Troubleshooting Guide En/Epsilon Drive Systems and FM Module Products November 15, 2001 P/N 400333-01 Revision: A1 ã2001 Control Techniques - All Rights Reserved
Table of Contents INTRODUCTION ------------------------------------------------------------------------------------------------------ 2 DRIVE STATUS DISPLAY ------------------------------------------------------------------------------------------ 2 HOW TO USE THIS MANUAL ------------------------------------------------------------------------------------- 3 SAFETY INSTRUCTIONS ------------------------------------------------------------------------------------------- 3 “C” RMS FOLDBACK DISPLAY ------------
“FM-3/4 HARDWARE ERROR” --------------------------------------------------------------------------------- 29 APPENDIX A: CABLE DIAGRAMS ---------------------------------------------------------------------------- 31 APPENDIX B: USING THE WATCH WINDOW ------------------------------------------------------------- 33 APPENDIX C: UPDATING FIRMWARE USING THE FLASH UPGRADE PROCESS ------------ 37 APPENDIX E: EN AND EPSILON DRIVES PHYSICAL CONNECTIONS ---------------------------- 44 APPENDIX F: SERIAL LOOPBACK TES
Troubleshooting Section 1
Introduction This document is intended to help a user troubleshoot the Control Techniques E Series and Epsilon Series Servo Drives. The user will be pointed to possible solutions through Fault descriptions and Flowcharts. Drive Status Display The 14-segment LED display is capable of displaying most letters of the English alphabet in both lower and upper case. Some characters outside of the alphabet are also used.
How to use this Manual Fault Codes The drive has several built in Fault detection circuits. If a fault is detected, the drive will display a specific Fault code character. Fault Description A brief description of the specific fault and possible causes are found just prior to the Troubleshooting Flow Chart. Troubleshooting Flow Charts Troubleshooting Flow charts are used to guide technicians through the fault isolation process. References to connector and cable pin outs are included within the Flowcharts.
“C” RMS Foldback A “C” indicates RMS Foldback in the display window on the EN/EB/EI drives. It is an indication that the RMS current Foldback is active. This is not a fault, does not disable the drive. Output RMS current limit is returned to 80%.
“C” RMS Foldback Display "C" RMS Foldback Excessive Load Yes Return to Normal Load Investigate - Check Foldback RMS in Watch Window* - Wrong drive/motor for application size * See Appendix B for information on Watch Window No Incorrect Motor Selected for Configuration Yes Select Correct Motor from Setup View or Motor Tab Download Known Good Application Yes Return to Normal Operation No No Corrupt Motor DDF file Yes Reinstall PowerTools FM or Pro RST Motor Phases Incorrectly Wired Download Kno
“c” Stall Foldback A “c” indicates Stall Foldback in the display window on the EN/EB/EI drives. This is not a fault and the drive will continue to operate. This display indicates that the current command to the motor is 80% of the rated stall current. Motor torque and drive current are reduced until the motor commanded velocity exceeds 100 RPM or the torque demand is reduced. This is done to protect the IGBT’s from excessive power loss due to a combination of slow motor speed and high torque.
“c” Stall Foldback display "c" Fault Stall Foldback Search for causes of Increased Load Yes Excessive Load Return Load to Original Size/Value Return to Normal Operation No Yes Incorrect Motor Selected for Configuration Select Correct Motor from Setup View or Motor Tab Download Known Good Application Return to Normal Operation No Yes High Inertia mismatch Determine potential causes for mismatch No RST Motor Phases Incorrectly Wired No Tuning Parameters not Optimal Yes Yes See Appendix A For
“*” Invalid Flash This fault is indicated by the display showing an Asterisk. It generally indicates that the “.fsh” (Flash) file is invalid. The most common cause of this fault is an interruption of the update of a Firmware Flash process.
“A” Drive Overtemp This fault is applicable to the Epsilon Drive only. It is indicated by the display showing an “A”. If the equipment cabinet that the drive is mounted in has any problem with its circulation of air or the cooling equipment malfunctions this fault will likely occur. Potential causes for the “A” Drive Overtemp fault • Sensed temperature in the IGBT (Insulated Gate Bi-polar Transistors a.k.a. Power Stage) has exceeded 100° Centigrade (212° F).
“I” Power-Up Self-Test This fault is indicated by the display showing a “I”. This display indicates drive did not complete its internal self test.
“N” NVM Invalid This fault is indicated by the display showing a “N”. NVM stands for Non Volatile Memory. Potential causes for the “N” NVM Invalid fault • Corrupt configuration file • Corrupt flash file • DSP is non operational “N” “NVM Invalid” "N" Fault NVM Invalid Yes Use Reset P/B to Reset Return to Operation No Download known good Configuration file Yes Return to Operation No Update Module or Base Drive to latest Flash (.
