Troubleshooting Guide – Handheld Programmer

The following table provides troubleshooting tips for Handheld Programmers (HHP):

ProblemCause
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 manualController 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 Supported1.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’dMake 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 RESET1. 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 DisplayProblemPossible CausesCorrective Steps
Em-brakeBrake ShortLoose/broken connection to brake or motor controller1. Inspect wire between brake and controller for damage or loose connections. Replace wire if needed.
Em-brake OpenBrake OpenBrake shorted to case, Missing/open brake, Loose/broken connection to brake, DC motor controller1. 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 ActiveQuick Stop/Drive InhibitA 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 ActDeadband Start Error1. 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 ShortMotor Short Or Second Drive Motor Short1. Loose/broken connection to brake or motor controller
2. 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 OpenMotor Open Or Second Drive Motor Open1. Loose/broken connection to brake or motor controller
2. Broken Motor
3. 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 ShortPower Relay ShortThe power relay on the controller has developed a short.Contact your OEM or representative for service of the motor controller.
Seat Motor ShortPSL Motor Short1. Loose/broken connection to PSL motor
2. Bad PSL motor
1. Inspect wire between PSL motor and controller for damage or loose connections. Replace wire if needed.
2. Replace PSL motor
OvertemperatureOver Temperature1. Operating in extreme environment (heat/terrain)
2. Brake is engaged while driving
3. 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 VoltOver Voltage Condition During ChargeThe 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 TimeoutCharge Mode Time OutThe 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 OvertempCharger Over Temperature ConditionThe 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 RevisionBad Software RevisionThe 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 VltgComponent FailureAn internal component on the CS1108 has failed.Contact your OEM or representative for service of the motor controller.

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