Hybrid Gen1/Gen 2 VCM Fault Codes

VCME100 – E115

VCME116 – E121

Left DeckE200 – E215

Right DeckE300 – E315

Mid DeckE400 – E415

Left TractionE500 – E515

Right TractionE600 – E615

BMS 1E700 – E715

BMS 2E800 – E815

BMS 3E900 – E906

VCMBit Fault Description

E100 Throttle signal fault (mismatch between throttle 1 and 2)

E101 Seat switch fault (mismatch between seat 1 and 2)

E102 Chute switch fault (mismatch between chute 1 and 2)

E103 Button hold fault – Start/Stop (held for >10s)

E104 Button hold fault – RCM (held for >10s)

E105 Button hold fault – Cruise (held for >10s)

E106 Button hold fault – Headlight (held for >10s)

E107 Button hold fault – PTO (held for >10s)

E108 Pre-charge failure (BACs failed to charge to B+)

E109 Communication failure (VCM not receiving communication from BACs)

E110 Parameter CRC fault (safety critical parameters have changed)

E111 VCM internal fault (microelectronic check failure)

E112 Welded contactor fault (system contactor enabled at start-up, prior to VCM command)

E113 Left Traction Communication

E114 Right Traction Communication

E115 Left Deck Communication

VCMBit Fault Description

E116 Right Deck Communication

E117 Mid Deck Communication

E118 Traction Direction

E119 Reverse Mow

E120 Battery 1 Communication

E121 Battery 2 Communication

Left Deck Bit Fault Description

E200 Controller over voltage

E201 Phase over current

E202 Current sensor calibration

E203 Current sensor over current

E204 Controller over temperature

E205 Motor Hall sensor fault

E206 Controller under voltage

E207 POST static gating test

E208 Network communication timeout

E209 Instantaneous phase over current

E210 Motor over temperature

E211 Throttle voltage outside range

E212 Instantaneous controller over voltage

E213 Internal error

E214 POST dynamic gating test

E215 Instantaneous under voltage

Right DeckBit Fault Description














E313 Internal error



Mid DeckBit Fault Description














E413 Internal error



Left TractionBit Fault Description














E513 Internal error



Right TractionBit Fault Description














E613 Internal error



BMS Faults 1Bit Fault Description

E700 COVP1

E701 COVP2

E702 CUVP1

E703 Reserved

E704 OTCP (OTCP_LT || OTCP_HT)

E705 OTDP (OTDP_LT || OTDP_HT)

E706 OCDP1

E707 OCCP

E708 OCDP2

E709 Reserved

E710 Cross Cond Charge

E711 Reserved

E712 Cell Volt Sensing

E713 Thermistor Sensing

E714 Cell Comm Slave

E715 BMS Error


E800 Current Sensor Short

E801 Current Sensor Open

E802 High Side Relay On

E803 High Side Relay Off

E804 B Plus Sensor

E805 Cell Deep Discharge

E806 Cell Imbalance

E807 Module Volt Delta

E808 Module Number

E809 Cell ID

E810 Cell Series

E811 Cell Parallel

E812 Master Board Type

E813 Reserved

E814 Current Sensor

E815 Config Data


E900 OTCP_HT

E901 OTCP_LT

E902 OTDP_HT

E903 OTDP_LT

E904 ROM Checksum

E905 Internal Data

E906 NVMEM Access

VCM Code E100

Throttle signal fault• This means that the one or both of the throttle voltages are out of

expected range• Possible causes:

– Sensors need re-calibrated– One or both of the sensors are not connected properly– Damaged, open or shorted harness– Failed sensor

• What to Check– Re-calibrate the sensors– Watch the throttle movement of both sensors on the VCM screen, one

throttle signal should increase while the other decreases.• Check the connections• Test the harness for continuity• Un-plug the throttle sensors, one at a time and move the throttle to identify which

sensor is not working, replace the sensor

VCM

VCM Code E101

Seat switch fault (match between seat 1 and 2)

• This means that the 2 signals from the seat switch may be matched

• Possible causes:– Leaning in seat/off center pressure on the seat switch (most common

cause)

– Poor seat switch connection/Dis-connected switch

– Damaged, open or shorted harness

– Failed switch, waterlogged

• What to Check– Test the switch

– Test the harness

VCM

VCM Code E102

Chute switch fault (match between chute 1 and 2)

• This means that the 2 signals from the chute switch may be matched.

