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Faults and warnings

When the controller detects a problem, it sets a bit in one of five status parameters and flashes a code on its LED.

  • A fault disables the motor phase bridge. The motor stops producing torque until the fault clears.
  • A warning is reported while the controller keeps running. Many warnings indicate that a foldback is reducing current to protect the battery, motor or controller.

Find the fault or warning by its parameter bit or LED flash code in the lookup table, then follow the link to its description, how to clear it and how to fix it.

LED flash codes

Each fault and warning has a two-digit flash code. The LED flashes the first digit, pauses briefly, flashes the second digit, then pauses for longer before repeating. Count the flashes carefully: the LED may be the only way to see which fault is active.

In the examples below, ( - ) is a flash, ( _ _ ) is a short pause and ( _ _ _ _ ) is a long pause.

Controller over voltage, flash code 1,1: one flash, a short pause, one flash, then a long pause. The sequence repeats until the fault clears.

( - _ _ - _ _ _ _ - _ _ - _ _ _ _ ... )

POST static gating test, flash code 1,8: one flash, a short pause, eight flashes, then a long pause.

( - _ _ - _ - _ - _ - _ - _ - _ - _ - _ _ _ _ )

If more than one fault or warning is active, the LED shows each code in turn, in parameter order (Faults, Faults2, Faults3, Warnings, Warnings2), and repeats the whole sequence until they clear. With both faults above active:

( - _ _ - _ _ _ _ - _ _ - _ - _ - _ - _ - _ - _ - _ - _ _ _ _ ... )

Lookup table

Parameter and bit Name Flash code
Faults bit 0 Controller over voltage 1,1
Faults bit 1 Phase over current 1,2
Faults bit 2 Current sensor calibration 1,3
Faults bit 3 Current sensor over current 1,4
Faults bit 4 Controller over temperature 1,5
Faults bit 5 Motor Hall sensor fault 1,6
Faults bit 6 Controller under voltage 1,7
Faults bit 7 POST static gating test 1,8
Faults bit 8 Network communication timeout 2,1
Faults bit 9 Instantaneous phase over current 2,2
Faults bit 10 Motor over temperature 2,3
Faults bit 11 Throttle voltage outside range 2,4
Faults bit 12 Instantaneous controller over voltage 2,5
Faults bit 13 Internal error 2,6
Faults bit 14 POST dynamic gating test 2,7
Faults bit 15 Instantaneous under voltage 2,8
Faults2 bit 0 Parameter CRC 3,1
Faults2 bit 1 Current scaling 3,2
Faults2 bit 2 Voltage scaling 3,3
Faults2 bit 3 Headlight undervoltage 3,4
Faults2 bit 4 Parameter3 CRC 3,5
Faults2 bit 5 CAN bus 3,6
Faults2 bit 6 Hall stall 3,7
Faults2 bit 8 Parameter2 CRC 4,1
Faults2 bit 9 Hall vs Sensorless position 4,2
Faults2 bit 12 Remote CAN fault 4,5
Faults2 bit 13 Accelerometer Side Tilt fault 4,6
Faults2 bit 14 Open Phase Fault 4,7
Faults2 bit 15 Analog Brake voltage out of range 4,8
Faults3 bit 0 Encoder Sin voltage range 9,1
Faults3 bit 1 Encoder Cos voltage range 9,2
Faults3 bit 2 Analog Input Voltage Range 9,3
Faults3 bit 3 Dual throttle out of range 9,4
Warnings bit 0 Communication timeout 5,1
Warnings bit 1 Hall sensor 5,2
Warnings bit 2 Hall stall 5,3
Warnings bit 3 Wheel speed sensor 5,4
Warnings bit 4 CAN bus 5,5
Warnings bit 5 Hall illegal sector 5,6
Warnings bit 6 Hall illegal transition 5,7
Warnings bit 7 Low battery voltage foldback 5,8
Warnings bit 8 High battery voltage foldback 6,1
Warnings bit 9 Motor temperature foldback 6,2
Warnings bit 10 Controller over temperature foldback 6,3
Warnings bit 11 Low battery SOC foldback 6,4
Warnings bit 12 High battery SOC foldback 6,5
Warnings bit 13 I2T overload foldback 6,6
Warnings bit 14 Low temperature battery / controller foldback 6,7
Warnings2 bit 0 Throttle out of range warning 7,1
Warnings2 bit 3 Dynamic flash full 7,4
Warnings2 bit 4 Dynamic flash read error 7,5
Warnings2 bit 5 Dynamic flash write error 7,6
Warnings2 bit 6 Parameters3 missing 7,7
Warnings2 bit 7 Missed CAN message 7,8
Warnings2 bit 8 Hot battery foldback 8,1
Warnings2 bit 9 ADC saturation warning 8,2

Faults and warnings by parameter and bit

Faults (address 258)

Controller over voltage

Parameter: Faults bit 0 · Flash code: 1,1 · Type: Fault (motor phase bridge disabled)

The filtered battery voltage measurement has exceeded the Slow over voltage threshold for greater than 1 second.

