Emerson FM-3 Troubleshooting Guide

Troubleshooting GuideEn/Epsilon Drive Systems and FM Module ProductsNovember 15, 2001 P/N 400333-01Revision: A1ã2001 Control Techniques - All Rights R

6“c” Stall FoldbackA “c” indicates Stall Foldback in the display window on the EN/EB/EI drives. This is nota fault and the drive will continue to oper

7 “c” Stall Foldback displaySearch forcauses ofIncreasedLoadReturn Load toOriginalSize/ValueReturn to NormalOperation Yes IncorrectMotor SelectedforCo

8“*” Invalid FlashThis fault is indicated by the display showing an Asterisk. It generally indicates that the“.fsh” (Flash) file is invalid. The most

9“A” Drive OvertempThis fault is applicable to the Epsilon Drive only. It is indicated by the display showingan “A”. If the equipment cabinet that the

10“I” Power-Up Self-TestThis fault is indicated by the display showing a “I”. This display indicates drive did notcomplete its internal self test.Pot

11“N” NVM InvalidThis fault is indicated by the display showing a “N”. NVM stands for Non VolatileMemory.Potential causes for the “N” NVM Invalid faul

12“U” Invalid ConfigurationThis fault is indicated by the display showing a “U”. This display indicates a change inthe physical configuration of the d

13“H” High DC BusThis 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

14“Z” Power Stage FaultThis fault is indicated by the display showing a “Z”. This indicates a fault in the PowerStage logic power supply or the Power

15 “Z” “Power Stage Fault”"Z" FaultPower Stage FaultShortedMotor StatorReset withReset P/B (EN)Internal Power StageOver Current;Switching Tr

16“u” Low DC BusThis fault is indicated by the display showing a “u”. Indicates a fault involving the DCbus and voltages or with its associated compon

17“u” “Low DC Bus Fault”Reset with Reset P/BOperationReturns ToNormalMeasureAC InputOn Power ConnectorEpsilon"u" Faultwhen usingAux PowerSup

18RSR-2 Troubleshooting Flow ChartRSR-2This information is provided for systems equipped with an RSR-2 and an ES Resistorpackage. If your system is no

19“e” Encoder StateThis fault is indicated by the display showing what appears to be a lower case “e”. Itindicates a fault involving the Encoder feedb

20“E” Encoder Line FaultThis fault is indicated by the display showing a “E”. Indicates a fault involving theEncoder feedback.Potential causes for the

21Motor Over Temperature FaultThis fault is indicated by the display showing a “M”. This indicates a fault involvingexcessive motor temperature.Potent

22“S” RMS Shunt Power FaultThis fault is indicated by the display showing a “S”. This indicates a fault involving thedrives internal shunt circuitry.

23“o” Over Speed FaultThis fault is indicated by the display showing a lower case “o”. This indicates a motorover speed has occurred.Potential causes

24“F” Following Error FaultThis fault is indicated by the display showing a “F”. This indicates the following errordetected exceeds the programmed lim

25“L” CW/CCW Limit FaultThis fault is indicated by the display showing an “L”. Encountering either Hardware orSoftware limits may cause this fault.Pot

iTable of ContentsINTRODUCTION ------------------------------------------------------------------------------------------------------ 2DRIVE STATUS DI

26All LED Segments OnAll LED segments being on simultaneously indicate this Fault.Potential causes for the All LED’s On fault• Wrong Serial cable• L

27All LED’s on FaultWrongSerialCable Yes No Yes Low ACInput ENLow ACInput Eb/Ei Yes Less than 90 VACLess than 60 VAC No No ENEb/EiLess than 90 VAC

28FM-3 Hardware ErrorThis fault is indicated by the display showing a “3”. This is a fault specific to the FM-3module only.Potential causes for the “3

29“FM-3/4 Hardware Error”TrajectoryFaultResetwith P/BRetryUnable to PerformVelocities, Accelerationsor Decelerationfor Motion FunctionsISROverrunRepla

30AppendixSection

31Appendix A: Cable DiagramsBRAID SHIELDGRN/YELADBCPE/GNDSTRRED 3RED 2RED 1FORM WIRECMDS CABLE WIRE DIAGRAMUENOT USEDZVU/V/WVW/GND+5 VDCMOTOR OVERTEMP

