Each BorgWarner/Sevcon Gen4 Motor Controller (Size 2, 4, and 6) is equipped with a green LED that flashes in a repetitive sequence when a fault is detected.
The green LED on the faulty Gen4 controller will flash a specific number of times, pause briefly, then repeat the sequence. Each pattern corresponds to a unique fault category.
For example, a sequence of three flashes followed by a short pause, then repeating (3 – pause – 3 – pause – …), indicates Fault Code 3: MOSFET/IGBT failure.
When multiple faults are present, the LED will indicate only the highest priority fault within the system
Fault Category Indication via LED Flashes
|
LED Flashes |
Fault Category |
|---|---|
|
0 (Off) |
Internal hardware failure |
|
1 |
Configuration fault |
|
2 |
Input sequence fault |
|
3 |
MOSFET/IGBT failure |
|
4 |
Contactor failure |
|
5 |
Miscellaneous |
|
6 |
Analogue input failure |
|
7 |
Battery faults |
|
8 |
Temperature faults |
|
9 |
Contactor coil short circuit |
|
10 |
Unit is Preoperational |
|
11 |
General |
|
12 |
CAN or communication faults |
|
13 |
Internal faults |
|
14 |
Peripheral faults |
|
15 |
Service required |
While the LED flash codes on Gen4 Motor Controllers provide a quick way to identify the type of fault, deeper diagnostic information requires the use of DVT software.
Specific Fault Codes & Recommended Action
Each fault category is associated with multiple specific fault codes, as detailed below:
| LED Flash | BorgWarner Fault Code | Fault Type (level description) |
Fault Message | Description / Fault Cause | Recommended Action |
| 1 | 0x4441 | Warning | Motor Characterisation Mode | Controller is configured in a mode intended to carry out characterisation | If motor characterisation mode has been configured or enabled then no action is required. Otherwise the configuration should be checked |
| 1 | 0x4C41 | Severe | Too many slaves | Number of slaves (0x2810,0) set higher than maximum allowed number of slaves (typically 7) | Check 0x2810,0 setting is correct |
| 1 | 0x5041 | Very Severe | Bad NVM Data | EEPROM or flash configuration data corrupted and data can not be recovered. | If firmware has recently been updated, revert to previous version. Contact BorgWarner for support. |
| 1 | 0x5042 | Very Severe | VPDO Out of Range | VPDO mapped to non-existent or invalid object | Check all VPDO mappings (0x3000 to 0x3400) |
| 1 | 0x5043 | Very Severe | Static Range Error | At least one configuration object is out of range | Set configuration object to valid value. Our of range object can be identified using 0x5621 or DVT CLI window. |
| 1 | 0x5044 | Very Severe | Dynamic Range Error | At least one configuration object is out of dynamic range. This is where one objects range depends on another object or hardware variant specific level. | Check all dynamic range objects. DVT CLI window indicates type of object which is out of range. |
| 1 | 0x5441 | Return to Base | Incompatible hardware version | Detected controller hardware version incompatible with software | Check correct software is programmed into controller. Reprogram if necessary. Contact BorgWarner |
| 1 | 0x5442 | Return to Base | Calibration Fault | Calibration settings in controller are out of range or not set | Controller current sensors require calibration. Contact BorgWarner |
| 2 | 0x4481 | Warning | Handbrake Fault (warn) | Handbrake is active when a direction selected | Warning to release the handbrake before driving |
| 2 | 0x4881 | Drive Inhibit | Seat Fault | Valid direction selected with operator not seated or operator is not seated for a user configurable time in drive. | Must be seated with switches inactive |
| 2 | 0x4882 | Drive Inhibit | Two Direction Fault | Both the forward and reverse switches have been active simultaneously for greater than 200 ms. | If both switches are selected then release both, then select required direction. If fault persists check vehicle wiring and configuration of mapping for digital inputs. |
| 2 | 0x4883 | Drive Inhibit | SRO Fault | FS1 (foot switch / throttle) active for user configurable delay (0x2914,2) without a direction selected. | Deselect FS1 (foot switch / throttle) and select direction first |
| 2 | 0x4884 | Drive Inhibit | Sequence Fault | Any drive switch active at power up as configured in 0x2918 | Deselect all drive switches and then reselect required switch. |
| 2 | 0x4885 | Drive Inhibit | FS1 Recycle Fault | FS1 (foot switch / throttle) active after a direction change and FS1 recycle function enabled (0x2914,1,bit1) | Deselect FS1 / throttle pedal |