To clear: The fault clears when battery voltage stays below Slow over voltage threshold for more than 1 second.

To fix:

  • Set Rated system voltage to the nominal voltage of the battery.
  • Check that Slow over voltage threshold is set correctly.

To disable or adjust: see Voltage protection.

Phase over current

Parameter: Faults bit 1 · Flash code: 1,2 · Type: Fault (motor phase bridge disabled)

The motor phase current measurement has exceeded the Averaged over current trip threshold for the number of samples specified by Averaged over current trip sample length.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Lower Current Regulator bandwidth to balance the controller current response against phase current spikes.
  • Reduce Rated motor current to reduce phase current peaks.
  • Check for intermittent short circuits between the phases and the battery terminals.
  • Consider a controller with a higher current rating.

Current sensor calibration

Parameter: Faults bit 2 · Flash code: 1,3 · Type: Fault (motor phase bridge disabled)

The phase A current sensor offset or phase C current sensor offset calibration of the current sensors has failed. The current sensor calibration reading at bootup is off by greater than 5%. The nominal value is 50%.

To clear: Reboot the controller.

To fix:

  • Eliminate possible magnetic fields.
  • If the fault does not clear after rebooting and removing possible magnetic field effects, contact ASI for support.

Current sensor over current

Parameter: Faults bit 3 · Flash code: 1,4 · Type: Fault (motor phase bridge disabled)

Current sensor built-in hardware overcurrent fault protection tripped due to an application over current or a current sensor failure.

To clear: Reboot the controller.

To fix:

  • If the fault trips during operation, see Instantaneous phase over current (Faults bit 9).
  • If the fault does not clear after a reboot, contact ASI for support.

Controller over temperature

Parameter: Faults bit 4 · Flash code: 1,5 · Type: Fault (motor phase bridge disabled)

The measured controller temperature for the power board (MOSFET) and/or dsp core temperature for the control board digital signal processor has exceeded the Controller over temperature trip threshold and the controller is commanded to run (Remote state command in remote control, commanded state in local control).

To clear: Allow the controller to cool and the controller temperature to drop below the threshold for more than 1 second.

To fix:

  • Improve cooling.
  • Reduce the current output.
  • Use a larger controller.

Motor Hall sensor fault

Parameter: Faults bit 5 · Flash code: 1,6 · Type: Fault (motor phase bridge disabled)

Motor position sensor type is Hall based or Hall start and sensorless run, the Hall sensor sequence was measured out of order (a skipped sector, or an illegal value such as all three Halls on at the same time), and Motor features bit 1 Fault tolerant hall is not enabled.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Run motor discovery again. The Hall table may be bad.
  • Set up the motor to run well in sensorless mode, then set Motor position sensor type to Hall start and sensorless run.
  • Check the Hall signals with an oscilloscope to make sure they operate as expected and that noise is not causing unexpected state changes at the controller.

To disable or adjust: see Position sensor tuning.

Controller under voltage

Parameter: Faults bit 6 · Flash code: 1,7 · Type: Fault (motor phase bridge disabled)

The filtered battery voltage measurement has dropped below the Slow under voltage threshold for greater than 1 second.

To clear: The fault clears when battery voltage stays above Slow under voltage threshold for more than 1 second.

To fix:

  • Set Rated system voltage to the nominal voltage of the battery.
  • Set Slow under voltage threshold correctly. For example, if your fully discharged battery is at 85% of its nominal voltage, set Slow under voltage threshold to that value.

To disable or adjust: see Voltage protection.

