NAVITAS TAC 2 User manual

Navitas Vehicle Systems Ltd.
Includes All Models Of TAC2 Including:
E-Z-GO®RXV® 48V (CURTIS®)
E-Z-GO® RXV® 23 48V (DANAHER®)
E-Z-GO® TXT® 48V Conversion
CLUB CAR® Precedent® Conversion
YAMAHA® YDRE2® TOYOTA®(NEOS®)
YAMAHA
®
G29
®
Conversion (MORIC®)
NAVITAS TAC 2
440A and 600A 48V-72V CONTROLLERS
Error Code and Troubleshooting
Guide
NavitasVS.com
1/21

INSTALLATION/ SERVICE MANUAL
1
FLASH
CODES
FLASH CODE
MESSAGE
DESCRIPTION SOLUTION HOW TO CHECK
1-1 Throttle Fault The foot switch is
not engaged and the
throttle signal voltage
is above minimum
throttle parameter.
This indicates the
foot switch is not
coming on or the
throttle has broken
where its off voltage
is to high
• Check wiring
• Replace throttle
• The diagnostic page of the App will
give you readings for the throttle
voltage and foot switch.
• Put the vehicle in neutral and
slowly depress the throttle.
• The foot switch should change from
Off to On before the throttle voltage
reaches around 1V.
• Standard throttles usually read
0.5V when off. The minimum
voltage to start the vehicle is
usually 1V. The maximum when
depressed should read around 4V.
1-2 Brake Fault The analog brake
signal is higher than
the high voltage
threshold which is
4.64V.
These types of brake
pedals are only
installed on certain
types of vehicles such
as RXV’s.
• Check wiring
• Replace brake switch
• The diagnostic page of the App
will give you readings for the brake
voltage
• Put the vehicle in neutral and
slowly depress the brake.
• Standard analog brakes usually
read 0.5V when off. The minimum
voltage to stop the vehicle is
usually 1V. The maximum when
depressed should read around 3V
to 4V
1-3 Charger
Interlock
Charger is connected
and the vehicle is not
in neutral.
Vehicle charging port
may be wet Club Car
On Board Computer
(OBC) is in sleep
mode.
• Disconnect the
Charger before trying
to move.
• Dry and clean the
charger port
• Depress the throttle
twice to wake up OBC.
• Replace charger port
on vehicle
• The diagnostic page of the App will
give you readings for the charger
input connected signal.
• The charger input will read
off when there is no charger
connected.
1-4 Temperature
(Controller)
Performance is
limited because the
controller is hot.
• Let vehicle cool
off, system is over
worked.
Check the temperature of the
controller with a non-contact
temperature sensor
1 - 5 Temperature
(Motor)
Performance is
limited because the
motor is hot.
• Let vehicle cool
off, system is over
worked.
• Check the temperature of the motor
with a non-contact temperature
sensor.
TROUBLESHOOTING
* Check the ‘Caution’ icon on app rst for fault descriptions or refer to the chart below

INSTALLATION/ SERVICE MANUAL
2
TROUBLESHOOTING cont’d
FLASH
CODES
FLASH CODE
MESSAGE
DESCRIPTION SOLUTION HOW TO CHECK
1 - 6 Solenoid High
Resistance
Voltage across
solenoid (battery
side (logic power)
to controller side
measured (B+
terminal)) is greater
than the hard coded
5V.
• Replace solenoid • Test the solenoid by measuring ohms
across the large terminals.
• The error usually only occurs when
drawing large currents (200A)
through the solenoid. The solenoid
may be under rated or oxidizing
with ag
1 - 7 Flash Memory
Error
Code updates from
the App may force
this error so cause
the user to press the
Initialize button and
Save button.
• Press the Initialize
button and Save
button in the App.
• Contact dealer as they have a
“Dealer/Technician” version of the
App.
1 - 8 Brake Check
Fault
Brake failed to hold
vehicle still during
start up tests.
Vehicle should not
move during brake
check.
• Check motor brake • Turn key off and disconnect brake
harness from motor brake. Try
pushing vehicle, you should not be
able to push vehicle.
• If new brake has been installed,
check installation, over/under
torquing brake can cause issues
1- 9 Brake Hold
Fault
Brake failed to hold
vehicle still when
stopped.
Wheels are still
turning with Parking
Brake set.
• Check motor brake • Turn key off and disconnect brake
harness from motor brake. Try
pushing vehicle, you should not be
able to push vehicle.
• If new brake has been installed,
check installation, over/under
torquing brake can cause issues
1- 10 Resistor
Missing
The large external
power resistor was
not detected during
start up tests.
• Check resistor wiring • Resistor wires should go to switched
side of solenoid and to the ‘R’
terminal on the controller
2 - 1 Direction
Switch Fault
Both FWD & REV
signal came on at
the same time.
• Check and replace
FWD & REV switch
• The diagnostic page of the App will
give you readings for the Forward
switch and Reverse switch
• Check the Switch. Does the Switch
feel the same when toggled from
FWD to Neutral to REV? If so check
continuity of the switch.