| 2 | 0x4886 | Drive Inhibit | Inch Fault | Inch switch active along with any drive switch active (excluding inch switches), seat switch indicating operator present or handbrake switch active. | Correct conditions need to be met for inching functionality (drive not selected, operator not present and handbrake released) |
| 2 | 0x488D | Drive Inhibit | Belly fault | Belly switch function has activated. | Deselect belly switch |
| 2 | 0x5081 | Very Severe | Invalid Steer Switches | Steering switches are in an invalid state | Check steering switches and wiring. Check steering map 0x2913 is valid |
| 3 | 0x54C1 | Return to Base | PowerFrame Overvoltage Fault | DC link voltage exceeds rated maximum for controller | Check battery condition and wiring. Ensure battery voltage is not too high for the controller operational rating |
| 3 | 0x54C2 | Return to Base | PowerFrame Fault | Current flow exceeds controller maximum. Caused by motor current too high, configuration error causing overcurrent, wiring fault/short or internal controller failure | Check motor control configuration and wiring. If fault is set persistently, disconnect motor cables to see if fault clears |
| 3 | 0x54C3 | Return to Base | PowerFrame s/c M1 upper | MOSFET / IGBT short circuit detection on M1 top devices. Fault condition is checked when powerframe disabled by comparing M1 terminal voltage to B+ | Check motor wiring. Check controller condition with motor disconnected |
| 3 | 0x54C4 | Return to Base | PowerFrame s/c M1 lower | MOSFET / IGBT short circuit detection on M1 bottom devices. Fault condition is checked when powerframe disabled by comparing M1 terminal voltage to B- | Check motor wiring. Check controller condition with motor disconnected |
| 3 | 0x54C5 | Return to Base | PowerFrame s/c M2 upper | MOSFET / IGBT short circuit detection on M2 top devices. Fault condition is checked when powerframe disabled by comparing M2 terminal voltage to B+ | Check motor wiring. Check controller condition with motor disconnected |
| 3 | 0x54C6 | Return to Base | PowerFrame s/c M2 lower | MOSFET / IGBT short circuit detection on M2 bottom devices. Fault condition is checked when powerframe disabled by comparing M2 terminal voltage to B- | Check motor wiring. Check controller condition with motor disconnected |
| 3 | 0x54C7 | Return to Base | PowerFrame s/c M3 upper | MOSFET / IGBT short circuit detection on M3 top devices. Fault condition is checked when powerframe disabled by comparing M3 terminal voltage to B+ | Check motor wiring. Check controller condition with motor disconnected |
| 3 | 0x54C8 | Return to Base | PowerFrame s/c M3 lower | MOSFET / IGBT short circuit detection on M3 bottom devices. Fault condition is checked when powerframe disabled by comparing M3 terminal voltage to B- | Check motor wiring. Check controller condition with motor disconnected |
| 3 | 0x54C9 | Return to Base | PowerFrame s/c checks incomplete | Unable to complete MOSFET / IGBT short circuit tests at power up | Ensure pre-charge has increased DC link voltage high enough for tests to be carried out. |
| 4 | 0x5101 | Very Severe | Line Contactor o/c | Line contactor open circuit – contactor did not close when the coil is energized. | Check line contactor operation and wiring. DC link fuse blown |
| 4 | 0x5102 | Very Severe | Line Contactor welded | Line contactor appears to be closed when the coil is NOT energized. | Check line contactor hasn’t welded closed and the wiring is correct. Make sure the line contactor is not mapped if there is not one connected and controlled by the motor inverter |
| 4 | 0x5103 | Very Severe | Contactor Drive Fault | Fault with contactor drive | Check contactor and wiring for short circuits. If fault persists replace the controller |
| 5 | 0x4546 | Warning | No Motor Speed Signal | No speed feedback from motor sensor | Check encoder wiring and speed measurement signal |
| 5 | 0x4548 | Warning | Steer Sensor warning | Invalid steer sensor state | Check steer sensor wiring and configuration |
| 5 | 0x454C | Warning | Electrolyte Low Level | Battery Electrolyte low level detected | Check battery electrolyte level |
| 5 | 0x454D | Warning | Electrolyte Cutout Level | Battery Electrolyte low level detected and cutback | Check battery electrolyte level |
| 5 | 0x4D42 | Severe | Motor Open Circuit Fault | Motor terminal is open circuit or disconnected from controller | Check motor wiring. Check controller condition |
| 5 | 0x4D43 | Severe | Motor stalled | No speed feedback from motor | Check encoder wiring and speed measurement signal |
| 6 | 0x458A | Warning | Seat (warning) | Seat switch open so configured regen settings in 0x2928 are being applied | Close the seat switch and recycle the selected direction |