POST static gating test

Parameter: Faults bit 7 · Flash code: 1,8 · Type: Fault (motor phase bridge disabled)

POST (Power on self-test of the bridge) static gating test measures the floating voltage of each phase (phase A voltage, phase B voltage and phase C voltage) relative to the battery voltage before the bridge is enabled. If it is equal to 50% of Battery Voltage +/- Open circuit voltage test window then it passes. This test occurs every time the motor is enabled, if not already turning.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Disconnect the three phase wires from the controller and reboot.
  • If the fault clears, the problem is in the motor or wiring harness: there may be a short through the motor or phase harness to the battery, or to the motor sensors. Water ingress into the motor can cause this.
  • If the fault does not clear with the phases disconnected, contact ASI for support.

Network communication timeout

Parameter: Faults bit 8 · Flash code: 2,1 · Type: Fault (motor phase bridge disabled)

The controller has not received a new heartbeat value in the high byte of Remote state command within the Command timeout threshold (1 sample) or the Average Command timeout threshold (100 samples). This applies when any of these is true:

  • Remote control: Control command source is serial stream and Remote state command is 2 (Run).
  • The CAN sync loss timeout applies.
  • Throttle sensor source is 5 (network voltage) and Remote Throttle Voltage is within the throttle window that activates the bridge.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Set Command timeout threshold and Average Command timeout threshold so that they catch real communication losses without nuisance trips from occasionally missed packets.
  • Make sure your network sends messages faster than the timeout thresholds, with a new value in the high byte of Remote state command on every heartbeat. We recommend a simple rolling counter from 0 to 255.

To disable or adjust: see Command timeouts.

Instantaneous phase over current

Parameter: Faults bit 9 · Flash code: 2,2 · Type: Fault (motor phase bridge disabled)

One instantaneous motor phase current measurement has exceeded the Instantaneous over current trip threshold. In firmware 6.026 and later, the fault requires 3 consecutive samples above the threshold.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Slow the current response to increase tolerance to motor transients: decrease Current Regulator bandwidth, reduce Rated motor current, or both.
  • Consider a controller with a higher current rating for demanding applications.

Motor over temperature

Parameter: Faults bit 10 · Flash code: 2,3 · Type: Fault (motor phase bridge disabled)

The measured motor temperature has exceeded the Motor over temperature trip threshold when the motor is enabled.

To clear: Allow the motor to cool and the motor temperature to drop below the threshold for more than 1 second.

To fix:

  • Set the Motor over temperature trip threshold to the upper temperature limit recommended by the motor OEM.
  • Set your Motor foldback starting temperature and Motor foldback ending temperature appropriately to reduce current output as motor temperature nears the Motor over temperature trip threshold.
  • Reduce Rated motor current and/or the active Rated motor power parameter to reduce motor heat generation when under full load.
  • Verify Motor temperature feedback V at … C are set accurately for your motor's thermistor.

To disable or adjust: see Motor temperature sensor.

Throttle voltage outside range

Parameter: Faults bit 11 · Flash code: 2,4 · Type: Fault (motor phase bridge disabled)

The measured throttle voltage is below the Throttle off voltage minus Throttle fault range, or above the Throttle full voltage plus Throttle fault range, and the Control command source is set to Throttle or Throttle or pedal sensor and Features2 bit 4 Throttle fault changed to warning is not set.

To clear: Return the throttle to within Throttle off voltage minus Throttle fault range and Throttle full voltage plus Throttle fault range.

To fix:

  • Set your Throttle off voltage, Throttle full voltage, and Throttle fault range correctly.
  • Double-check your throttle wiring and that your input source voltage changes with the throttle position.

To disable or adjust: see Throttle.

Instantaneous controller over voltage

Parameter: Faults bit 12 · Flash code: 2,5 · Type: Fault (motor phase bridge disabled)

One instantaneous battery voltage measurement has exceeded the Fast over voltage threshold while the bridge is enabled.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Make sure the battery or power supply is adequately sized.
  • Make sure the battery is not unclamping because of a sensitive regen or charge protection threshold. This can happen when the application regenerates into the battery while the motor is above its base speed, causing an instantaneous voltage spike.

To disable or adjust: see Voltage protection.

Internal error

Parameter: Faults bit 13 · Flash code: 2,6 · Type: Fault (motor phase bridge disabled)

Execution time was not enough to run all of the code. The fault triggers before the controller attempts to run the code. This should not occur in normal operation. It typically appears only after a loss of power interrupts a save to flash and corrupts the parameters.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Check the Switching frequency and Maximum interrupt execution time parameters.

