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 ---------------------------------------------------------------------------------- 5

“c” STALL FOLDBACK DISPLAY -------------------------------------------------------------------------------- 7

“ “*” FLASH INVALID”---------------------------------------------------------------------------------------------- 8

“ A” DRIVE OVERTEMP” ------------------------------------------------------------------------------------------ 9

“I” “POWER-UP SELF-TEST” ----------------------------------------------------------------------------------- 10

“N” “NVM INVALID” ---------------------------------------------------------------------------------------------- 11

“U” “INVALID CONFIGURATION”---------------------------------------------------------------------------- 12

“H” “HIGH DC BUS FAULT”------------------------------------------------------------------------------------- 13

“Z” “POWER STAGE FAULT” ---------------------------------------------------------------------------------- 15

“U” “LOW DC BUS FAULT”-------------------------------------------------------------------------------------- 17

RSR-2 TROUBLESHOOTING FLOW CHART--------------------------------------------------------------- 18

“e” “ENCODER STATE FAULT” -------------------------------------------------------------------------------- 19

“E” “ENCODER LINE FAULT”---------------------------------------------------------------------------------- 20

“M” “MOTOR OVER TEMPERATURE FAULT” ----------------------------------------------------------- 21

“S” “RMS SHUNT POWER FAULT” --------------------------------------------------------------------------- 22

“O” “OVER SPEED FAULT” ------------------------------------------------------------------------------------- 23

“F” “FOLLOWING ERROR FAULT” -------------------------------------------------------------------------- 24

“L” CW/CCW LIMIT FAULT ------------------------------------------------------------------------------------ 25

TROUBLESHOOTING FLOW CHART FOR “CW/CCW LIMIT FAULT” --------------------------- 25

ALL LED SEGMENTS ON----------------------------------------------------------------------------------------- 26

ALL LED’S ON FAULT -------------------------------------------------------------------------------------------- 27

FM-3 HARDWARE ERROR--------------------------------------------------------------------------------------- 28

i
“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 TEST ------------------------------------------------------------------- 46

ii
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.

Drive Display - Normal Operating Modes – No FM Module

Displayed Character Status Description
b Brake Engaged Brake Control Output = On
d Drive is disabled Power Stage is disabled
P Drive is in Pulse Mode Ready to receive Pulses
V Drive is in Velocity Mode Analog Velocity mode
T Drive is in Torque Mode Analog Torque mode
+ Summation Mode Velocity Summation Mode
C RMS Foldback active Motor Torque limited to
80%continuous
c Stall Foldback active High Current demand for
For Motor speed extended period of time
prevents drive damage
. (period) Ready to Run If period missing Drive in
STOP mode
*(asterisk) Reboot Displayed during a Drive
reboot after download

Table 1

Drive Display - Normal Operating Status Codes – EN with FM Module

or Ei Drive
Table 2

Displayed Character Status Description

R Ready FM-3/4 ready to execute
motion command.
d Disabled Power stage disabled
h Homing Drive is homing.
X Indexing Index is executing.
J Jogging Jog is executing.
P Program Program is executing.
\ Stopping Drive is decelerating.

2
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.
An Appendix contains the relevant cable pin outs.

Resetting Faults
Some of the detected faults may be reset using the front panel mounted pushbutton. Other
faults require the power to be cycled. The cause of the fault should be understood and
corrected before resetting.

Important Contact Information

Telephone: (952) 995-8000 or (800) 397-3786
FAX: (952)-995-8099
Website and Email: www.emersonct.com
Technical Support: (952) 995-8033 or (800) 397-3786
Technical Support Email: [email protected]
Training Email: [email protected]

Safety Instructions
Failure to follow safe installation guidelines can cause death or serious injury. The
voltages used in the product can cause severe electrical shock and/or burns, and could be
lethal. Extreme care is necessary at all times when working with or adjacent to it. The
installation must comply with all relevant safety legislation in the country of use.