| 6 | 0x458B | Warning | Footbrake (warning) | Customer specific fault. Raised when analog footbrake voltage does not match digital footbrake switch state | Check footbrake wiring and installation |
| 6 | 0x4981 | Drive Inhibit | Throttle Fault | Throttle value (0x2620,0) is greater than 20% at power up. | Release throttle and re-apply. Check wiring |
| 6 | 0x4982 | Drive Inhibit | E-Brake Wire off | Wire-off detected in electrobrake circuit | Check electrobrake wiring, ensure current flows when energised |
| 6 | 0x4983 | Drive Inhibit | Direction Change | Direction is changed and vehicle speed is greated than allowed in 0x2929,2 | Neutral switch should be selected to clear the fault |
| 6 | 0x5181 | Very Severe | Digital Input Wire Off | Digital input wire-off | Check wiring and configuration |
| 6 | 0x5182 | Very Severe | Analog Input Wire Off | Analog input voltage outside of configured range (0x46C0 – 0x46C7) | Check wiring and configuration is correct in 0x46c0 to 0x46c7. If analog input is not used the range should be set to the minimum and maximum limits |
| 6 | 0x5183 | Very Severe | Analog Output Over Current | Contactor driver over current protection has activated | Ensure contactor doesn’t exceed maximum current and check contactor wiring for short circuits. Make sure contactor or load is NOT capacitive such as contactors with economizer circuits |
| 6 | 0x5184 | Very Severe | Analog Output On with No Failsafe | Internal hardware failsafe circuitry not working | Contact driver failed startup checks. Internal circuit has failed or external wiring issues with contactor connected to B- / logic ground. For Gen4 DC the contactor output used needs to be configured in 0x46A5, if none are used a resistor needs to be fitted in place of a contactor for the test to complete – see Gen4DC manual / AppNote |
| 6 | 0x5185 | Very Severe | Analog Output Off with Failsafe | Contactor driver circuit has failed start up checks | Contact driver couldn’t activate for startup checks. Internal circuit has failed or external coil short circuit or wiring issue connecting contactor driver to keyswitch |
| 6 | 0x5186 | Very Severe | Analog Output Over Temperature | Contactor driver over temperature | Ensure contactor doesn’t exceed maximum current and check contactor wiring |
| 6 | 0x5187 | Very Severe | Analog Output Under Current | Contactor driver unable to achieve current target in current mode | Ensure contactor driver current target is within range for available voltage |
| 6 | 0x5188 | Very Severe | Analog Output Short Circuit | Contactor driver MOSFET short circuit detected | Check contactor and wiring for short circuits. If fault persists replace the controller |
| 7 | 0x45C1 | Warning | BDI (battery discharge) warning | BDI remaining charge (0x2790,1) is less than configured BDI Warning level (0x2C30,5). No action is taken by the controller. For information only. | Charge battery (or if commissioning controller and battery is charged check BDI configuration in 0x2C30) |
| 7 | 0x45C2 | Warning | BDI (battery discharge) cutout | BDI remaining charge (0x2790,1) is less than configured BDI Cutout level (0x2C30,4). The low BDI drivability profile is applied if configured in 0x2931. | Charge battery (or if commissioning controller and battery is charged check BDI configuration in 0x2C30) |
| 7 | 0x45C3 | Warning | Low Battery cutout | Battery voltage is less than the configured Under Voltage limit (0x2C02,2) for longer than the protection delay (0x2C03,0) | Charge battery (or if commissioning controller and battery is charged check BattApp configuration in 0x2C01, 0x2C02, 0x2C03) |
| 7 | 0x45C4 | Warning | High Battery cutout | Battery voltage is greater than the configured Over Voltage limit (0x2C01,2) for longer than the protection delay (0x2C03,0) | Charge battery (or if commissioning controller and battery is charged check BattApp configuration in 0x2C01, 0x2C02, 0x2C03) |
| 7 | 0x45C5 | Warning | High Capacitor cutout | Capacitor voltage is greater than the configured Over Voltage limit (0x2C01,2) for longer than the protection delay (0x2C03,0) | Charge battery (or if commissioning controller and battery is charged check BattApp configuration in 0x2C01, 0x2C02, 0x2C03) |
| 7 | 0x45C6 | Warning | Vbat below rated min | Battery voltage is less than rated minimum voltage for controller for longer than 1sec | Charge battery or check DC link voltage is within controller operating range (NOTE: This fault is sometimes seen at power down) |