POST dynamic gating test

Parameter: Faults bit 14 · Flash code: 2,7 · Type: Fault (motor phase bridge disabled)

If the POST static gating test passes, POST (Power on self-test of the bridge) dynamic gating test enables and PWMs only one of the 6 high or low side per phase MOSFETs at a time. The 3 low-side must measure 15% of battery voltage +/- High/Lowside turn on voltage test window. The three high sides must measure 85% of battery voltage +/- High/Lowside turn on voltage test window. This test occurs every time the motor is enabled if not already turning.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Make sure the Key-in supply is adequately powered and stable. It feeds the regulator that powers the control board and the phase gate drivers. Without enough power, the gate driver is starved and the MOSFETs might not switch correctly.
  • If the fault continues, contact ASI for support.

Instantaneous under voltage

Parameter: Faults bit 15 · Flash code: 2,8 · Type: Fault (motor phase bridge disabled)

One instantaneous battery voltage measurement was less than the Fast under voltage threshold when the bridge was enabled.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Set Rated system voltage to the nominal voltage of the battery.
  • Set Fast under voltage threshold to the safe lower limit of the battery.
  • Make sure the battery positive and negative terminals are powered and secure.
  • Make sure the battery or power supply is adequately sized and is not unclamping because of sensitive output short-circuit protection. This can happen when the bridge is enabled with a high current command, causing the measured battery voltage to sag instantaneously.

To disable or adjust: see Voltage protection.

Faults2 (address 299)

Parameter CRC

Parameter: Faults2 bit 0 · Flash code: 3,1 · Type: Fault (motor phase bridge disabled)

Parameter block 1 in flash is corrupted or blank.

To clear: The controller must be factory recalibrated.

To fix:

  • Make sure saving to flash is not interrupted by a loss of power.
  • If you need to recover the controller, contact ASI.

Current scaling

Parameter: Faults2 bit 1 · Flash code: 3,2 · Type: Fault (motor phase bridge disabled)

The Rated motor current is set too low for the measurable range.

To clear: Increase Rated motor current in steps, saving to flash and rebooting each time, until the fault clears.

To fix:

  • If you cannot increase Rated motor current, use a smaller BAC controller.
  • If the parameter file is corrupt, contact ASI for support.

Voltage scaling

Parameter: Faults2 bit 2 · Flash code: 3,3 · Type: Fault (motor phase bridge disabled)

The Rated system voltage is set too low for the measurable range.

To clear: Set Rated system voltage within the nominal voltage limits on the specification sheet, save to flash and reboot.

To fix:

  • If the parameter file is corrupt, contact ASI for support.

Headlight undervoltage

Parameter: Faults2 bit 3 · Flash code: 3,4 · Type: Fault (motor phase bridge disabled)

internal rail voltage is below 5 V for 100 ms while bits 1, 2 or 3 of Remote Digital Commands (HeadLight, RunLight, BrkLight) are enabled over the network. This is a legacy fault. It should not occur on current hardware.

To clear: Turn off all light commands, reboot the controller, or send a fault reset command.

To fix:

  • Find and isolate the short circuit on the voltage rail.
  • If the fault triggers with all peripherals disconnected, contact ASI for support.

Parameter3 CRC

Parameter: Faults2 bit 4 · Flash code: 3,5 · Type: Fault (motor phase bridge disabled)

Parameter block 3 in flash is corrupted or blank.

To clear: The controller must be factory recalibrated.

To fix:

  • Make sure saving to flash is not interrupted by a loss of power.
  • If you need to recover the controller, contact ASI.

CAN bus

Parameter: Faults2 bit 5 · Flash code: 3,6 · Type: Fault (motor phase bridge disabled)

CAN bus errors are greater than the fault threshold per CAN 2.0 specifications, and Communications Configuration Vector bit 1 CAN faults is enabled.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Check that all nodes and terminations on the network are correct.
  • Check that the CAN baud rate is set correctly on all devices.
  • Replace the CAN transceiver.

To disable or adjust: see CANopen.

Hall stall

Parameter: Faults2 bit 6 · Flash code: 3,7 · Type: Fault (motor phase bridge disabled)

No motor hall transitions for greater than Hall stall fault time and commanding greater than 20% motor current.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Turn off the system and, if it is safe, find the cause of the motor stall, such as an obstruction or bad wiring.

To disable or adjust: see Hall stall fault.

Parameter2 CRC

Parameter: Faults2 bit 8 · Flash code: 4,1 · Type: Fault (motor phase bridge disabled)

Parameter block 2 in flash is corrupted or blank.

