppNote |
4 |
6 |
5 |
0x5185 |
20869 |
Very Severe |
Analogue Output Off with Failsafe |
Contactor driver circuit has failed start up checks |
Contact driver couldn't activate for startup checks. Internal circuit has failed or external coil short circuit or wiring issue connecting contactor driver to keyswitch |
4 |
6 |
6 |
0x5186 |
20870 |
Very Severe |
Analogue Output Over Temperature |
Contactor driver over temperature |
Ensure contactor doesn't exceed maximum current and check contactor wiring |
4 |
6 |
7 |
0x5187 |
20871 |
Very Severe |
Analogue Output Under Current |
Contactor driver unable to achieve current target in current mode |
Ensure contactor driver current target is within range for available voltage |
4 |
6 |
8 |
0x5188 |
20872 |
Very Severe |
Analogue Output Short Circuit |
Contactor driver MOSFET short circuit detected |
Check contactor and wiring for short circuits. If fault persists replace the controller |
4 |
7 |
1 |
0x51C1 |
20929 |
Very Severe |
Power Supply Interrupt |
Not used |
Not used |
4 |
7 |
2 |
0x51C2 |
20930 |
Very Severe |
Capacitor Precharge Failure |
Capacitor voltage (0x5100,3) did not rise above 5V at power up |
Check battery connection for reverse polarity, or check internal / external short circuit across the DC link.Potential failure of pre-charge circuit. |
4 |
7 |
3 |
0x51C3 |
20931 |
Very Severe |
KL15/30 Too High |
The voltage applied to the KL15/30 is above the controller rated maximum |
Check KL15/30 supply voltage is within allowed range |
4 |
8 |
1 |
0x5201 |
20993 |
Very Severe |
Heatsink / device overtemp |
Controller heatsink (or junctions, capacitors, PCB) has reached critical high temperature, and the controller has shut down. |
Allow controller to cool down to normal operating temperature. If liquid cooled check coolant flow. |
4 |
11 |
1 |
0x52C1 |
21185 |
Very Severe |
Encoder Fault |
Encoder input wire-off is detected. |
Check encoder wiring – especially shielding and routing of encoder cables. Check configuration is valid and peak / trough correct for sincos |
4 |
11 |
2 |
0x52C2 |
21186 |
Very Severe |
Motor Overcurrent Fault |
Motor current exceeded controller rated maximum |
Check motor configuration and wiring. Typically caused by current control gains or motor parameters incorrect. |
4 |
11 |
3 |
0x52C3 |
21187 |
Very Severe |
Current Control Fault |
Motor controller unable to maintain control of motor currents |
Check motor configuration and wiring. Typically caused by current control gains or motor parameters incorrect. For PMAC check encoder alignment |
4 |
11 |
4 |
0x52C4 |
21188 |
Very Severe |
Motor Overspeed Fault |
Motor speed has exceeded overspeed threshold in 0x4624 |
Check speed limit gains and configuration. Ensure motor speed is not too high for configuration. |
4 |
11 |
5 |
0x52C5 |
21189 |
Very Severe |
Encoder Alignment Severe |
Encoder is not aligned properly. |
Ensure encoder offset and sequence is correct |
4 |
11 |
6 |
0x52C6 |
21190 |
Very Severe |
di / dt fault (suspected s/c) |
Large rate of change of current detected multiple times. Suspected MOSFET, motor or wiring short circuit. |
Check motor wiring – especially for motor terminals shorted to B-. Check controller condition. |
4 |
11 |
7 |
0x52C7 |
21191 |
Very Severe |
Vcap Overvotlage (software measurement) |
Measured capacitor voltage has exceeded controller maximum. |
Check battery condition and wiring. Check battery voltage is not too close to controller maximum. |
4 |
11 |
8 |
0x52C8 |
21192 |
Very Severe |
Device overcurrent |
Motor current exceeded controller rated maximum |
Check motor configuration and wiring. Typically caused by current control gains or motor parameters incorrect. |
4 |
12 |
1 |
0x5301 |
21249 |
Very Severe |
CAN bus Fault |
CANbus fault condition detected on multinode system. |
Check CANbus wiring and configuration |
4 |
12 |
2 |
0x5302 |
21250 |
Very Severe |
Bootup not received |