• Possible causes:– Chute is not properly installed

– Poor/dis-connected chute switch connection


– Failed switch

• What to Check– Re-install the chute

– Test the switch


VCM

VCM Code E103

Button hold fault – Start/Stop (held for >10s)

• This means that the start/stop button has been pressed for more then 10 seconds

• Possible causes:– Operator error (most common from going into diagnostic mode)

– Button stuck

• What to Check– Verify the button returns

– Instruct the operator press and release the button

– Replace VCM

VCM

VCM Code E104

Button hold fault – RCM (held for >10s)

• This means that the RCM button has been pressed for more then 10 seconds

• Possible causes:– Operator error

– Button stuck



– Replace VCM

VCM

VCM Code E105

Button hold fault – Cruise (held for >10s)

• This means that the Cruise button has been pressed for more then 10 seconds


– Button stuck



– Replace VCM

VCM

VCM Code E106

Button hold fault – Headlight (held for >10s)

• This means that the Headlight button has been pressed for more then 10 seconds


– Button stuck



– Replace VCM

VCM

VCM Code E107

Button hold fault – PTO (held for >10s)

• This means that the PTO button has been pressed for more then 10 seconds


– Button stuck



– Replace VCM

VCM

VCM Code E108

Pre-charge failure (Motor controllers failed to charge to B+)

• This means that the controllers failed to charge to battery voltage. Traction controller did not reach 50% of the B+ voltage in 5-10 seconds

• Possible causes:– Malfunction of the SPDM

– Malfunction of the motor controller

VCM

VCM Code E109

Communication failure (VCM not receiving communication from controllers)

• This means that the VCM Can not communicate with one or both of the motor controllers

• Possible causes:– Controller disconnected

– Poor connection at the control or VCM or battery


– External electro-magnet or radio frequency interference

• What to Check– Check the connections


– Replace the controller

VCM

VCM Code E110

Parameter CRC fault (safety critical parameters have changed)

• This means that there is a parameter checksum fault.

• Possible causes:– Parameter checksum fault

– Setting in software has been corrupted or changed

– Software installation error

– Software corrupted

– Throttle calibration error

• What to Check– If persists, replace the VCM

VCM

VCM Code E111

VCM internal fault (microelectronic check failure)

• This means that the VCM failed an internal test

• Possible causes:– The VCM is faulty

• What to Check– Cycle the key switch on and off

– If it persists, replace the VCM

VCM

VCM Code E112

Welded contactor fault (system contactor enabled at start-up, prior to VCM command)

• This means that the VCM senses battery voltage is already applied to the motor controllers prior to startup

• Possible causes:– The system contactor has failed in the closed state

– Excessive regen caused diode failure in Contactor module

– A short in the harness

• What to Check– Disconnect the Contactor connections, test for continuity across the

Positive lug and red wires going to the controller power connectors.• If there is continuity, replace the contactor. If not, check the harness for a short.

• If contactor and harness are good, replace VCM.

VCM

VCM Code E113

Left Traction Communication Fault.

This means that the VCM and the motor has stopped communication over CAN.

• Possible causes:– A poor network connection.

– A faulty controller.

• What to Check– Check the harness connections.

– Check the harness for continuity.

VCM

VCM Code E114

Right Traction Communication Fault.






VCM

VCM Code E115

Left Deck Communication Fault.






VCM

VCM Code E116

Right Deck Communication Fault.






VCM

VCM Code E117

Mid Deck Communication Fault.






VCM

VCM Code E118

Traction Direction

This means that the VCM software has set the system to a risk addressed, safe state (RAS). The traction motor controller is driving the motor at a speed that is inconsistent with the throttle position.

• Possible causes:– A faulty controller.

• What to Check– Replace the controller

VCM

VCM Code E119

Reverse Mow

If the system is not in RCM, the rider is driven in reverse and the deck motor controller is still commanding the deck motor to be driven, the system will default to a risk addressed, safe state (RAS).

• Possible causes:– A faulty controller.