Qualified Person
For the purposes if this manual and products, a “qualified person” is one who is familiar
with the installation, construction and operation of the equipment and the hazards
involved. In addition this individual has the following qualifications:
• Is trained and authorized to energize, de-energize, clear, ground, and tag circuits and
equipment in accordance with established safety practices.
• Is trained in the proper care and use of protective equipment in accordance with
established safety practices.
• Is trained in rendering first aid.

3
“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%.

Potential Causes for RMS Foldback

• Excessive Load or Friction
• Motor does not match DDF file or Drive type
• Corrupt Motor DDF file
• RST Motor phases incorrectly wired

Notes

4
“C” RMS Foldback Display

"C"
RMS
Foldback

Return * See Appendix B for

Yes Investigate
Excessive to information on
- Check Foldback RMS in Watch Window*
Load Normal Watch Window
- Wrong drive/motor for application size
Load
No

Yes
Incorrect Select Correct
Download Yes
Motor Selected Motor from Return to
Known Good
for Setup View Normal Operation
Application
Configuration or Motor Tab
No
No

Corrupt
Motor DDF
file

Yes

Reinstall Download Yes

Return to
PowerTools Known Good
Normal Operation
FM or Pro Application

RST Motor Yes

Phases Incorrectly
See
Wired
Appendix A Wire
End
For Correctly
Correct Wiring per diagram
for Eb/Ei/En

5
“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. IGBT’s can overheat under these conditions unless
current is reduced.

Potential Causes for Stall Foldback

• Sustained high current demand at low speed
• Wrong motor selected for configuration
• High inertia mismatch
• RST Motor phases incorrectly wired
• Tuning parameters not optimized
• Torque is commanded when machine path is blocked or stopped.

Notes

6
“c” Stall Foldback display

"c" Fault
Stall Foldback

Search for
Yes Return Load to Return to
causes of
Excessive Load Original Normal
Increased
Size/Value Operation
Load
No

Yes
Incorrect Select Correct
Download
Motor Selected Motor from Return to
Known Good
for Setup View Normal Operation
Application
Configuration or Motor Tab

No

Use Emersize
Yes Determine program to Contact
High Inertia potential determine Technical Support
mismatch causes correct for Assistance
for mismatch motor/drive
match
No

Yes
RST Motor See
Wire Download
Phases Incorrectly Appendix A Reutrn to
Correctly Known Good
Wired For Normal Operation
per diagram Application
Correct Wiring
for Eb/Ei/En
No

Tuning Refer to
Parameters Tuning Download
Reutrn to
not Optimal Procedure in Known Good End
Normal Operation
Epsilon E Series Application
Yes Reference Manual

7
“*” 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.

Potential causes for the Flash Invalid fault

• Incompatible file for the hardware present
• Corrupt flash file

“ “*” Flash Invalid”

"*" Fault
Asterisk Displayed
Invalid Flash

Flash
Incompatible file Yes
Remove Power Base Drive Upgrade
for Hardware
& FM Module OK FM Module
Present
See Appendix C
No

Flash
Corrupt Upgrade
End
Flash File Base Drive
See Appendix C

Very Important Notice!

Before attempting
Flash upgrade
contact Tech
Support.

Notes

8
“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).
• Noise

“ A” Drive Overtemp”

"A" Fault
Drive Overtemp
Epsilon Only

Cycle Power
to Reset

Check for
Yes
Yes continuity between
Possible Ready for Normal
Drive Resets Drive Ground and
Noise Problem Operation
Motor Ground
with Power Off
No
No

Check Cable Routing and

Spacing between
Feedback and Motor Power
Cable or any other cable with
potential to generate noise

Check for
Remove Power Yes Air Flow Restriction
Allow Cool Down Air Filters change Drive Resets
Approx. 30 minutes if needed
Air Conditioning problems
No

High Ambient
Derate by Contact
Temperature End
Check Application 3% for every degree Tech Service
in Cabinet o o
o 40 to 50 C max
Above 40 C

Notes

9
“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.