“U” Invalid Configuration This fault is indicated by the display showing a “U”. This display indicates a change in the physical configuration of the drive. It is not known if setup data in the FM module matches the current drive and motor attached.
“H” High DC Bus This fault is indicated by the display showing a “H”. The DC bus is internal to the drive. This indicates a fault involving the DC bus and voltages or with its associated components.
“Z” Power Stage Fault This fault is indicated by the display showing a “Z”. This indicates a fault in the Power Stage logic power supply or the Power stages of the drive.
“Z” “Power Stage Fault” "Z" Fault Power Stage Fault No Shorted Motor Stator Disconnect Motor Power Cable at Motor Remove Power Ohm out Motor Use Procedure in Appendix D Stator OK Return Motor To Factory Segment #1 Ohm Out Motor Cable See Appendix A for Daigram Cable OK No End Replace Cable Yes Segment 2 Internal Power Stage Over Current; Switching Transistor Failure Segment 2 Reset with Reset P/B (EN) No Reset Successful Or Internal Power Stage Over Temperature Check application insure Drive
“u” Low DC Bus This fault is indicated by the display showing a “u”. Indicates a fault involving the DC bus and voltages or with its associated components.
“u” “Low DC Bus Fault” Yes "u" Fault Low DC Bus Reset with Reset P/B Segment 1 Operation Returns To Normal End No Measure AC Input On Power Connector RSR-2 Malfunction or Improper Installation Yes When Input AC returns to 96 to 264 VAC Reapply Power Refer to RSR-2 Troubleshooting Flowchart End Segment 2 No Rapid Cycling of Power Epsilon "u" Fault when using Aux Power Supply (+24VDC) Yes Remove Power for 10 seconds Use PowerTools to Disable Monitoring Reapply Power Operation Returns To Norm
RSR-2 Troubleshooting Flow Chart RSR-2 This information is provided for systems equipped with an RSR-2 and an ES Resistor package. If your system is not configured in such a manner please use this for reference purposes only.
“e” Encoder State This fault is indicated by the display showing what appears to be a lower case “e”. It indicates a fault involving the Encoder feedback.
“E” Encoder Line Fault This fault is indicated by the display showing a “E”. Indicates a fault involving the Encoder feedback.
Motor Over Temperature Fault This fault is indicated by the display showing a “M”. This indicates a fault involving excessive motor temperature. Potential causes for the “M” High DC Bus fault • Motor thermal sense switch is open due to excessive heat build up in the motor.
“S” RMS Shunt Power Fault This fault is indicated by the display showing a “S”. This indicates a fault involving the drives internal shunt circuitry. The shunt power parameter is an internally calculated parameter.
“o” Over Speed Fault This fault is indicated by the display showing a lower case “o”. This indicates a motor over speed has occurred. Potential causes for the “o” Over Speed fault • Motor speed exceeds 150% of maximum value as defined in “stdmotor.ddf” file • Actual motor speed exceeds programmed motor limit speed • Pulse mode maximum frequency rating exceeded • Noise “o” “Over Speed Fault” "o" Over Speed Fault Speed Exceeds 150% of value "stdmotor.ddf" file Yes Check "stdmotor.
“F” Following Error Fault This fault is indicated by the display showing a “F”. This indicates the following error detected exceeds the programmed limit value.
“L” CW/CCW Limit Fault This fault is indicated by the display showing an “L”. Encountering either Hardware or Software limits may cause this fault.
All LED Segments On All LED segments being on simultaneously indicate this Fault. Potential causes for the All LED’s On fault • Wrong Serial cable • Low AC • Low APS Voltage • Faulty FM module • Shorted or overloaded (>0.
All LED’s on Fault All LED Display Segments On Wrong Serial Cable Yes CT Serial Cable Yes Check No used Pins have any Continuity to Shield Refer to Serial CAble Diagram in Appendix A No Refer to Serial CAble Diagram in Appendix A Must Match Diagram Shown Move to Next Possibility End * System can operate from an Aux Power Supply or from AC not both.
FM-3 Hardware Error This fault is indicated by the display showing a “3”. This is a fault specific to the FM-3 module only. Potential causes for the “3” FM-3 Hardware Error • FM-3 has been applied to an incompatible drive such as an older FM-3 on a newer base drive. Consult Tech Support for details. • All other faults under this fault type (“3”) are displayed on the FM-3 LCD Display. • Trajectory Fault- normally related to velocities, accelerations or decelerations the FM-3 is unable to perform.