32REC2XMIT3GND5REDSHLDBLKWHT1523SHLDGNDXMITRECTIA CABLE WIRE DIAGRAMDDS CABLE WIRE DIAGRAM231REDDRAIN WIRE2371WHT44RS485+9BLK9RS485-66GND5GRN5GND88GND

33Appendix B: Using the Watch WindowThis procedure covers the usage of the Watch Window diagnostic tool. The Watch Window is built into thePowerTools

34After clicking on the “Upload Drives” icon, the software will attempt to open a communication channelwith the drive system. If you have your communi

35Step 2: Configuring the Watch WindowOpen the Watch Window configurator by clicking on the “Watch Window” option in the PowerTools FM“Tools” menu as

ii“FM-3/4 HARDWARE ERROR” --------------------------------------------------------------------------------- 29APPENDIX A: CABLE DIAGRAMS -------------

36Figure 6The Watch Window is a floating dialog box and can be left open even if the programming software isminimized as shown in Figure 7. Closing t

37Appendix C: Updating Firmware Using the Flash Upgrade ProcessThis procedure covers the steps necessary to upgrade the operating firmware in either a

38Step 2: Establishing CommunicationsOnce the Flash Upgrade tool has been launched, it will immediately attempt to open a communicationschannel with t

39If communications were successful, your screen will look similar to the one in Figure 3.Figure 3Step 3: Selecting the Flash fileClick on the “Select

40Figure 4Once you have selected the flash file (by clicking on it) and clicked on the Open button, the file explorerwindow will close and you will be

41Figure 6

42Appendix D: Ohming Motor ProcedureOhmingOut MotorDisconnectMotor Cablefrom MotorConnect OhmmeterLeads betweenPins A and Bon Motor ConnectorConnect O

43For motors not listed contact Control Techniques to obtain information.D.C. ResistanceMOTOR (Ohms)NT-207 11.1NT-212 4.6NT-320 1.5NT-330 1.2NT-345 1.

44Appendix E: En and Epsilon Drives Physical ConnectionsEpsilon Eb/Ei DrivesAC Power InputDC Bus AccessAuxiliary LogicPower ConnectionMotor FeedbackCo

45En DrivesAC Power Input(Located on top of drive)Auxiliary Logic Power, DCBus access(Located under plasticknockout on top of drive)FM Module Connecto

1TroubleshootingSection

46Appendix F: Serial Loopback TestThis procedure will demonstrate how to test the operation of a serial communication port (COM port) on anIBM compati

47Initial TestsIf you are having communications problems and you are sure that the serial cable you are using is correctlyconfigured per the serial ca

48Figure 3Begin by giving the new connection a name. A good choice would be “Comx Test” where x is the numberof the Com port you are testing. In this

49Next, you will be presented with the dialing properties dialog box. This program assumes that you aretrying to connect to another computer using a m

50Figure 7Do not expect the ability to communicate with an En/Ei/Eb drive using HyperTerminal. The En family ofdrive products, including Epsilon drive

51To complete the settings for the new connection, Select “Properties” from the HyperTerminal “File” menuas shown in Figure 9.Figure 9

52Click on the “Settings” tab as shown in Figure 10.Figure 10Expand the “Emulation” drop down list and select “ANSI” from the list.Figure 11Save your

53Figure 12Close the HyperTerminal Program.Step 3: Testing the PortThis step works best if you have a partner to help you.Begin by removing the serial

54Using the keyboard on your computer, type in some characters as shown in Figure 14. If your serial port isworking correctly, whatever you type on th

2IntroductionThis document is intended to help a user troubleshoot the Control Techniques E Seriesand Epsilon Series Servo Drives. The user will be po

3How to use this ManualFault CodesThe drive has several built in Fault detection circuits. If a fault is detected, the drive willdisplay a specific Fa

4“C” RMS FoldbackA “C” indicates RMS Foldback in the display window on the EN/EB/EI drives. It is anindication that the RMS current Foldback is active

5“C” RMS Foldback DisplayExcessiveLoad Yes No IncorrectMotor SelectedforConfiguration Yes No Download Known GoodApplication Yes CorruptMotor DDFfile