Potential causes for the “I” Power-Up Self-Test fault

• Incorrect firmware in drive or module
• Failed internal component
• Failed FM module

“I” “Power-Up self-Test”

"I" Fault
Power-Up Self-Test

Connect Computer
Drive and FM Module Check Website
to Drive, Check Module
for latest Flash Rev.
Establish Flash level
and download
Communications

No
Upgrade Return Module
Flash Module
successful to Factory
See Appendix C

Yes End
Return to
Service

No
Drive Only Recycle Functions Return Drive
Power Normally to Factory

End

Very Important Notice!

Before attempting
Flash upgrade
contact Tech
Support.

Notes

10
“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
Return to Operation
to Reset

No

Download Yes
known good Return to Operation
Configuration file

No
Yes
Update Module or
Base Drive
to latest Return to Operation
Flash (.fsh) file

No

DSP
Return to Factory End
Non Operational

Notes

11
“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.

Potential causes for the “U” Invalid configuration fault

• FM module not on the drive at previous power up
• FM module on the drive at this power up was missing at the prior power up

“U” “Invalid Configuration”

"U" Fault
Invalid Configuration

FM Module
Press and Hold Display Ready for
Present Download
Drive Reset P/B Changes Normal
prior to last Configuration file
for 12 seconds to "d" Operation
Power Cycle

Yes
No
End

No Module
Present
prior to last
Power Cycle

Notes

12
“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.

Potential causes for the “H” High DC Bus fault

• DC Bus exceeds 440 VDC (EN), 415 VDC (Epsilon)
• Open Shunt Resistor either internal or external
• RSR-2 module malfunction or improper installation
• High AC input line
• High inertial load, deceleration ramps too aggressive

“H” “High DC Bus Fault”

"H" Fault
High DC Bus

System Uses RSR-2 Module Yes

EN-204 Use RSR-2
and ES Unit
All Epsilon Troubleshooting
External Shunt Resistor
Drives Procedure

No
Potential Misapplication
EN-208 Open Internal No
or External Resistor
And EN-214
Drives Shunt Resistor/Shunt Fuse * RSR and ES Maybe Needed
Contact Tech Support
Yes
No
Return Returns
"H" Fault to Factory to Return
End
High DC Bus Normal Operation to Factory

Yes
Yes
High AC Monitor No
Reset
Input line AC Input
with Reset P/B
>264 VAC 47-63 Hz

"H" Fault Yes

Investigate Cause
High DC Bus > 264 VAC
for Increase

Examine Program
High Inertia Load/
Investigate Modify Motion
Decel Ramps
High Inertia AT/DT/VEL
Overly Agressive
as required

*Shunt Fuse or Resistor cannot Returns No

Return
be checked in field. to End
to Factory
Normal Operation

13
“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.

Potential causes for the “Z” Power Stage fault

• Power Stage over-temperature or over-current
• Power Stage switching transistor failure
• Loss of Power Stage logic power supply
• Use of improper serial or sync cables
• Motor shorted to ground
• Motor Phases shorted
Notes

14
“Z” “Power Stage Fault”

"Z" Fault
Power Stage
Fault

No
Disconnect Ohm out Return
Shorted Remove Motor Power Motor Stator Motor
Motor Stator Power Cable Use Procedure OK To
at Motor in Appendix D Factory

Segment #1
End
No
Ohm Out Motor Cable Cable Replace
See Appendix A for Daigram OK Cable

Yes

Segment 2

Internal Power Stage Reset with

Over Current; Reset P/B (EN) No Return Drive
Switching Transistor Failure To Factory
Reset Successful
include Description
Segment 2 Or of Application

Internal Power Stage Check application

Reset by
Over Temperature insure Drive Ambient
Cycle Power
< 40 degrees C
(Eb/Ei)

End

Fault Detected
when using
Serial Cable

Segment 3 Yes
Continuity Not Recommended
No pin 6 to pin 6 for use with
EMC Serial Ohm Out
or pin 5 to pin 6 E Series/Epsilon
Cable Serial Cable
or pin 6 to shield/Gnd? Drives
Yes

Using
Yes Continuity
Sync functions Ohm Out Replace
pin4 to pin 8
and Sync Cable Cable
or pin 4 to shield/Gnd?
Sync Cabless

15
“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.