To clear: The controller must be factory recalibrated.

To fix:

  • Make sure saving to flash is not interrupted by a loss of power.
  • If you need to recover the controller, contact ASI.

Hall vs Sensorless position

Parameter: Faults2 bit 9 · Flash code: 4,2 · Type: Fault (motor phase bridge disabled)

The controller compares the Hall and sensorless positions. In Motor position sensor type hall based and hall start and sensorless run, the fault triggers if they differ by more than 30 degrees.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Check the Hall offset angle parameter.
  • Run Motor discover mode 2 again. Check that the Hall sector table is valid and that discovery provides an autotune hall offset angle.
  • If you use a Hall signal emulator, make sure its offset is consistent across speed and load.

Remote CAN fault

Parameter: Faults2 bit 12 · Flash code: 4,5 · Type: Fault (motor phase bridge disabled)

When Communications Configuration Vector bit 7 CAN enable is set, any device on the network can trigger this fault by writing to Remote Digital Commands bit 13 CAN remote fault.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Check the CAN traffic to find which device set Remote Digital Commands bit 13 CAN remote fault, and review the cause at that device.

Accelerometer Side Tilt fault

Parameter: Faults2 bit 13 · Flash code: 4,6 · Type: Fault (motor phase bridge disabled)

The accelerometer is configured and the data it reads is out of range. This is a legacy fault. It should not occur on current hardware.

Open Phase Fault

Parameter: Faults2 bit 14 · Flash code: 4,7 · Type: Fault (motor phase bridge disabled)

Open phase fault detection is enabled with Level 1 Features bit 2 Open phase fault detection, and the difference between the RMS currents of any two phases has been greater than Open Phase Fault Detection Threshold (address 1966) for more than 1 second.

To clear: Send a fault clear command or cycle the key switch.

To fix:

  • Check and fix the phase connections. One of the phases appears to be disconnected or loose.

To disable or adjust: see Open phase fault.

Analog Brake voltage out of range

Parameter: Faults2 bit 15 · Flash code: 4,8 · Type: Fault (motor phase bridge disabled)

The measured brake voltage is below the Analogue brake off voltage minus Analog brake fault range, or above the Analogue brake full voltage plus Analog brake fault range.

To clear: Return the brake to within Analogue brake off voltage minus Analog brake fault range and Analogue brake full voltage plus Analog brake fault range.

To fix:

  • Set your Analogue brake off voltage, Analogue brake full voltage, and Analog brake fault range correctly.
  • Double-check your brake wiring and that your input source voltage changes with the brake position.

To disable or adjust: see Regenerative braking.

Faults2 bits 7, 10 and 11 are reserved.

Faults3 (address 363)

Encoder Sin voltage range

Parameter: Faults3 bit 0 · Flash code: 9,1 · Type: Fault (motor phase bridge disabled)

The measured Encoder Sin voltage is below the Encoder Sine Low Voltage or above the Encoder Sine High Voltage, and the Motor position sensor type is set to Encoder.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Set your Encoder Sine Low Voltage and Encoder Sine High Voltage correctly.
  • Double-check your Encoder wiring and that your input source voltage changes with motor position.

Encoder Cos voltage range

Parameter: Faults3 bit 1 · Flash code: 9,2 · Type: Fault (motor phase bridge disabled)

The measured Encoder Cos voltage is below the Encoder Cos Low Voltage or above the Encoder Cos High Voltage, and the Motor position sensor type is set to Encoder.

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Set your Encoder Cos Low Voltage and Encoder Cos High Voltage correctly.
  • Double-check your Encoder wiring and that your input source voltage changes with motor position.

Analog Input Voltage Range

Parameter: Faults3 bit 2 · Flash code: 9,3 · Type: Fault (motor phase bridge disabled)

An ADC input is saturated: above 3.3 V at the DSP, after the input voltage divider, for 100 PWM periods. Behaviour depends on the firmware version:

  • 6.026 and later: this fault triggers only for inputs whose bit is not enabled in ADC Saturation Control (address 239).
  • 6.025 rev02: this fault never triggers. ADC saturation warning (Warnings2 bit 9) is set instead.
  • 6.024 to 6.025: this fault always triggers.

To clear: Remove the source of voltage that makes the input exceed its rating.

To fix:

  • Remove the source of voltage that makes the input exceed its rating.

An input voltage above its rating can damage the controller. Remove the cause as soon as possible.

To disable or adjust: see ADC saturation.