CANopen slave has not transmitted boot up message at power up |
Check status of all nodes on CANbus and multinode configuration. |
4 |
12 |
3 |
0x5303 |
21251 |
Very Severe |
LPRX queue overrun |
Low priority CAN receive queue overflow. CANbus fault condition detected on multinode system. |
Check CANbus wiring and configuration. Ensure transmitting node is sending at correct rate |
4 |
12 |
4 |
0x5304 |
21252 |
Very Severe |
LPTX queue overrun |
Low priority CAN transmit queue overflow. CANbus fault condition detected on multinode system. |
Check CANbus wiring and configuration. Ensure messages are being acknowledged and bus load is not too high |
4 |
12 |
5 |
0x5305 |
21253 |
Very Severe |
HPRX queue overrun |
High priority CAN receive queue overflow. CANbus fault condition detected on multinode system. |
Check CANbus wiring and configuration. Ensure transmitting node is sending at correct rate |
4 |
12 |
6 |
0x5306 |
21254 |
Very Severe |
HPTX queue overrun |
High priority CAN transmit queue overflow. CANbus fault condition detected on multinode system. |
Check CANbus wiring and configuration. Ensure messages are being acknowledged and bus load is not too high |
4 |
12 |
7 |
0x5307 |
21255 |
Very Severe |
CAN overrun |
CANbus fault condition detected on multinode system. |
Check CANbus wiring |
4 |
12 |
8 |
0x5308 |
21256 |
Very Severe |
CAN OFF bus |
CAN OFF bus fault condition detected on multinode system. |
Check CANbus wiring and configuration (all nodes are same baud rate and no duplicate COB-ids configured). If single node check 0x5901,0 is not enabled unless required |
4 |
12 |
9 |
0x5309 |
21257 |
Very Severe |
Nodeguarding Failed |
Not used |
Not used |
4 |
12 |
10 |
0x530A |
21258 |
Very Severe |
Short PDO received |
Received RPDO doesn't contains enough bytes |
Check PDOs on all CANbus nodes are configured correctly and match up to configuration of transmitting nodes. Ensure there are no duplicate COB-IDs |
4 |
12 |
11 |
0x530B |
21259 |
Very Severe |
CANopen Heartbeat Failed |
Heartbeat not received within configured time out (0x1016) |
Check status of all nodes on CANbus. Heartbeat consumer is set correctly in 0x1016 to match slave nodes |
4 |
12 |
12 |
0x530C |
21260 |
Very Severe |
CANopen slave in wrong state |
CANopen slave has changed to unexpected state (typically failed to go operational) |
Check status of all nodes on CANbus. Configuration issues such as multiple masters on bus, duplicate node ID or heartbeat COBIDs can trigger the fault. |
4 |
12 |
13 |
0x530D |
21261 |
Very Severe |
CAN ESTAT set |
Internal CANbus fault |
Check CAN configuration |
4 |
12 |
14 |
0x530E |
21262 |
Very Severe |
SDO Handle Error |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
15 |
0x530F |
21263 |
Very Severe |
SDO Timeout Error |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
16 |
0x5310 |
21264 |
Very Severe |
SDO Abort Error |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
17 |
0x5311 |
21265 |
Very Severe |
SDO State Error |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
18 |
0x5312 |
21266 |
Very Severe |
SDO Toggle Error |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
19 |
0x5313 |
21267 |
Very Severe |
SDO Rx Error |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
20 |
0x5314 |
21268 |
Very Severe |
SDO Length Error |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
21 |
0x5315 |
21269 |
Very Severe |
SDO Tx Error |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
22 |
0x5316 |
21270 |
Very Severe |
SDO unknown event |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
23 |
0x5317 |
21271 |
Very Severe |
SDO Bad Source |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
24 |
0x5318 |
21272 |
Very Severe |
SDO bad error number |
Internal CANbus fault |
Check SDO client and server COBID are set correctly |
4 |
12 |
25 |
0x5319 |
21273 |
Very Severe |
Motor slave in wrong state |