Potential causes for the “u” Low DC Bus fault

• DC Bus falls below 96 VDC
• Low AC line, below 90 VAC for greater than 50 milliseconds (3 cycles of 60 Hz)
• RSR-2 module malfunction or improper installation
• Repeated rapid cycling of AC power to amplifier
• Removal of AC Input AC Voltage Normal
• Removal of Aux Supply Powering Logic (Normal)

Notes

16
“u” “Low DC Bus Fault”

Yes
Operation
"u" Fault Reset with
Returns To End
Low DC Bus Reset P/B
Normal

Segment 1
No

Measure When Input AC returns

AC Input to 96 to 264 VAC
On Power Connector Reapply Power

RSR-2 Malfunction Yes Refer to RSR-2

or Troubleshooting
Improper Installation Flowchart End
Segment 2
No
Yes Operation
Rapid Remove Power
Reapply Power Returns To
Cycling of Power for 10 seconds
Normal

Epsilon
Use Open PowerTools
"u" Fault
PowerTools On Menu Bar
when using
to Disable Click on Options >
Aux Power
Monitoring Preferences>General
Supply (+24VDC)

Segment 3
Go On Line
with the Drive,
Check Box Operation
In Detailed Mode Reset with
Select Advanced Tab Returns To
Select Advanced Tab Reset P/B
Normal
Uncheck Box by
Low DC Bus Enable

End

Increase Input AC
Operation
> 120 VAC or
Returns To End
Increase AT
Normal
(E-Series)
Segment 4
Low Input AC
< 120 VAC &
u Fault
Rapid DT with
Large Load
24 VDC
APS
Disabled,
Low Bus
(Epsilon)

17
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.

RSR-2 No Normal Operation

"H" Check For Correct
May potentially
Fault Correct Connection Wiring
Be Faulty
on Drive
Yes

Yes
Power LED On Steady,
Check Shunt LEDs On
RSR-2 Reset Functions During Drive
Fuse Drive Ready Correctly Deceleration Period
Replace if for Operation Trig In/Trig Out*
Open

Yes *Only active if RSR-2

RSR-2 Check Correct Connection
is set up as Master or
Fault LED of ES Resistor Cycle Power to
Follower device.
On R+ and R-, Bus+ ands Bus-, EN or Epsilon
and PE

No
RSR-2
Disregard
Configured for
this Flowchart
Master/Follower

Yes
Check for
Master + 10 to +30 VDC
Check Connection Between
Trig Out to Follower Trig In *DC IN +24 V
and DC IN 0 V

Yes
External Shunt Over Temp
Contact
Operated with Over Condition
Tech Support
Temp Sensing Detected in
ES Unit

18
“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.

Potential causes for the “e” Encoder State fault

• Any Encoder Output and its Compliment in same state
• Poor Shielding (Use “E” Fault Flow Chart)
• Custom Cable

“e” “Encoder State Fault”

"e"
Encoder State Fault

No
Check PowerTools Pro
Recycle Returns to
Advanced Tab End
Power Normal Operation
Enabled

Yes
No
Invalid Check +5 VDC
Encoder State J7 pin 7 to pin 17 (Gnd) EN Return Drive
End
Reporting J6 pin 7 to pin 17 (Gnd) Epsilon to Factory
Should be 4.9 to 5.15 vdc

Yes

Check Continuity
No
Encoder Phases Replace
End
Motor to Drive Cable Cable
Power Off

Cable
OK?

Yes

Contact
End
Tech Support

Use Emerson CT Feedback Cable

Noise Check Cable Contact
or
Routing Tech Support
Cable with A, B, and Z shielded

19
“E” Encoder Line Fault
This fault is indicated by the display showing a “E”. Indicates a fault involving the
Encoder feedback.

