When motor testing is complete; make the motor connections per schematic.
Light Bulb Test (Curtis Manual)
To conduct the light bulb test, you can use a single light bulb or lamp. We typically use a rubber insulated socket available at the hardware store. Connect B+ and M- to the two wires to the lamp. Make sure they are taped well and will not touch each other. The controller will work as a dimmer switch as you move the throttle. This verifies the operation of the controller.
Testing Logic Section
Since we have established that there is power to the controller and that the motor is operable, the next group of tests are associated with verifying that the input signals are correct. If the input is incorrect, the controller will not operate.
Key Switch Input (KSI)
The KSI terminal must see Traction Battery Pack voltage when the ignition key is on. Do not use the 12V auxiliary battery as the power supply.
The voltage between the KSI terminal and the B- busbar should be the same the voltage between the B- and B+ busbars. If the KSI terminal does not have Traction Pack voltage, then either the the KLK f\use is blown (check continuity) or the small 12V relay has malfunctioned. You can bypass the relay temporarily to determine if this is the problem simply by removing the green wires from the relay and connecting them together. The 12V/ 40 amp relay is readily available at most auto supply stores.
The potentiometer (PB-6) output signal should vary from 0 to 5000 ohms as it goes from “off” to “on”. Remove the leads from the controller, and test with an ohmmeter. If the resistance in the “off” position is greater than 100 ohms, the controller will not work. It will be in its High Pedal Disable (HPD) mode. See the Manufacturer’s Maual for a complete description of HPD.
Half Speed Reverse
This should not prevent the operation of the controller. Its operation is to cut back on power once energized.
High Pedal Disable
The High Pedal Disable (HPD) feature of the controller will disable the controller from operation. To check the potentiometer leads to the controller, remove them and check the resistance. It should be less than 100 ohms when off. Adjust the potentiometer, if required. Be very careful and be sure to mark your initial position so that you can return to it if all goes bad.
Any questions, please call EVA at (603) 569-2100.