“FM-3/4 Hardware Error” "3" or "4" Hardware Error Faults Yes Trajectory Fault Unable to Perform Velocities, Accelerations or Deceleration for Motion Functions Locate Specific Motions containing offending Velocity, Accel/Decel Modify to Acceptable Limits Reset with P/B Retry No ISR Overrun Yes Replace Module Contact Tech Support for RGA No No Prog* Yes *No Prog will occur Module contains No Valid Configuration Download Known Good Configuration Sync between FM Module & Base Drive Lost Recycle P
Appendix Section 30
Appendix A: Cable Diagrams FORM WIRE BRAID SHIELD GRN/YEL PE/GND D R A S B RED 2 T C RED 3 RED 1 Drive to Motor Cable CMDS CABLE WIRE DIAGRAM Motor Feedback Cable A B A/ C B N B/ P Z M Z/ U U E U/ R V F S V/ W G W/ H +5 VDC K GND T MOTOR OVERTEMP A NOT USED V Drive to Motor Cable Shown is Flex Cable Wire Colors for non-Flex is: R = Brown; S = Black; T= Blue BLU ORN P GRN BRN P BLK YEL P WHT/BRN BRN/WHT P WHT/GRY GRY/WHT P RED/ORG ORG/RED P RED/BLU B
XMIT 3 REC 2 GND 5 RED 2 REC WHT 3 XMIT BLK Emerson CT Serial Cable 5 GND SHLD 1 SHLD TIA CABLE WIRE DIAGRAM 1 1 2 2 RED 3 RS485+ 4 RS485- 9 GND 6 GND 5 GND 8 GND 7 RED 4 BLK BKL/WHT 6 P BLU/WHT 5 RED/WHT 8 DRAIN WIRE P BLK 9 GRN P BLU 3 WHT 1 YEL P YEL/WHT 7 DRAIN WIRE 2 RX 3 TX 4 RS485+ 9 RS485- 6 5 GND 8 7 DDS CABLE WIRE DIAGRAM Emerson CT DDS Cable +A 1 -A 2 +B 3 -B 5 +Z 6 -Z 7 GND 8 4 BLK BRN P RED ORG P YEL GRN P
Appendix B: Using the Watch Window This procedure covers the usage of the Watch Window diagnostic tool. The Watch Window is built into the PowerTools FM and PowerTools Pro programming software. It is used to actively monitor Modbus registers within a base En/Eb drive as well as an Ei drive and any En drive that is equipped with an FM1/2/3/4 programming module. Please refer to the appropriate procedure listed below for your particular application.
After clicking on the “Upload Drives” icon, the software will attempt to open a communication channel with the drive system. If you have your communications setup properly, you will see the dialog box shown in Figure 2. If you get a communications error, refer to the Serial Communications Troubleshooting flowchart. Figure 2 Once you have clicked on the “OK” button as shown in Figure 2, the current drive configuration will be uploaded and your screen will look like the screen in Figure 3.
Step 2: Configuring the Watch Window Open the Watch Window configurator by clicking on the “Watch Window” option in the PowerTools FM “Tools” menu as shown in Figure 4. Figure 4 The available Modbus registers are arranged by group in the configuration window as shown in Figure 5. The “All” group has all of the registers arranged in alphabetical order. To reduce the number of selections, choose a group of registers from the drop down list.
Figure 6 The Watch Window is a floating dialog box and can be left open even if the programming software is minimized as shown in Figure 7. Closing the software will close the Watch Window .
Appendix C: Updating Firmware Using the Flash Upgrade Process This procedure covers the steps necessary to upgrade the operating firmware in either an En/Eb/Ei drive or a FM programming module. The Flash Upgrade procedure should only be performed when absolutely necessary. There are compatibility issues that must be considered prior to performing this procedure. Please ensure that the hardware you are attempting to upgrade is fully compatible with the new firmware before proceeding.
Step 2: Establishing Communications Once the Flash Upgrade tool has been launched, it will immediately attempt to open a communications channel with the drive system as shown in Figure 2. If communications are not successful, please refer to the Serial Communications Troubleshooting flowchart for assistance.
If communications were successful, your screen will look similar to the one in Figure 3. Figure 3 Step 3: Selecting the Flash file Click on the “Select File” button (see Figure 3). Doing so will open a window that will allow you to navigate to the folder where you have stored the downloaded flash (.fsh) file as shown in Figure 4. NOTE: If you are going to use a flash file that is located on the PowerCD, it is a good idea to copy the file from the PowerCD to a local folder on your computer’s hard drive.