Dual throttle out of range

Parameter: Faults3 bit 3 · Flash code: 9,4 · Type: Fault (motor phase bridge disabled)

The difference between throttle setpoints calculated from the primary throttle and the secondary throttle is larger than the Dual analog throttle fault threshold.

To clear: Reset the throttle inputs so that both setpoints are within the Dual analog throttle fault threshold from each other, or increase the Dual analog throttle fault threshold to a higher value to compensate for input noise.

To fix:

  • Set your Throttle sensor source, Throttle off voltage, Throttle full voltage, Throttle deadband threshold and Throttle fault range correctly for your primary throttle source.
  • Set your Secondary throttle source for dual analog throttle, Secondary throttle off voltage, Secondary throttle full voltage and Dual analog throttle fault threshold correctly for your secondary throttle.
  • Double-check your throttle wiring that your input source voltages change with throttle position, and that the throttle setpoint and secondary throttle setpoint closely match throughout the entire throttle active range.

To disable or adjust: see Throttle.

Faults3 bits 4 to 15 are reserved.

Warnings (address 277)

Communication timeout

Parameter: Warnings bit 0 · Flash code: 5,1 · Type: Warning

The controller has not received a valid heartbeat over an elapsed time that exceeds the Command timeout threshold (1 sample) or the Average Command timeout threshold (100 samples). It also triggers Network communication timeout (Faults bit 8).

To clear: Reboot the controller or send a fault reset command.

To fix:

  • Set the Command timeout threshold and Average Command timeout threshold.
  • Make sure your network heartbeat is faster than the timeout thresholds.

To disable or adjust: see Command timeouts.

Hall sensor

Parameter: Warnings bit 1 · Flash code: 5,2 · Type: Warning

Warnings bit 5 or bit 6 is set. See Hall illegal sector and Hall illegal transition. If Motor features bit 1 Fault tolerant hall is enabled, the controller switches to sensorless operation. If it is not enabled, the controller triggers Motor Hall sensor fault (Faults bit 5).

To clear: Clear Warnings bits 5 and 6.

To fix:

Hall stall

Parameter: Warnings bit 2 · Flash code: 5,3 · Type: Warning

If Hall stall fault time is not 0, the controller detects a Hall stall when the controller status is Running and the motor is drawing at least 20% of Rated motor current. Below that current, the controller does not issue the warning. If Hall stall fault time is 0, the controller does not issue the warning. If Motor features bit 1 Fault tolerant hall is enabled, it stays a warning. If it is not enabled, the controller also triggers Motor Hall sensor fault (Faults bit 5) and Hall stall (Faults2 bit 6).

To clear: Command the controller off (Remote state command in remote control, commanded state in local control). The warning clears after Hall stall fault time elapses. Alternatively, reboot the controller.

To fix:

  • Turn off the system and, if it is safe, find the cause of the motor stall, such as an obstruction or bad wiring.

To disable or adjust: see Hall stall fault.

Wheel speed sensor

Parameter: Warnings bit 3 · Flash code: 5,4 · Type: Warning

If an external Wheel speed sensor source is selected, the controller compares wheel RPM (motor based) with wheel RPM (speed sensor based). The warning triggers when the difference is more than 30 rpm, motor current is above 7.5%, 2 seconds have elapsed, and Motor features bit 2 bottom bracket motor is disabled. The controller then switches to motor-based speed calculation.

To clear: Reboot the controller.

To fix:

  • Enable the Motor features bit 2 Bottom bracket motor (varying gear ratio) to ignore the wheel RPM (motor based) and only use the wheel RPM (speed sensor based).
  • Set Wheel speed sensor pulses per revolution to correct value.

To disable or adjust: see Speed sensor.

CAN bus

Parameter: Warnings bit 4 · Flash code: 5,5 · Type: Warning

CAN bus errors are greater than the warning threshold per CAN 2.0 specifications, and Communications Configuration Vector bit 1 CAN faults is enabled.

To clear: The warning clears when CAN bus errors fall back below the CAN 2.0 hardware error thresholds.

To fix:

  • Check that all nodes and terminations on the network are correct.
  • Check that the CAN baud rate is set correctly on all devices.
  • Replace the CAN transceiver.

To disable or adjust: see CANopen.

Hall illegal sector

Parameter: Warnings bit 5 · Flash code: 5,6 · Type: Warning

The Hall sector has a value of -1 based on the Hall table. All three Halls are 0 or all three are 1 simultaneously.