Potential causes for the “E” Encoder Line Fault

• Loss of Encoder feedback
• Excessive noise induced into Encoder cable
• Drive and motor operating at different ground potentials
• Improper feedback wiring or potential cable issues
• Flexing of a non-flex cable
• Use of non-Emerson CT serial cables

“E” “Encoder Line Fault”

"E" * EN & Epsilon

Encoder Line shipped after
Fault
October 2001
Yes No
Check +5 VDC
Remove
Loss of J7 pin 7 to pin 17 (Gnd) EN En Fuse
FM Module
Encoder Feedback J6 pin 7 to pin 17 (Gnd) Epsilon Open
(if so equipped)
Should be 4.9 to 5.15vdc
Reapply Power
Yes

No
*Resettable
Use PowerTools Select "Status" Tab or Fuse Open
Select Analog Mode, "Watch Window" to Allow to cool
Configure Drive and Motor, View "Position Feedback Encoder" Reset is
Download to Drive DO NOT Enable Drive Automatic
Rotate Motor Shaft by Hand

No
Yes
Counts are Displayed? Yes
Return to
Increases with CW Rotation
Normal Operation
Decreases with CCW Rotation Replace Drive
and Return
Replace Motor
No to Factory
and Return
to Factory
Check Routing
Yes & Condition of
Noise Feedback Cable
Recycle Power Return to
Induced in Feedback in Runs End
Run Programs Normal Operation
Cable Relay Coils W/O
Diodes in System
No
Yes Check Continuity Motor Case
Motor and Drive If Resistance Measured
to Motor Feedback Connector Shells
Operating at different Contact Factory
J5* Epsilon or J8* EN
Gorund Potentials Tech Support
Must be Zero!
No
* Refer to Appendix E Replace Drive
for Connector Locations and Return
to Factory
Check +5 VDC End
Yes
Use of non-Emerson CT J7 pin 7 to pin 17 (Gnd) EN No
Serial Cable J6 pin 7 to pin 17 (Gnd) Epsilon
Should be 4.9 to 5.15vdc
Replace with CT Approved Cable Yes
Return to
Normal Operation

20
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.
• Flexing of a non-flex cable
• Improper wiring
• Defective thermal switch internally in the motor
• Noise

“M” “Motor Over Temperature Fault”

"M" Fault
Motor Over Temperature

Motor Thermal No
Yes
Switch open Allow Motor to cool Thermal Switch
Return to Factory
due to excessive Approximately 30 mimutes Resets
internal heat
End
No
Yes
Disconnect Check continuinty of Yes Return to Service
Flexing
Motor Motor Feedback cable pin A
of non Flex Cable
Feedback Cable Flex cable during test
Replace Cable
No
No
Yes
Disconnect Motor Feedback Cable
Reconnect and Return to Service
at every connection point,
Improper Wiring Yes
use ohmmeter to check
from Drive to Motor
continuinty of Pin A in cable Replace defective section
If Flex cable try and Flex or entire Cable
No No

Yes
Defective Check Continuity pins T to A Return to Service
Motor Thermal of Motor Feedback Connector
Switch MG/NT Motors
No
shall read short if switch is reset
Yes Return to Factory
No

Noise Check Routing

Return to Service End
of Cables
Yes

21
“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.

Potential causes for the “S” High DC Bus fault

• Internal shunt power calculation has exceeded capability of internal shunt circuitry
• High Inertial load
• High AC line
• Short rapid moves coupled with very short deceleration ramps

“S” “RMS Shunt Power Fault”

"S"
RMS Shunt Power
Fault

Internal Shunt Power

Yes Return
Calculation exceeds Reset with
to
capacity of Reset P/B
Normal Operation
intenal shunt circuitry

No
Reduce
Yes No
Load
High Interial Returns
Check for Return
Load to End
Increase in to Factory
Normal Operation
Acutal Load
No
Yes
Yes
High AC Monitor No
Reset
Input line AC Input
with Reset P/B
>264 VAC 47-63 Hz

Yes
No Investigate Cause
> 264 VAC
for Increase

Short Rapid Yes

Determine
Moves coupled
which Motions
with Very Rapid
cause fault and
Deceleration Ramps
alter as needed

22
“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 Yes

Check "stdmotor.ddf" file Investigate cause
150% of value
for exact Motor RPM Spec. of Motor Overspeed
"stdmotor.ddf" file

No

Actual Motor Speed Yes

Check "over speed limit" Download
Exceeds Programmed
in software Corrected file
Over Speed Limit

No

Pulse Mode Yes Reduce Incoming

Maximum Frequency Pulse Frequency Return to Service End
rating exceeded to < 8 Mhz

No

Yes Check Contnuity

Check Routing
Noise of Feedback Cable Reset
of Power and
Shield from using Reset P/B
Feedback Cables
Motor to Drive

23
“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.