INSTALLATION/ SERVICE MANUAL
3
TROUBLESHOOTNG cont’d
FLASH
CODES
FLASH CODE
MESSAGE
DESCRIPTION SOLUTION HOW TO CHECK
2 - 2 Main
Solenoid
Voltage across
solenoid (battery
side to controller
side measured
B+ terminal ) is
greater than the
hard coded 1V
after solenoid has
closed
• Conrm the solenoid
is working properly.
Change solenoid if
required.
• Put vehicle in Neutral. Measure voltage
on main terminals (high current
connections) of the solenoid. Depress
throttle and listen for solenoid to click.
If solenoid clicks and the voltage does
not drop to zero between the main
terminals. Replace solenoid.
• If solenoid does NOT click measure the
voltage across the small terminals of the
solenoid when the throttle is depressed.
It should read the battery voltage. If it
reads the battery voltage the solenoid
is bad. If it does not read the battery
voltage check vehicle wiring
2 - 3 Controller not
pre-charging
Abnormally
low voltage on
the controller
between B+ and
B-.
• Clean and dry off the
controller
• Check voltage
• Check all wires
are connected to
controller
• DO NOT replace the
controller until all of
the “How to Check”
diagnostics regarding
Flash Code 2 - 4
have been completed
and the motor has
been tested for short
circuits!
• The dashboard page of the App will give
you readings for the battery voltage.
• Visually check for debris or moisture on
controller terminals and wires (There
may be a short across the B+ and B-
terminals).
• Check the voltage between B+ and
B- on the controller. It should equal the
battery pack voltage.
• Check that the wires are not damaged.
• Check that no accessories (light kits,
stereos, etc.) are using the frame as a
ground.
• Remove all cables except B- from the
controller.
• Tape cables so they do not touch each
other or the vehicle frame. Controller
harness should remain plugged into the
controller.
• Move Run/Tow switch to Run, turn on
key switch, depress the throttle. If Flash
Code 2-4 returns replace the controller.
• Otherwise there is a wiring problem.
Reconnect wires one at a time (turn off
RUN/TOW switch each time) until Flash
Code 2-4 returns. This will indicate
where the wiring issue is located.

INSTALLATION/ SERVICE MANUAL
4
TROUBLESHOOTING cont’d
FLASH
CODES
FLASH CODE
MESSAGE
DESCRIPTION SOLUTION HOW TO CHECK
2 - 4 Main
Solenoid
Current Fault
Solenoid coil
takes too much
current.
• Check for loose wires
or a short across
small terminals on
the solenoid.
• Replace main
solenoid.
• Check for loose wires. If there is a diode
across the solenoid check that it is not
shorted.
• Test solenoid by measuring resistance
across the small terminals of the
solenoid. The resistance should be
greater than 48 OHMS if it is a single
coil solenoid and greater than 20 OHMS
if it is a double coil solenoid.
2 - 4 Parking Brake
Solenoid
(Connected to
motor) Current
Fault
Solenoid coil
takes too much
current.
• Check for loose wires
or a short across
small terminals on
the solenoid.
• Replace main
solenoid.
• Check for loose wires. If there is a diode
across the solenoid check that it is not
shorted.
• Test solenoid by measuring resistance
across the small terminals of the
solenoid. The resistance should be
greater than 48 OHMS if it is a single
coil solenoid and greater than 20 OHMS
if it is a double coil solenoid.
2-8 Precharging
Too fast
1. Main solenoid
may be welded.
2. (External
Resistor Option
Only) Regen
resistor may
be incorrectly
connected to
battery side of
main solenoid.
• Check Main Solenoid
• Check resistor wiring
• 1. Turn Key off and place in Tow.
Measure voltage across large terminals
of solenoid. If you measure 0V, the
solenoid is welded
• 2a. Check Resistor wiring. Resistor
wires should go to switched side of
solenoid (controller side) and to the ‘R’
terminal on the controller.
• 2b. Turn Key off and place in Tow.
Disconnect controller ‘B+’ and ‘R’
cables. Make sure to isolate them with
electrical tape. Place in Run and turn
Key on check to see if error changes. If
error changes, turn key off and place in
Tow again. Then reconnect ‘B+’ cable
and repeat. If error does not reappear,
repeat process again and reconnect
resistor to ‘R’ terminal. If the problem
reappears, recheck the resistor wiring.