To clear: Reboot the controller.

To fix:

  • Check that the Hall table is correct. If it is correct, the problem is with the Hall sensors.
  • Check that the Hall sensors are wired correctly and transition when the motor is rotated by hand and under load.

Hall illegal transition

Parameter: Warnings bit 6 · Flash code: 5,7 · Type: Warning

Based on the Hall table, the Hall sector changed by more than 1.

To clear: Reboot the controller.

To fix:

  • Check that the Hall table is correct. If it is correct, the problem is with the Hall sensors.
  • Check that the Hall sensors are wired correctly and transition when the motor is rotated by hand and under load.

Low battery voltage foldback

Parameter: Warnings bit 7 · Flash code: 5,8 · Type: Warning

battery voltage is lower than Low battery foldback starting voltage threshold. Motor current is being reduced to protect the battery.

To clear: The warning clears when battery voltage is above the Low battery foldback starting voltage.

To fix:

  • Charge your battery.
  • Set the Rated system voltage and Low battery foldback starting voltage.

To disable or adjust: see Battery foldbacks.

High battery voltage foldback

Parameter: Warnings bit 8 · Flash code: 6,1 · Type: Warning

battery voltage is higher than High battery foldback starting voltage threshold. Motor regeneration current is being reduced to protect the battery.

To clear: The warning clears when battery voltage is below the High battery foldback starting voltage.

To fix:

  • Set Rated system voltage and High battery foldback starting voltage.

To disable or adjust: see Battery foldbacks.

Motor temperature foldback

Parameter: Warnings bit 9 · Flash code: 6,2 · Type: Warning

motor temperature is higher than Motor foldback starting temperature threshold. Motor current is being reduced to protect the motor.

To clear: The warning clears when motor temperature is below the Motor foldback starting temperature.

To fix:

  • Set Motor foldback starting temperature and Motor foldback ending temperature correctly.

To disable or adjust: see Motor foldbacks.

Controller over temperature foldback

Parameter: Warnings bit 10 · Flash code: 6,3 · Type: Warning

controller temperature is higher than the Controller foldback starting temperature threshold. Motor current is being reduced to protect the controller.

To clear: The warning clears when controller temperature is below the Controller foldback starting temperature.

To fix:

  • Improve cooling.
  • Reduce the load.
  • Use a larger controller.

Low battery SOC foldback

Parameter: Warnings bit 11 · Flash code: 6,4 · Type: Warning

battery state of charge is lower than Low battery state of charge foldback starting capacity. Motor current is being reduced to protect the battery.

To clear: The warning clears when battery state of charge is above the Low battery state of charge foldback starting capacity.

To fix:

  • Charge your battery.
  • Set Voltage model battery state of charge gain and Voltage model battery state of charge offset so the controller calculates the state of charge correctly.
  • Make sure Low battery state of charge foldback starting capacity is higher than Low battery state of charge foldback end capacity.

To disable or adjust: see Battery foldbacks.

High battery SOC foldback

Parameter: Warnings bit 12 · Flash code: 6,5 · Type: Warning

battery state of charge is higher than the High battery state of charge foldback starting capacity. Motor regeneration current is being reduced to protect the battery.

To clear: The warning clears when battery state of charge is below the High battery state of charge foldback starting capacity.

To fix:

  • Charge your battery according to the manufacturer's instructions, using the recommended charger to avoid overcharging.
  • Set Voltage model battery state of charge gain and Voltage model battery state of charge offset so the controller calculates the state of charge correctly.
  • Make sure High battery state of charge foldback starting capacity is lower than High battery state of charge foldback end capacity.

To disable or adjust: see Battery foldbacks.

I2T overload foldback

Parameter: Warnings bit 13 · Flash code: 6,6 · Type: Warning

I²t (heat model) overload: the controller current output has been above Overload heating current for longer than Overload heating time, and motor current is reduced to protect the motor, the battery or both. If Motor features bit 3 Disable motor I^2t enable battery I^2t is set, the controller monitors battery current. If it is not set, it compares motor current against Overload heating current. Current output is limited to Overload cooling current until Overload cooling time has elapsed.

To clear: Allow the motor to cool for the time set by Overload cooling time.

To fix:

  • Set Overload heating current and Overload heating time for your application so that component temperatures stay within their manufacturers' thermal limits. You may need to test in different climates and environments to find the right values.

To disable or adjust: see Motor foldbacks.