Potential causes for the “F” Following Error Fault

• Friction
• Faulty wiring
• Programmed acceleration/deceleration ramps are too fast

“F” “Following Error Fault”

"F"
Following Error
Fault

Yes Check Movement Check

Disconnect
of All Parts Lubrication
Friction Motor from
Moved/Controlled by of All
Load
This Motor Mechanical Parts

No
Gear Reducer Add/Change
Reconnect
Used? Reducer Oil
Motor to
Check condition with Recommended
Load
and level of Oil Oil

Reset
Return to
with End
Normal Operation
Reset P/B

Programmed Examine Alter

Accel/Decel All Motions Accel/Decel Reset Return to
Ramps that may be Ramps for with P/B Normal Operation
Yes
Too Agressive Causing Fault Suspect Motions

No
Following
Error Limit Alter Reset
Return to End
Setting too Following Error with
Normal Operation
Agressive Yes Limit Reset P/B
FM-2/3/4

No
No Reset
Yes
Faulty Inspect Motor Check Motor to Drive with
Wiring to Drive Wiring Wiring for Splices Reset P/B

Poor Replace
Splices Cable

24
“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.

Potential causes for the “L” CW/CCW Limit fault

• CW/CCW limit sensor active
• Reached the end of the hardware or software established limits in either direction
• Polarity of input function is incorrect for wiring configuration at the input connector

Troubleshooting Flow Chart for “CW/CCW Limit Fault”

"L"
CW/CCW
Limit Fault

Yes Jog Yes

Travel Limit "L" Fault
Off Switch Return to
Prox Switch Resets
in Opposite Normal Operation
Active Automatically
direction

No
No

Check
Change Input
Check Input Wiring
Polarity/
Polarity of Input for Polarity
Modify Wiring
Selected

End
Yes
Jog
Travel Limit Check/Adjust "L" Fault
Off Limit
Software Limit Software Resets
in Opposite
Active? Limit Automatically
direction

Return to
Normal Operation

25
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 (>0.25A) encoder

Notes

26
All LED’s on Fault

All LED
Display
Segments On

Check
Yes Refer to
Wrong Yes CT No used Pins
Serial CAble
Serial Serial have any
Diagram
Cable Cable Continuity to
in Appendix A
Shield
No

Refer to
Must Match Move
Serial CAble
Diagram to Next End
Diagram
Shown Possibility
in Appendix A

* System can operate from

an Aux Power Supply
or from AC not both.
No

Yes Low AC Less than

*Low Input EN 90 VAC
Investigate
AC Reason for
Input Low AC Voltage

Low AC Less than

Input Eb/Ei 60 VAC End
No

*Low EN Less than Investigate

Auxiliary Power 90 VAC Reason for
Supply Voltage Low Voltage
Eb/Ei
Yes Less than
+18 VDC
No

Yes Base Drive

Malfunctioning Remove Module Replace
Remove Power Operates
FM Module Reapply Power Module
Normally
No End
Shorted or
Yes No
Overloaded J6 Eb/EI J7 EN
+ 5 VDC Replace
(>0.25A) pin 11 +5vdc pin 12 ground
OK? Drive
Encoder Should be + 4.9 to 5.15 VDC
Power Supply

Yes

Check
Feedback Cable Cable Replace
for shorts OK? Motor
See Appendix A

27
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.
• ISR Overrun- is triggered by the modules flash memory problem.
• No Program- indicates that there is no current configuration contained in the base
drive.
• Out of Sync- indicates that the system is not operating in a synchronized mode. Sync
between the module and base drive has been lost.
• Program Fault- indicates an FM-3 user program fault.

