Troubleshooting methods for controller faults

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Troubleshooting methods for controller faults

(1) Judging whether the controller powers on normally

1. Switch the gear lever to change direction, the R/D display on the instrument panel will change accordingly, and the digital instrument display is normal, indicating that the controller is working properly.

2. Turn the key on and press the accelerator to listen if the controller sounds a long beep.

3. With the key turned on, check whether there is voltage (the voltage value is the same as the battery voltage) between pin 1 of the terminal and B-.

(2) Judging whether the forward/reverse signal is normal

1. Check whether the R/D display on the instrument panel is correct when the instrument can display.

2. With the controller powered off, measure whether pin 4 (gear lever pushed to forward gear) and pin 3 (gear lever pushed to reverse gear) of the terminal are connected to pin 5. If it is determined that the direction signal is incorrect or there is no signal display, please check the gear selector and wiring.

(3) Brake signal

1. Check whether the brake light is on when the brakes are not depressed. If so, the brake switch may be faulty.

2. With the brake light off, measure whether there is a 12V voltage between pin 26 and 27. If so, there may be a problem with the wiring.

(4) Accelerator does not output

1. With the controller powered on normally, turn the key on and press the accelerator to listen if the controller makes a long beep. If there is no beep, the accelerator does not output.

2. With the key turned on, shift to neutral and press the accelerator to measure the output voltage of the accelerator. If the voltage between pins 8 and 31 is around 12V, the accelerator power supply is normal. Then measure whether there is voltage between pins 20 and 31. If the output voltage is less than 0.5V, the accelerator output is abnormal.

(5) Encoder signal abnormality

If the controller wiring is correct, and the vehicle does not move when the accelerator is lightly pressed or moves very slowly while the motor heats up rapidly, the motor encoder signal may be abnormal.

Step 1:

Swap the AB positions of the encoder and see if the vehicle can move normally. If it still cannot be started normally, there may be a problem with the encoder signal.

Step 2:

Methods for judging whether the motor encoder is damaged:

1. Turn on the key to power the controller on, and use a multimeter to measure the power supply of the motor encoder. Confirm that the voltage between pins 6 and 29 should be around 5V.

2. With the controller powered on and in neutral, manually push the car or rotate the wheel to rotate the motor. Check whether the speedometer on the instrument panel indicates or use a computer upper machine software to check whether the motor speed is displayed.

If the encoder power supply is normal and there is no speed indication when the motor is rotating, the motor encoder is damaged.

Possible causes of encoder signal abnormality: encoder power supply abnormality, breakage, poor terminal contact, incorrect terminal signal sequence, encoder damage.

(6) Motor phase sequence is incorrect

If the controller wiring is correct, and the vehicle moves backward in forward gear and forward in reverse gear, adjust the motor phase sequence, that is, swap the U, V or V, W phases of the motor.

The solution