Low temperature battery / controller foldback

Parameter: Warnings bit 14 · Flash code: 6,7 · Type: Warning

The battery temperature or the controller temperature has fallen below Cold battery foldback starting temperature. Current is reduced to protect the battery and controller.

To clear: Allow the controller or battery to warm up and the temperature to rise above the Cold battery foldback starting temperature.

To fix:

  • Set Cold battery foldback starting temperature and Cold battery foldback ending temperature to safe values for your application.
  • See controller specification sheet for lower operating temperature limit.

To disable or adjust: see Battery foldbacks.

Warnings bit 15 is reserved.

Warnings2 (address 359)

Throttle out of range warning

Parameter: Warnings2 bit 0 · Flash code: 7,1 · Type: Warning

Measured throttle voltage sensor source lower than Throttle off voltage minus Throttle fault range or higher than Throttle full voltage plus Throttle fault range and Features2 bit 4 Throttle fault changed to warning is enabled, and Control command source has throttle and one other control source selected (e.g., Pedal and throttle).

To clear: Reboot the controller.

To fix:

  • Set your Throttle off voltage, Throttle full voltage, and Throttle fault range correctly.
  • Double-check your throttle wiring and that your input source voltage changes with the throttle position.

To disable or adjust: see Throttle.

Dynamic flash full

Parameter: Warnings2 bit 3 · Flash code: 7,4 · Type: Warning

The Dynamic flash available is filled, and there is no more space left to write.

To clear: Power cycle the controller so the dynamic flash function can correct itself.

To fix:

  • If the warning returns after a power cycle, contact ASI for support.

Dynamic flash read error

Parameter: Warnings2 bit 4 · Flash code: 7,5 · Type: Warning

Unable to read the variables stored in the dynamic flash.

To clear: Power cycle the controller so the dynamic flash function can correct itself.

To fix:

  • If the warning returns after a power cycle, contact ASI for support.

Dynamic flash write error

Parameter: Warnings2 bit 5 · Flash code: 7,6 · Type: Warning

The controller could not write to the dynamic flash.

To clear: Power cycle the controller so the dynamic flash function can correct itself.

To fix:

  • If the warning returns after a power cycle, contact ASI for support.

Parameters3 missing

Parameter: Warnings2 bit 6 · Flash code: 7,7 · Type: Warning

The self-check at boot found that the Parameters3 sector in flash is missing.

To clear: Save the parameters to flash. This writes the Parameters3 sector, and the self-check at the next reboot no longer finds it missing.

Missed CAN message

Parameter: Warnings2 bit 7 · Flash code: 7,8 · Type: Warning

CAN mailbox overflow indicator. When the can message overflow count value is incremented, this warning will also be set. can message overflow count is the count of received CAN messages that did not have an available mailbox and thus overwrote a previously received CAN message.

To clear: Reboot the controller.

To fix:

  • Find the source of the overflow. If the count increments only during boot, you can ignore it. If it increments during operation, identify the source.

Hot battery foldback

Parameter: Warnings2 bit 8 · Flash code: 8,1 · Type: Warning

The battery temperature is higher than the Hot battery foldback starting temperature (address 1969). Discharge and regen current are linearly reduced from 100% at the Hot battery foldback starting temperature to 0% at the Hot battery foldback ending temperature (address 1970).

To clear: The battery temperature is below the Hot battery foldback starting temperature.

To fix:

  • Allow the battery to cool.
  • Set Hot battery foldback starting temperature and Hot battery foldback ending temperature to safe values for your battery.

To disable or adjust: see Battery foldbacks.

ADC saturation warning

Parameter: Warnings2 bit 9 · Flash code: 8,2 · Type: Warning

An ADC input is saturated: above 3.3 V at the DSP, after the input voltage divider, for 100 PWM periods. Behaviour depends on the firmware version:

  • 6.026 and later: set only for inputs whose bit is enabled in ADC Saturation Control (address 239). For other inputs, Analog Input Voltage Range (Faults3 bit 2) triggers instead.
  • 6.025 rev02: set for any saturated input.

To clear: The warning cannot be cleared until you fix the input that is causing the ADC to saturate.

To fix:

  • Remove the source of voltage that makes the input exceed its rating.

An input voltage above its rating can damage the controller. Remove the cause as soon as possible.

To disable or adjust: see ADC saturation.

Warnings2 bits 1, 2, 10, 11, 12, 13, 14 and 15 are reserved.