Troubleshoot - Hand Held Programmer

The following table provides troubleshooting tips for Hand-Held Programmers (HHP):

Problem	Cause
Unit does not power up.	1.Bad cable between motor controller and HHP 2. Dead batteries
Unit powers up, cannot change values.	The HHP is not compatible with the motor controller. Contact the vehicle OEM or Control Solutions for advice.
Unit powers up displaying: BAD REV! See user manual	Controller software revision is incompatible with drive parameters. Contact the vehicle OEM or Control Solutions for advice.
Unit powers up controller but LCD is blank.	HHP memory corrupted or HHP damaged. Return to manufacturer for repair.
When recalling the factory configuration, unit displays: Function Not Supported	1.Controller does not support reset functionality. Other HHP functions will still work normally.
When recalling the saved configuration from memory, unit displays: BAD ID/REV! Mem rcl cancel’d	Make sure that the controller that the recall is being attempted to is the same type and revision as the controller the parameters were saved from. Try a newer controller revision and/or make sure controller is the same type as the cloned controller.
When powering up the HHP, unit displays: Comm Error! PLEASE RESET	1. Bad cable between motor controller and HHP 2. Power cycle the motor controller.

The HHP is a useful tool in troubleshooting motor controller problems. It displays the motor controller error codes in the
LCD display window in a readable format. To troubleshoot an error, follow these steps.

1. Find the error displayed in the table below.
2. Follow the Corrective Steps in the table to resolve the problem.

If the Corrective Steps does not solve your problem contact Control Solutions Technical Support for the next steps to
resolve the problem.

Error Display	Problem	Possible Causes	Corrective Steps

Em-brake Short	Brake Short	Loose/broken connection to brake or motor controller	1. Inspect wire between brake and controller for damage or loose connections. Replace wire if needed.

Em-brake Open	Brake Open	Brake shorted to case, Missing/open brake, Loose/broken connection to brake, DC motor controller	1. Inspect wire between brake and controller for damage or loose connections. Replace wire if needed.2. Brake is missing from unit.3. Brake broken.

Inhibit Active	Quick Stop/Drive Inhibit	A safety sensing device such as a seat switch, proximity sensor, emergency stop button has been activated.	1. Clear the condition that is activating the safety device.2. The safety device could be faulty and needs to be replaced.

Pwr-up Throt Act	Deadband Start Error	1. The throttle was engaged during vehicle power up.2. The throttle is automatically returning to neutral when released.	1. Make sure the throttle is in the neutral position prior to turning on the vehicle.2. The throttle is faulty and not automatically returning to the neutral position when released. Contact your local service center to have it re-centered.

Drive Mtr ShortDrive2 Mtr Short	Motor Short Or Second Drive Motor Short	1. Loose/broken connection to brake or motor controller2. Broken Motor	1. Inspect wire between brake and controller for damage or loose connections. Replace wire if needed.2. The drive motor is faulty and should be replaced.

Drive Mtr OpenDrive2 Mtr Open	Motor Open Or Second Drive Motor Open	1. Loose/broken connection to brake or motor controller2. Broken Motor3. The drive motor was disengaged (such as in a free wheel mode).	1. Inspect wire between brake and controller for damage or loose connections. Replace wire if needed.2. The drive motor is faulty and should be replaced.3. Re-engage the drive motor

Power Rly Short	Power Relay Short	The power relay on the controller has developed a short.	Contact your OEM or representative for service of the motor controller.

Seat Motor Short	PSL Motor Short	1. Loose/broken connection to PSL motor2. Bad PSL motor	1. Inspect wire between PSL motor and controller for damage or loose connections. Replace wire if needed.2. Replace PSL motor
Overtemperature	Over Temperature	1. Operating in extreme environment (heat/terrain)2. Brake is engaged while driving3. Excessive load on vehicle A slow down in vehicle speed may accompany this error code.	1. Operate the vehicle in accordance with OEM specifications.2. Check brake for faulty operation.3. Reduce load on vehicle If a slow down has occurred then stop, turn off the unit and wait for it to cool down. The unit will return to full operating range.
Charge Over Volt	Over Voltage Condition During Charge	The battery voltage is too high during charge charge cycle.	1. The batteries should be inspected for problems by a qualified technician.2. Check the battery charger and its connections for problems.

Charge Md Timeout	Charge Mode Time Out	The charge cycle did not complete within 24 hours.	1. Check the battery charger and its connections for problems.2. The batteries should be inspected for problems by a qualified technician.

Charge Overtemp	Charger Over Temperature Condition	The charger overheated during the charge cycle (valid for CS1204 charger only). Check the battery and charger for problems.	1. The batteries should be inspected for problems by a qualified technician.2. Battery charger is faulty.

Bad SW Revision	Bad Software Revision	The software revision of the programmer is the wrong version for the software in the controller.	The hand held programmer is not compatible with the motor controller. Contact the vehicle OEM or Control Solutions for advice.

Component FailureUnknown FaultBad Curlim Vltg	Component Failure	An internal component on the CS1108 has failed.	Contact your OEM or representative for service of the motor controller.