Troubleshooting Flow Chart for “FM-3 Hardware Error”

• See combined Flow Chart for FM-3/4

FM-4 Hardware Error

This fault is indicated by the display showing a “4”. Indicates a fault specific to the FM-4
module. This is similar to a FM-3.

Potential causes for the “4” FM-4 Hardware Error

• All other faults under this fault type (“4”) are displayed on the FM-4 LC Display
• Trajectory Fault- normally related to velocities, accelerations or decelerations the
FM-4 is unable to perform.
• ISR Overrun- is triggered by the modules flash memory problem.
• No Program indicates that there is no current configuration contained in the base
drive.
• Out of Sync- indicates that the system is not operating in a synchronized mode. Sync
between the module and base drive has been lost.
• Program Fault- indicates a FM-4 user program fault.

Troubleshooting Flow Chart for “FM-4 Hardware Error”

• See combined Flow Chart for FM-3/4

Note
Two bars are shown in the display during the Flash Upgrade process.
This is a normal indication.

28
“FM-3/4 Hardware Error”

"3" or "4"
Hardware
Error Faults

Unable to Perform
Yes Locate Specific
Velocities, Reset
Trajectory Motions containing offending
Accelerations with P/B
Fault Velocity, Accel/Decel
or Deceleration Retry
Modify to Acceptable Limits
for Motion Functions
No

Yes Contact
ISR
Replace Module Tech Support
Overrun
for RGA

No
Module
*No Prog will occur
Yes Download for a new drive
contains
No Prog* No Valid
Known Good
out of the box.
Configuration
Configuration Modules are shipped
with no program
No
loaded. Download
configuration file.
Sync
between
Yes Recycle Check
Out of FM Module
Power Configuration
Sync &
Retry file
Base Drive
Lost

No
User Program Error
Yes
Program Review Program
Fault Alter to correct
Highlighted Program Errors

29
Appendix
Section

30
Appendix A: Cable Diagrams

BRAID SHIELD FORM WIRE

PE/GND D GRN/YEL

R RED 1
A
RED 2 Drive to Motor Cable
S B
T C RED 3

Drive to Motor Cable

CMDS CABLE WIRE DIAGRAM
Shown is Flex Cable
Wire Colors for non-Flex is:
R = Brown; S = Black; T= Blue

BLU
A B 1 A
ORN P
A/ C 10 A/
GRN
B N 2 B
Motor P
BRN P
11
B/ B/
Feedback Cable BLK
Z M 3 Z
YEL P
Z/ U 12 Z/
WHT/BRN
U E 4 U
BRN/WHT P
U/ R 13 U/
WHT/GRY 5
V F V
GRY/WHT P
V/ S 14 V/
W G RED/ORG 6 W
ORG/RED P
W/ H 15 W/
RED/BLU 7
+5 VDC K +5 VDC
BLU/RED P
GND T 17 GND
RED/GRN
MOTOR OVERTEMP A 9 MOTOR OVERTEMP
GRN/RED P
NOT USED V 16 NOT USED
Z

CFCS CABLE WIRE DIAGRAM

31
RED
XMIT 3 2 REC
WHT
REC 2 3 XMIT
BLK Emerson CT
GND 5 5 GND
SHLD Serial Cable
1 SHLD

TIA CABLE WIRE DIAGRAM

1 1 1
YEL
2 2 2 RX
RED BLU P
3 3 3 TX
WHT RED
RS485+ 4 4 4 RS485+
BLK BLK P
RS485- 9 9 9 RS485-
BKL/WHT
GND 6 6 6
GRN BLU/WHT P
GND 5 5 5 GND
RED/WHT
GND 8 8 8
DRAIN WIRE YEL/WHT P
GND 7 7 7
DRAIN WIRE