• What to Check– Replace the controller

VCM

VCM Code E120

Battery 1 Communication

This means that the VCM did not receive CAN bus communication from the battery 1.


– A faulty battery.



– Test battery

VCM

VCM Code E121

Battery 2 Communication

This means that the VCM did not receive CAN bus communication from the battery 2.


– A faulty battery.



– Test battery

VCM

Motor Fault Code E*00

Controller over voltage

• This means that the Controller measured battery voltage above 62.5V (filtered)

• Possible causes:– Could have faults within bad controller.

– Micro is measuring voltage from a voltage divider circuit

Home

Motor Faults Code E*01

Phase over current

• This means that the Controller measured 110A (AC, peak) or more motor current for 10 samples.

• Possible causes:– This can be caused by mis-matched hall sensor data.

– bad motor phase connection.

– Internal motor short, could be open.

Home


Current sensor calibration

• This is a setup/manufacturing fault meaning the parameters loaded have not been accepted. This will not occur in the field, as these parameters cannot change.

• Possible causes:– Checksum fault

– Corrupted software

Home


Current sensor over current

• This means that the Current sensor has measured its maximum value (sensor is saturated) meaning actual current can be anywhere between that value and infinity.

• Possible causes:– Bad sensor in BAC

Home


Controller over temperature

• This means that the Controller PCBA temperature hits 100 ºC

• Possible causes:– Problem with temp measurement on board

– External heat source.

Home


Motor Hall sensor fault

• This means that the Hall sensors reporting invalid state, either 111 or 000.

• Possible causes:– Can be broken hall wire

– bad hall sensor or unplugged.

– Also see temp fault with unplugged connector.

Home


Controller under voltage

• This means that the Controller saw 0V (this cannot happen)

• Possible causes:– Bad measurement. Cannot measure its own voltage at 0V

– Replace controller

Home


POST static gating test

• This means that the Motor phase is shorted to B+ or GND.

• Possible causes:– Can be internal to controller, motor, or harness this is the initial check.

– Likely inside the controller. Single motor phase.

– Open or all shorted will pass

Home


Network communication timeout

• This means that the BAC did not receive RUN command. Average limit 250ms, single message limit 1s be in your run state.

• Possible causes:– Heartbeat signal. CAN bus is trashed, lost CAN,

– May be unlikely to reach VCM with bad coms

Home


Instantaneous phase over current

• This means that the Controller measured 115A (AC, peak) or more motor current for 1 sample.

• Possible causes:– This can be caused by mis-matched hall sensor data,

– bad motor phase connection

– Internal motor short, could be open.

Home


Motor over temperature

• This means that the Traction motor hits 155 ºC, Deck motor hits 120 ºC

• Possible causes:– Should not occur due to internal circuit protection

– Possible measurement problem

– Thermistor short to ground

Home


Throttle voltage outside range

• We do not have a throttle configured, you cannot see this fault

• Possible causes:– No physical throttle connected directly to the BAC. We use network

throttle.

– Network throttle as it is not directly connect to the controller.

Home


Instantaneous controller over voltage

• This means that the Controller measured battery voltage above 67.5V (inst.)

• Possible causes:– Bad measurement on controller board

– External power source?

– Spike?

Home


Internal error

• This is similar to VCM microelectronic failures.

• Possible causes:– Bad controller

– Try power cycle, replace if persists

Home


POST dynamic gating test

• This means that the Motor phases are shorted together. Controller does control over all 3 phases

• Possible causes:– Can be internal to controller, motor, or harness

Home


Instantaneous under voltage

• This means that the Controller saw 0V (this cannot happen)

• Possible causes:– Cannot measure it’s own voltage at 0V

– Bad measurement on board

Home

BMS Faults 1 Code E700

COVP1(Cell Over Voltage Protection 1)

• This means that the battery management system has detected a maximum cell voltage > 4.2V for 3 seconds with the charger plugged in.

• Possible causes:– Overcharging

– Unbalanced cells in the pack

– CAN communications failed and the charger overcharged the pack

• What to Check– Unplug charger and use the vehicle

BMS Faults 1


COVP2(Cell Over Voltage Protection 2)

• This means that the battery management system has detected a maximum cell voltage > 4.3V for 3 seconds.