INSTALLATION/ SERVICE MANUAL
5
FLASH
CODES
FLASH CODE
MESSAGE
DESCRIPTION SOLUTION HOW TO CHECK
3 - 1 Battery Under
Voltage
Batteries are
empty or too low.
• Recharge batteries
• Check for bad or
damaged batteries.
• Check battery cables
are not loose or
damaged.
• Check solenoid
• Use a battery load tester to verify
battery condition after charging.
• Connect volt meter batteries. (Use
alligator clips). Measure the voltage
while driving to see if the voltage
drops.
• Connect Volt meter to the controller if
the voltage drops at the controller and
not at the battery then the solenoid
may be bad.
3 - 2 Battery Over
Voltage
Batteries are over
charged or not
excepting any
more regenerative
currents
• Check for bad or
damaged Batteries.
• Check Battery Cables
are not loose or
damaged.
• Check Solenoid
• Use a battery load tester to verify
battery condition after charging.
• Connect volt meter batteries. (Use
alligator clips). Measure the voltage
while driving to see if the voltage rises.
• Connect volt meter to the controller if
the voltage rises at the controller and
not at the battery then the solenoid
may be bad.
3 - 3 Motor Over
Current
Motor current has
risen above the
maximum motor
current parameter.
• Check Motor U,V,W
cables are not
shorted to ground
See diode chart below
• The diagnostics page of the App will
give you readings for the U phase
voltage, V phase voltage, W phase
voltage
• The phases should read around half the
battery voltage.
• Disconnect phases at controller and
check readings again
4-5 Over Current
Fault
Motor current
has exceeded
controller current
limit.
• Release throttle and
reapply to drive
• Error code will clear when key is off
and in Tow.

INSTALLATION/ SERVICE MANUAL
6
FLASH
CODES
FLASH CODE
MESSAGE
DESCRIPTION SOLUTION HOW TO CHECK
4-7 Power Stage
Fault
Controller has
failed power check
on startup
• Check motor
connections
• Turn Key off, place in Tow.
• Disconnect U,V,W from controller.
• Place in Run, turn on Key.
• Check if error message now shows
that motor is not connected. If error
continues to show, contact Navitas
Support. Please take screenshot of
error message to provide to Navitas
Support
4-8 Encoder A
input Fault
Speed input A is
not changing when
Motor Current is
Applied
• Check speed sensor • With Key off and vehicle in Tow,
disconnect speed encoder harness from
motor. (4 pin connector at motor)
• Place vehicle in Run and turn Key on.
• Using a volt meter, measure the voltage
at each of the pins. You should read
5V, 3V, 3V, 0V on the wires.
• Reconnect to controller with app.
Go to Diagnostics page and look for
Encoder A & B inputs.
• With a piece of wire or a paperclip,
short the 3V wires to the 0V wire and
check on the app if the input has gone
from high to low. If it has, the inputs
at the controller are working and the
sensor may be at fault.
4-9 Encoder B
input Fault
Speed input A is
not changing when
Motor Current is
Applied
• Check speed sensor

INSTALLATION/ SERVICE MANUAL
7
NON-FLASH CODE ERRORS. Note: The list below shows some possible issues when the Controller does not show a
Flash Code Error. These issues are mainly related to the Vehicle. Always check the Manufacturers Service Manual.
ISSUE CAUSE HOW TO CHECK
The Vehicle is moving
slower than normal.
• Batteries are discharged
• Bad or damaged motor
• Faulty speed sensor
• Faulty throttle
• OTF programmer is locked
at low speed
• Re-charge the batteries
• Check brakes are releasing properly and vehicle is easy
to push
• Check motor
• With the App verify throttle reaches maximum value
• Connect the OTF programmer, unlock it and adjust
to desired speed. Note: Lock OTF programmer before
removing it or the settings may change.
Vehicle is shutting
down
• Check vehicle wiring for
loose connections
• Check the OBC (On Board
Computer)
• Check the OBC by referring to the “OBC section” in the
manufacturer’s service manual.
Vehicle feels sluggish
after driving for a
while.
• Battery cables are
undersized
• Upgrade the power cables to recommended 4AWG
Faulty Controller • Controller malfunction • Use a digital multi-meter set to diode mode
• Remove all wires and cables on controller
• Use “Controller Diode Test” chart below to test the
controller
Car Stutters • Motor cables are not
connected properly
• Check motor cables properly connected U-U< V-V, W-W
• Check speed sensor wires not crossed.
BLACK LEAD RED LEAD VOLTAGE
B+ U 0.42 V approx.
U B- 0.42V approx.
B+ V 0.48V approx.
V B- 0.48V approx.
B+ W 0.48V approx.
W B- 0.48V approx.
Table 1 Controller Test Diode Chart
TROUBLESHOOTING cont’d