Motor control slave has not responded as expected to controlword sent by TracApp or PumpApp. This can either be the same controller for single node systems or a slave node connected over CAN |
Typically caused when the motor controller can't enable due to being unable to complete power on checks due to spinning motors or insufficient DC link voltage. Bridge enable timeout is also known to trigger this fault. |
4 |
12 |
26 |
0x531A |
21274 |
Very Severe |
Ren Protocol |
CAN device on vehicle not responding |
Check connection to CANbus, ensure all devices on bus are communicating. |
4 |
13 |
1 |
0x5341 |
21313 |
Very Severe |
Invalid DSP Protocol |
DSP reports invalid protocol version on dual processor platform |
Internal hardware fault. Ensure compatible firmware is programmed in both processors |
4 |
13 |
2 |
0x5342 |
21314 |
Very Severe |
OSC Watchdog Fault |
Internal hardware fault |
Internal hardware fault. Contact BorgWarner |
4 |
13 |
3 |
0x5343 |
21315 |
Very Severe |
Fault List Overflow |
Attempting to set too many faults. |
Internal software fault. Ensure correct firmware and settings are loaded. Logic supply is above critical level. |
4 |
13 |
4 |
0x5344 |
21316 |
Very Severe |
SPI Comms Fault |
Communication error between host and DSP processors (or gate drive and MCP) |
Internal hardware fault. Ensure compatible firmware is programmed in all processors |
4 |
13 |
5 |
0x5345 |
21317 |
Very Severe |
Scheduler stack overflow fault |
Less than 10% of the stack is free on one of the RTOS tasks. |
Internal software fault. Check configuration and contact BorgWarner |
4 |
13 |
6 |
0x5346 |
21318 |
Very Severe |
Internal supply out of range fault |
An internal logic supply rail has gone out of range |
Internal hardware fault |
4 |
14 |
1 |
0x5381 |
21377 |
Very Severe |
CANopen anon EMCY level 4 |
EMCY message received from non-Sevcon node and anonymous EMCY level (0x2830,0) is set to 4. |
Check status of non-Sevcon nodes on CANbus |
4 |
14 |
3 |
0x5383 |
21379 |
Very Severe |
Boost over voltage |
Boost stage is above maximum operating voltage |
Check input voltage is within range |
4 |
14 |
4 |
0x5384 |
21380 |
Very Severe |
Input under voltage |
DC input voltage is under the specified minimum |
Check input voltage is within range |
4 |
14 |
5 |
0x5385 |
21381 |
Very Severe |
Input over voltage |
DC input voltage is over the specified maximum |
Check input voltage is within range |
4 |
14 |
6 |
0x5386 |
21382 |
Very Severe |
Output over voltage |
Output voltage is over the specified maximum |
Check output voltage and load is within range |
4 |
14 |
7 |
0x5387 |
21383 |
Very Severe |
Output under Voltage |
Output voltage is below the specified maximum |
Check output voltage and load is within range |
4 |
14 |
8 |
0x5388 |
21384 |
Very Severe |
Boost under Voltage |
Boost stage is below minimum operating voltage |
Check input voltage is within range |
4 |
14 |
9 |
0x5389 |
21385 |
Very Severe |
Motor Over temperature |
Motor temperature critical |
Allow to cool to normal operating temperature and check motor cooling. Also check thermistor configuration and wiring |
4 |
14 |
10 |
0x538A |
21386 |
Very Severe |
Device under temperatrue |
Device temperature reached critical low temperature |
Heat the controler or with the logic enabled wait for it to warm to the required minimum temperature |
5 |
1 |
1 |
0x5441 |
21569 |
Return to Base |
Incompatible hardware version |
Detected controller hardware version incompatible with software |
Check correct software is programmed into controller. Reprogram if necessary. Contact BorgWarner |
5 |
1 |
2 |
0x5442 |
21570 |
Return to Base |
Calibration Fault |
Calibration settings in controller are out of range or not set |
Controller current sensors require calibration. Contact BorgWarner |
5 |
3 |
1 |
0x54C1 |
21697 |
Return to Base |
PowerFrame Overvoltage Fault |
DC link voltage exceeds rated maximum for controller |