| 7 | 0x45C7 | Warning | Vbat above rated max | Battery voltage is greater than rated maximum voltage for controller for longer than 1sec | Charge battery or check DC link voltage is within controller operating range |
| 7 | 0x45C8 | Warning | Vcap above rated max | Capacitor voltage is greater than rated maximum voltage for controller for longer than 1sec | Charge battery or check DC link voltage is within controller operating range |
| 7 | 0x45C9 | Warning | Vcap cutback for motoring torque | Capacitor voltage is in low voltage cutback region configured in 0x4612 for motor control / torque conditioner drive voltage cutback map | Charge battery and DC link voltage is within configured range (if commissioning controller check drive torque cutback map 0x4612 is correct) |
| 7 | 0x45CA | Warning | Vcap cutback for regen torque | Capacitor voltage is in high voltage cutback region configured in 0x4619 (or 0x4612 if 0x4619 not present) for motor control / torque conditioner regen voltage cutback map | Charge battery and DC link voltage is within configured range (if commissioning controller check regen torque cutback map 0x4619 is correct, use 0x4612 if 0x4619 not present) |
| 7 | 0x45CE | Warning | Vcap to Vkey (Vbat) difference | Vcap is below 7/8 of Vkey (Vbat) due to DC link pre-charge problems | Charge battery or check pre-charge |
| 7 | 0x4DC3 | Severe | Power Supply (keyswitch) Critical | Battery voltage has dropped below critical level | Check controller voltage supply |
| 7 | 0x51C2 | Very Severe | Capacitor Precharge Failure | Capacitor voltage (0x5100,3) did not rise above 5V at power up | Check battery connection for reverse polarity, or check internal / external short circuit across the DC link.Potential failure of pre-charge circuit or relay. |
| 8 | 0x4601 | Warning | Device too cold | Low heatsink temperature has reduced available power to motor | Allow controller to warm up to normal operating temperature |
| 8 | 0x4602 | Warning | Device too hot | High heatsink / junction / PCB track / capacitor temperature has reduced available power to motor | Allow controller to cool down to normal operating temperature. Check coolant flow rate / air flow is sufficient for required motor current |
| 8 | 0x4603 | Warning | Motor in thermal cutback | High measured (0x4600,3) or estimated (0x4602,8) motor temperature has reduced available power to motor as configured in 0x4620, 0x4621, 0x461E, 0x461F | Allow motor to cool down to normal operating temperature. Check motor cooling or motor thermistor configuration and wiring. If not using a thermistor and this fault is set make sure motor estimate is configured correctly (or disabled in 0x4621,1 = 0 and 0x4621,2 = 100) |
| 8 | 0x4604 | Warning | Motor too cold | Motor measured temperature is below -30degC | Check motor thermistor connection or allow motor to warm up. Check motor thermistor configuration and wiring |
| 8 | 0x5201 | Very Severe | Heatsink / device overtemp | Controller heatsink (or junctions, capacitors, PCB) has reached critical high temperature, and the controller has shut down. | Allow controller to cool down to normal operating temperature. If liquid cooled check coolant flow. |
| 10 | 0x4681 | Warning | Unit in pre-operational | Controller is in pre-operational state | If configured and ready for use, change state to operational. If controller is slave check master state |
| 10 | 0x4682 | Warning | IO can’t initialise | Controller has not received all configured RPDOs at power up | Check PDOs on all other CANbus nodes are configured correctly and match up with controller RPDO configuration. Check CAN wiring. |
| 10 | 0x4683 | Warning | RPDO Timeout (warning) | One or more configured RPDOs not received with 3sec at start up or 500ms during normal operation. | Check status of all nodes on CANbus. Check PDOs on all CANbus nodes are configured correctly and match up with controller RPDO configuration |
| 10 | 0x4A81 | Drive Inhibit | RPDO Timeout (drive inhibit) | One or more configured RPDOs not received with 3s at start up or 500ms during normal operation. | Check status of all nodes on CANbus. Check PDOs on all CANbus nodes are configured correctly and match up. |
| 10 | 0x4E81 | Severe | RPDO Timeout (severe) | One or more configured RPDOs not received with 3s at start up or 500ms during normal operation. | Check status of all nodes on CANbus. Check PDOs on all CANbus nodes are configured correctly and match up. |
| 11 | 0x46C2 | Warning | SinCos Tracking Warning | SinCos tracked Min-Max (trough-peak) values are deviating from the configured levels and are heading towards a voltage rail or converging together. Typically due to thermal or mechanical variation | Check sincos sensor, wiring and encoder configuration |