• Possible causes:– Overcharging due to faulty charger

– Unbalanced cells in the pack

– CAN communications failed and the charger overcharged the pack

• What to Check– Discharge the battery if the vehicle will turn on

– Replace charger

– Replace battery

BMS Faults 1


CUVP1(Cell Under Voltage Protection 1)

• This means that the BMS has detected a cell voltage less than 2.7V for 3 seconds

• Possible causes:– Unbalanced cells

– Rapid discharge of the battery

• What to Check– Plug in charger

BMS Faults 1


OTCP (Over Temperature in Charge Protection) High and Low Temp.

• This means that the charger is detected and the cell temperature is either <-10°C or > 60°C for at least 5 seconds.

• Possible causes:– Extreme external temperatures

– Overcharged cells

• What to Check– Allow battery to cool reach ambient temperature and either plug in

the charger to finish charging or use the vehicle normally

BMS Faults 1


OTDP (Out-of-range Temperature in Discharge Protection) High and Low Temp.

• This means that the cell temperature is either <-20°C or >70°C. Or the Charge/Discharge FET temperature is > 120°C.

• Possible causes:– Extreme external temperatures

– High current discharge (driving fast while deck in low and cutting)

• What to Check– Allow battery to cool

– Reduce current draw on the system, raise deck, slow down

BMS Faults 1


OCDP1 (Over Current in Discharge Protection)

• This means that the current draw is exceeding 130 amps total for a full pack or 100 amps total for a ¾ “lite” pack.

• Possible causes:– High current discharge (driving fast while deck in low and cutting)

– Loose power connection?

• What to Check– Reduce current draw on the system, raise deck, slow down, less

towing weight, etc.

– Check power connections

BMS Faults 1


OCCP (Over Current in Charge Protection)

• This means that the charge current is exceeding 12.5 A for a full pack or 9.63 A for a ¾ “lite” pack in the normal temperature range (within 0°C and 45°C) or 11 A for a full pack or 8.5 A for a ¾ “lite” pack in the high/low temp extremes.

• Possible causes:– Temperature extremes

– Faulty charger

– Incorrect charger used

• What to Check– Charge unit in normal temp range

– Confirm correct charger is used

– Replace charger

BMS Faults 1


OCDP2 (Over Current in Discharge Protection)

• This means that there is a current draw >180 for a full pack have or >137.5 A for a ¾ “lite” pack.

• Possible causes:– High current discharge (driving fast while deck in low and cutting)

– Loose power connection?

• What to Check– Reduce current draw on the system, raise deck, slow down, less

towing weight, etc.

– Check power connections

BMS Faults 1


BMS Error

• This means that the BMS has detected an internal error.

• Possible causes:– Internal battery error

• What to Check– Turn the key off then on again

– Replace battery if it persists

BMS Faults 1


OTCP_HT (Over Temperature in Charge Protection (High Temp.))

• This means that the max cell temperature is >60°C with the charger connected for 5 seconds.

• Possible causes:– Charging vehicle in high temperatures

– External temperature influence

• What to Check– Charge unit indoors or in a cooler environment

BMS Faults 3


OTCP_LT (Over Temperature in Charge Protection (Low Temp.))

• This means that the min cell temperature is <-10°C with the charger connected for 5 seconds.

• Possible causes:– Charging vehicle in low temperatures

• What to Check– Charge unit indoors or in a warmer environment

BMS Faults 3


OTDP_HT (Over Temperature in Discharge Protection(High Temp.))

• This means that the max cell temperature is >70°C for 3 seconds. Or the Charge/Discharge FET temperature is > 120°C.

• Possible causes:– Operating vehicle in high temperatures

– Outside temperature influence

• What to Check– Allow battery to cool

– Reduce load on unit

BMS Faults 3


OTDP_LT (Over Temperature in Discharge Protection (Low Temp.))

• This means that the min cell temperature is <-20°C for 3 seconds

• Possible causes:– Operating vehicle in low temperatures

• What to Check– Warm battery up

BMS Faults 3

Hybrid Gen1/Gen 2 VCM Fault Codes

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Transcript of Hybrid Gen1/Gen 2 VCM Fault Codes