Specifications

Chapter 2. Troubleshooting 35
Common Problems & Solutions
NOTE
Some software-related causes are provided because it is sometimes
difficult to identify a problem as either hardware or software related.
Problem Cause Solution
Communication
(serial) not operative,
or receive garbled
characters
1. Improper interface connections or
communication protocol
2. COM port disabled
3. In daisy chain, unit may not be set to
proper address
1. See Troubleshooting Serial Communication section below.
2.a. Enable serial communication with the E1 command.
2.b. If using RS-485, make sure the internal jumpers are set accordingly (see
page 6). Make sure COM 2 port is enabled for sending 6000 language
commands (execute the PORT2 and DRPCHKØ commands).
3. Verify DIP switch settings (see page 5), verify proper application of the
ADDR command.
Direction is reversed. 1. Phase of step motor reversed (motor
does not move in the commanded
direction).
2. Phase of encoder reversed (reported
TPE direction is reversed).
1. Swap the A+ and A– connection at the MOTOR connector.
2. Swap the A+ and A– connection at the ENCODER connector.
SOFTWARE ALTERNATIVE: If the motor (and the encoder if one is used) is
reversed, you can use the CMDDIR1 command to reverse the polarity of both
the commanded direction and the polarity of the encoder feedback counts).
Distance, velocity, and
accel are incorrect as
programmed.
1. Incorrect resolution setting. 1.a. Set the drive resolution to 25,000 steps/rev (DRES25ØØØ command).
1.b. Set the encoder resolution (post-quadrature) for your encoder. If using
Compumotor E series encoders, issue the ERES4ØØØ command.
Encoder counts
missing.
1. Improper wiring.
2. Encoder slipping.
3. Encoder too hot.
4. Electrical noise.
5. Encoder frequency too high.
1. Check wiring.
2. Check and tighten encoder coupling.
3. Reduce encoder temperature with heatsink, thermal insulator, etc.
4.a. Shield wiring.
4.b. Use encoder with differential outputs.
5. Peak encoder frequency must be below 1.6MHz post-quadrature. Peak
frequency must account for velocity ripple.
Erratic operation. 1. Electrical Noise.
2. Improper shielding.
3. Improper wiring.
1. Reduce electrical noise or move ZETA6104 away from noise source.
2. Refer to the Electrical Noise portion of the Technical Reference section in
the Compumotor/Digiplan catalog.
3. Check wiring for opens, shorts, & mis-wired connections.
LEDs See Diagnostic LEDs above
Motion does not occur. 1. Check LEDs.
2. End-of-travel limits are active.
3. Improper wiring.
4. P-CUT (Pulse cut-off) not grounded.
5. Load is jammed.
6. No torque from motor.
1. See Diagnostic LEDs above.
2.a. Move load off of limits or disable limits with the LHØ command.
2.b. Set LSPOS to a value less than LSNEG.
3. Check motor and end-of-travel limit connections.
4. Ground the P-CUT connection.
5. Remove power and clear jam.
6. See problem: Torque, loss of .
Motor creeps at slow
velocity in encoder
mode.
1. Encoder direction opposite of motor
direction.
2. Encoder connected to wrong axis.
1. Switch encoder connections A+ & A- with B+ & B-.
2. Check encoder wiring.
Programmable inputs
not working.
1. IN-P (input pull-up) not connected to a
power supply.
2. If external power supply is used, the
grounds must be connected together.
3. Improper wiring.
1.a. When inputs will be pulled down to 0V by an external device, connect IN-P
to +5V supplied or other positive supply.
1b. When inputs will be pulled to 5V or higher by an external device, connect
IN-P to 0V.
2. Connect external power supply's ground to ZETA6104's ground (GND).
3. Check wiring for opens, shorts, and mis-wired connections.
Programmable outputs
not working.
1. Output connected such that it must
source current (pull to positive voltage).
2. OUT-P not connected to power source.
3. If external power supply is used, the
grounds must be connected together.
4. Improper wiring.
1. Outputs are open-collector and can only sink current -- change wiring.
2. Connect OUT-P to the +5V terminal or to an external supply of up to 24V.
3. Connect the external power supply's ground to the ZETA6104's ground
(GND).
4. Check wiring for opens, shorts, and mis-wired connections.
Torque, loss of. 1. Improper wiring.
2. No power(POWER LED off).
3. Overtemp, low voltage, or motor fault.
4. Drive shutdown.
5. Current standby mode enabled
1. Check wiring to the motor, as well as other system wiring.
2. Check power connection (POWER LED should be on.
3. Check LED status (see Diagnostic LEDs above).
4. Enable drive with the DRIVE1 command.
5. If more torque is needed at rest, disable standby mode (DAUTOSØ command)
Trigger inputs not
working.
1. If external power supply is used, the
grounds must be connected together.
2. Improper wiring.
1. Connect external power supply's ground to ZETA6104's ground (GND).
2.a. Check wiring for opens, shorts, and mis-wired connections.
2.b. When inputs will be pulled down to 0V by an external device, connect
AUX-P to +5V supplied or other positive supply.
2.c. When inputs will be pulled to 5V or higher by an external device, connect
AUX-P to 0V.