| 11 | 0x46C3 | Warning | Fault Ride Through | A fault ride through event has been encountered, but operation is allowed to continue although the system may be derated | Investigate cause of the original fault that is activating fault ride through |
| 11 | 0x46C6 | Warning | Encoder PLL Deactivated (warning) | Encoder PLL has turned off due to poor angle tracking | Check PLL gains, encoder setup and wiring – especially shielding and routing of encoder cables |
| 11 | 0x52C1 | Very Severe | Encoder Fault | Encoder input wire-off is detected. | Check encoder wiring – especially shielding and routing of encoder cables. Check configuration is valid and peak / trough correct for sincos |
| 11 | 0x52C2 | Very Severe | Motor Overcurrent Fault | Motor current exceeded controller rated maximum | Check motor configuration and wiring. Typically caused by current control gains or motor parameters incorrect. |
| 11 | 0x52C3 | Very Severe | Current Control Fault | Motor controller unable to maintain control of motor currents | Check motor configuration and wiring. Typically caused by current control gains or motor parameters incorrect. For PMAC check encoder alignment |
| 11 | 0x52C4 | Very Severe | Motor Overspeed Fault | Motor speed has exceeded overspeed threshold in 0x4624 | Check speed limit gains and configuration. Ensure motor speed is not too high for configuration. |
| 12 | 0x4B01 | Drive Inhibit | CAN bus-off (drive inhibit) | CANbus off fault condition detected on multinode system. NOTE: normally this is a Very Severe CAN off fault | Check CANbus wiring and configuration (no duplicate COB-IDs, correct baud rate). If controller is standalone check configuration in 0x5901,0 |
| 12 | 0x4F01 | Severe | CANopen unexpected slave state | CANopen slave has changed to unexpected state | Check status of all nodes on CANbus. |
| 12 | 0x5301 | Very Severe | CAN bus Fault | CANbus fault condition detected. | Check CANbus wiring and configuration |
| 12 | 0x5302 | Very Severe | CANopen Bootup not received | CANopen slave has not transmitted boot up message at power up | Check status of all nodes on CANbus and multinode configuration. |
| 12 | 0x5304 | Very Severe | CAN Lo-Pri Tx queue overrun | Low priority CAN transmit queue overflow. | Check CANbus wiring and configuration. Ensure messages are being acknowledged and bus load is not too high |
| 12 | 0x5305 | Very Severe | CAN Hi-Pri Rx queue overrun | High priority CAN receive queue overflow. | Check CANbus wiring and configuration. Ensure transmitting node is sending at correct rate |
| 12 | 0x5306 | Very Severe | CAN Hi-Pri Tx queue overrun | High priority CAN transmit queue overflow. | Check CANbus wiring and configuration. Ensure messages are being acknowledged and bus load is not too high |
| 12 | 0x5308 | Very Severe | CAN bus-off | CAN OFF bus fault condition detected on multinode system. | Check CANbus wiring and configuration (all nodes are same baud rate and no duplicate COB-ids configured). If single node check 0x5901,0 is not enabled unless required |
| 12 | 0x530A | Very Severe | CANopen Short PDO received | Received RPDO doesn’t contains enough bytes | Check PDOs on all CANbus nodes are configured correctly and match up to configuration of transmitting nodes. Ensure there are no duplicate COB-IDs |
| 12 | 0x530B | Very Severe | CANopen Heartbeat Failed | Heartbeat not received within configured time out (0x1016) | Check status of all nodes on CANbus. Heartbeat consumer is set correctly in 0x1016 to match slave nodes |
| 12 | 0x530C | Very Severe | CANopen device in wrong state | CANopen slave has changed to unexpected state (typically failed to go operational) | Check status of all nodes on CANbus. Configuration issues such as multiple masters on bus, duplicate node ID or heartbeat COBIDs can trigger the fault. |
| 12 | 0x530F | Very Severe | CANopen SDO Timeout Error | Internal CANopen fault | Check SDO client and server COBID are set correctly |
| 12 | 0x5319 | Very Severe | Motor slave in wrong state | Motor control slave has not responded as expected to controlword sent by TracApp or PumpApp. This can either be the same controller for single node systems or a slave node connected over CAN | Typically caused when the motor controller can’t enable due to being unable to complete power on checks due to spinning motors or insufficient DC link voltage. Bridge enable timeout is also known to trigger this fault. |