Figure 4 Once you have selected the flash file (by clicking on it) and clicked on the Open button, the file explorer window will close and you will be returned to the Flash Upgrade screen. You will notice that the hardware information in the window is now active (not grayed out), and you are now ready to begin the upgrade process itself. Step 4: Performing the Upgrade To start the Flash Upgrade process, select the hardware you would like to upgrade from the Flash Upgrade window as shown in Figure 5.
Figure 6 41
Appendix D: Ohming Motor Procedure Ohming Out Motor Disconnect Motor Cable from Motor Connect Ohmmeter Leads between Pins A and B on Motor Connector Slowly Rotate Motor Shaft CW or CCW Observe Ohmmeter Reading See Resistance chart this page for motor under test Connect Ohmmeter Leads between Pins D and C on Motor Connector phase to ground test Connect Ohmmeter Leads between Pins D and A on Motor Connector phase to ground test Slowly Rotate Motor Shaft CW or CCW Observe Ohmmeter Reading See Resistance
For motors not listed contact Control Techniques to obtain information. MOTOR NT-207 NT-212 NT-320 NT-330 NT-345 NT-355 MG-205 MG-208 MG-316 MG-340 MG-455 MG-490 MG-4120 D.C. Resistance (Ohms) 11.1 4.6 1.5 1.2 1.3 1.0 18.5 7.3 3.9 1.9 1.1 0.4 0.
Appendix E: En and Epsilon Drives Physical Connections Epsilon Eb/Ei Drives AC Power Input DC Bus Access Motor Power Connection Status Display Auxiliary Logic Power Connection Drive Reset Pushbutton Serial Port Digital Inputs/Outputs Analog Outputs Motor Feedback Connection Command Connector 44
En Drives AC Power Input (Located on top of drive) FM Module Connector Auxiliary Logic Power, DC Bus access (Located under plastic knockout on top of drive) Analog Outputs Drive Reset Pusbutton Status Display Command Connector Serial Port Digital I/O Motor Feedback Connection Motor Power Connection 45
Appendix F: Serial Loopback Test This procedure will demonstrate how to test the operation of a serial communication port (COM port) on an IBM compatible PC running Windows 95 or Windows 98. This procedure may also apply to computers running Windows NT 4 and Windows 2000 although this procedure has not been verified on those operating systems. This procedure relies on a Windows communications utility called “HyperTerminal” being installed on your computer.
Initial Tests If you are having communications problems and you are sure that the serial cable you are using is correctly configured per the serial cable wiring diagram (see Appendix A), verify that none of the following are true before proceeding: 1. There are no other programs consuming the serial port’s resources.
Figure 3 Begin by giving the new connection a name. A good choice would be “Comx Test” where x is the number of the Com port you are testing. In this example, Com 1 is being tested.
Next, you will be presented with the dialing properties dialog box. This program assumes that you are trying to connect to another computer using a modem. However, if you expand the “Connect Using” drop down box, you will see not only your modem (if you have one installed) but also all of the available Com ports. Select the Com port you would like to test from this list. Figure 5 Next, configure the properties for the Com port you have selected.
Figure 7 Do not expect the ability to communicate with an En/Ei/Eb drive using HyperTerminal. The En family of drive products, including Epsilon drives, communicate using a binary form of communication (Modbus). HyperTerminal uses ASCII protocol for all of its communications and therefore will not work. The point of this test is not to test the ability of the En/Epsilon drive to communicate, but rather to test the operation of your PCs Com port.
To complete the settings for the new connection, Select “Properties” from the HyperTerminal “File” menu as shown in Figure 9.
Click on the “Settings” tab as shown in Figure 10. Figure 10 Expand the “Emulation” drop down list and select “ANSI” from the list. Figure 11 Save your new connection by selecting “Save” from the HyperTerminal “File” menu.
Figure 12 Close the HyperTerminal Program. Step 3: Testing the Port This step works best if you have a partner to help you. Begin by removing the serial cable from the En/Epsilon drive communications port if you’ve not done so already. Be sure that the other end remains connected to your computer’s serial port. Have your partner hold the serial cable in his/her hand with the row of 5 pins facing him or her on top as shown in Figure 13.
Using the keyboard on your computer, type in some characters as shown in Figure 14. If your serial port is working correctly, whatever you type on the keyboard should be echoed back to the HyperTerminal screen. If you do not see any characters on the HyperTerminal screen, and you are sure that you have the correct pins shorted together on the cable, this would indicate that your computer’s serial port is not functioning.