Check battery condition and wiring. Ensure battery voltage is not too high for the controller operational rating |
5 |
3 |
2 |
0x54C2 |
21698 |
Return to Base |
PowerFrame Fault |
Current flow exceeds controller maximum. Caused by motor current too high, configuration error causing overcurrent, wiring fault/short or internal controller failure |
Check motor control configuration and wiring. If fault is set persistently, disconnect motor cables to see if fault clears |
5 |
3 |
3 |
0x54C3 |
21699 |
Return to Base |
PowerFrame s/c M1 upper |
MOSFET / IGBT short circuit detection on M1 top devices. Fault condition is checked when powerframe disabled by comparing M1 terminal voltage to B+ |
Check motor wiring. Check controller condition with motor disconnected |
5 |
3 |
4 |
0x54C4 |
21700 |
Return to Base |
PowerFrame s/c M1 lower |
MOSFET / IGBT short circuit detection on M1 bottom devices. Fault condition is checked when powerframe disabled by comparing M1 terminal voltage to B- |
Check motor wiring. Check controller condition with motor disconnected |
5 |
3 |
5 |
0x54C5 |
21701 |
Return to Base |
PowerFrame s/c M2 upper |
MOSFET / IGBT short circuit detection on M2 top devices. Fault condition is checked when powerframe disabled by comparing M2 terminal voltage to B+ |
Check motor wiring. Check controller condition with motor disconnected |
5 |
3 |
6 |
0x54C6 |
21702 |
Return to Base |
PowerFrame s/c M2 lower |
MOSFET / IGBT short circuit detection on M2 bottom devices. Fault condition is checked when powerframe disabled by comparing M2 terminal voltage to B- |
Check motor wiring. Check controller condition with motor disconnected |
5 |
3 |
7 |
0x54C7 |
21703 |
Return to Base |
PowerFrame s/c M3 upper |
MOSFET / IGBT short circuit detection on M3 top devices. Fault condition is checked when powerframe disabled by comparing M3 terminal voltage to B+ |
Check motor wiring. Check controller condition with motor disconnected |
5 |
3 |
8 |
0x54C8 |
21704 |
Return to Base |
PowerFrame s/c M3 lower |
MOSFET / IGBT short circuit detection on M3 bottom devices. Fault condition is checked when powerframe disabled by comparing M3 terminal voltage to B- |
Check motor wiring. Check controller condition with motor disconnected |
5 |
3 |
9 |
0x54C9 |
21705 |
Return to Base |
MOSFET s/c checks incomplete |
Unable to complete MOSFET / IGBT short circuit tests at power up |
Internal software fault |
5 |
3 |
10 |
0x54CA |
21706 |
Return to Base |
Pump MOSFET s/c |
Short circuit detected for pump MOSFETs |
Check motor wiring. Check controller condition with motor disconnected |
5 |
3 |
10 |
0x54CA |
21706 |
Return to Base |
IGBT M1 Low Driver Fail |
IGBT driver circuit failure |
Check status of IGBT |
5 |
3 |
11 |
0x54CB |
21707 |
Return to Base |
IGBT M1 High Driver Fail |
IGBT driver circuit failure |
Check status of IGBT |
5 |
3 |
12 |
0x54CC |
21708 |
Return to Base |
IGBT M2 Low Driver Fail |
IGBT driver circuit failure |
Check status of IGBT |
5 |
3 |
13 |
0x54CD |
21709 |
Return to Base |
IGBT M2 High Driver Fail |
IGBT driver circuit failure |
Check status of IGBT |
5 |
3 |
14 |
0x54CE |
21710 |
Return to Base |
IGBT M3 Low Driver Fail |
IGBT driver circuit failure |
Check status of IGBT |
5 |
3 |
15 |
0x54CF |
21711 |
Return to Base |
IGBT M3 High Driver Fail |
IGBT driver circuit failure |
Check status of IGBT |
5 |
13 |
1 |
0x5741 |
22337 |
Return to Base |
Invalid Powerframe Rating |
Unable to identify hardware |
Check correct software is programmed into controller. Reprogram if necessary. Contact BorgWarner |
5 |
14 |
1 |
0x5781 |
22401 |
Return to Base |
CANopen anon EMCY level 5 |
EMCY message received from non-Sevcon node and anonymous EMCY level (0x2830,0) is set to 5. |
Check status of non-Sevcon nodes on CANbus |
5 |
14 |
2 |
0x5782 |
22402 |
Return to Base |
Boost Enable Mismatch |
Boost enable state from hardware and processor comms does not match |
Check DCDC Unit |