| 13 | 0x4741 | Warning | Scheduler stack overflow warning | This warning is set if any task has between 10% and 20% of its stack free. | Internal software warning. Contact BorgWarner. |
| 13 | 0x4F41 | Severe | Internal SW Fault | Internal software fault – typically set in combination with another fault | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F42 | Severe | Out of memory | Out of memory – internal software fault | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F43 | Severe | General DSP error | Unknown error raised by motor model code – internal software fault | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F44 | Severe | Timer Error | Unable to allocate timer – internal software fault | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F45 | Severe | Queue Error | Unable to post message to queue – internal software fault | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F46 | Severe | Scheduler Error | Unable to create task in scheduler – internal software fault | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F48 | Severe | I/O Internal SW Error | Input Output subsytem fault – internal software fault or configuration error | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F49 | Severe | GIO Internal SW Error | Generic IO subsystem fault – internal software fault or configuration error | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F4C | Severe | OBD Internal SW Error | Object Dictionary subsystem fault – internal software fault or parameter range error fault | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F4D | Severe | VehApp Internal SW Error | Vehicle Application subsystem fault – internal software fault or configuration error | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F4E | Severe | DMC Internal SW Error | Drives and Motion Control subsystem fault – internal software fault or configuration error | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F4F | Severe | TracApp Internal SW Error | Traction Application subsystem fault – internal software fault or configuration error | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F53 | Severe | App Manager Internal SW Error | Application Manager subsystem fault – internal software fault or configuration error | If other faults are set, resolve the conditions for these faults. Check configuration is valid and recycle keyswitch. If this is the only fault set contact BorgWarner with the fault data bytes, controller report and dcf configuration file |
| 13 | 0x4F54 | Severe | Autozero Range Error | Current sensor auto-zero value outside of allowed range | Internal hardware fault or check configuration in 0x4654,0 (if available) |
| 13 | 0x4F55 | Severe | DSP motor parameter error | Internal software fault or configuration object is out of range: Also may indicate issue with IPM 3D tables | Set configuration object to valid value. Out of range object can be identified using 0x5621 or DVT CLI window (if enabled) |
| 13 | 0x5343 | Very Severe | Fault List Overflow | Attempting to set too many faults. | Internal software fault. Ensure correct firmware and settings are loaded. Logic supply is above critical level. |
| 13 | 0x5345 | Very Severe | Scheduler stack Overflow | Less than 10% of the stack is free on one of the RTOS tasks. | Internal software fault. Check configuration and contact BorgWarner |
| 14 | 0x4781 | Warning | CANopen anon EMCY level 1 | EMCY message received from non-BorgWarner node and anonymous EMCY level (0x2830,0) is set to 1. | Check status of non-BorgWarner nodes on CANbus |
| 14 | 0x4B81 | Drive Inhibit | CANopen anon EMCY level 2 | EMCY message received from non-BorgWarner node and anonymous EMCY level (0x2830,0) is set to 2. | Check status of non-BorgWarner nodes on CANbus |
| 14 | 0x4F81 | Severe | CANopen anon EMCY level 3 | EMCY message received from non-BorgWarner node and anonymous EMCY level (0x2830,0) is set to 3. | Check status of non-BorgWarner nodes on CANbus |
| 14 | 0x5381 | Very Severe | CANopen anon EMCY level 4 | EMCY message received from non-BorgWarner node and anonymous EMCY level (0x2830,0) is set to 4. | Check status of non-BorgWarner nodes on CANbus |
| 14 | 0x5781 | Return to Base | CANopen anon EMCY level 5 | EMCY message received from non-BorgWarner node and anonymous EMCY level (0x2830,0) is set to 5. | Check status of non-BorgWarner nodes on CANbus |
| 15 | 0x47C1 | Warning | Vehicle Service Required | Vehicle service next due time (0x2850,5) has expired. If supported Service driveability profile (0x2925) will activate. | Service vehicle and reset service hours counter. Or check service configuation if service indication not required. |