DDS CABLE WIRE DIAGRAM

Emerson CT DDS Cable

BLK
+A 1 1 +A
BRN P
-A 2 2 -A
RED
+B 3 3 +B
ORG P
-B 5 5 -B
YEL Emerson CT
+Z 6 6 +Z
GRN P SNCDD Cable
-Z 7 7 -Z
BLU
GND 8 8 GND
VIO P
4 4
DRAIN WIRE
SNCDD CABLE WIRE DIAGRAM

32
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 FM-
1/2/3/4 programming module. Please refer to the appropriate procedure listed below for your particular
application.
Using the Watch Window with PowerTools FM Software
This procedure applies to:
• En base drive systems without a FM module attached
• En drive systems with a FM-1 or FM-2 module attached
• Epsilon drive systems
• Ei (Epsilon Indexing) drive systems

Step 1: Going Online with the Drive System

In order to use the Watch Window diagnostic tool, you must be online with the drive system. The easiest
way to establish an online connection is to click on the “Upload All” icon from the PowerTools FM toolbar
as shown in Figure 1.

Figure 1

33
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. Please note the “Connected” status in the
lower right corner of the status bar.

Connection status shown

here

Figure 3

34
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 5
Configure the Watch Window by selecting the registers that you would like to monitor from the group that
you have chosen as shown in Figure 6. Once you have selected a register, the Watch Window will appear
on your screen with the registers you have selected.

35
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
.

Figure 7

36
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. If
you are in doubt, contact the Control Techniques Technical Support department before you begin to reduce
the potential for problems. Failure to do so may result in non-operational equipment and downtime for your
machine.
It is important to note that you cannot Flash Upgrade a base drive through a FM module. In order to Flash
Upgrade the base drive, you must remove the FM module first. In some cases, both the base drive and the
FM module will need to be upgraded. In that case, upgrade the base drive first and then the FM module.
It is not advisable to attempt to upgrade more than 1 piece of hardware at a time. Therefore, disconnect any
drive to drive serial cables before proceeding and upgrade only 1 piece of hardware at a time.
Obtaining Firmware Upgrades
The latest revisions of firmware for your drive or FM module may be freely downloaded from our company
website at: www.emersonct.com. The files are located in the “Sales & Support/File Downloads” area.
These files have the file extension .fsh and are organized according to product type.
The firmware flash files are also located on our PowerCD. A PowerCD is included in the box along with all
of our equipment.

Step 1: Launching the Flash Upgrade Tool

In this example, the firmware of a FM-3 module is being upgraded.
Presuming that you have already located/downloaded the appropriate flash file, the first step is to launch
the Flash Upgrade tool. To launch the tool, select “Program Flash” from the “Tools” menu in PowerTools
Pro as shown in Figure 1.

Figure 1

37
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.

Figure 2

38
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. Doing so will avoid the possibility of
any data read errors that can occur between your PC and the CD-ROM drive thereby resulting in the
interruption of the Flash Upgrade process.
WARNING: If the Flash Upgrade process is interrupted, there is a good chance that you will not be able to
proceed without factory assistance. Never interrupt the Flash Upgrade process.

39
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 5
Once you have selected the hardware to upgrade, click on the “Upgrade” button to begin the process as
shown in Figure 6.

40
Figure 6

41
Appendix D: Ohming Motor Procedure

Ohming
Out Motor

Slowly Rotate
Connect Ohmmeter
Disconnect Connect Ohmmeter Motor Shaft
Leads between
Motor Cable Leads between CW or CCW
Pins B and C
from Motor Pins A and B Observe Ohmmeter Reading
on Motor Connector
on Motor Connector See Resistance chart this page
phase to phase test
for motor under test

Slowly Rotate Slowly Rotate

Motor Shaft Connect Ohmmeter Motor Shaft
CW or CCW Leads between CW or CCW
Observe Ohmmeter Reading Pins A and C Observe Ohmmeter Reading
See Resistance chart this page on Motor Connector See Resistance chart this page
for motor under test phase to phase test for motor under test

Connect Ohmmeter
Connect Ohmmeter
Leads between Ohmmeter Shall Ohmmeter Shall
Leads between
Pins D and C Read Inifinity Read Inifinity
Pins D and B
on Motor Connector (open circuit) (open circuit)
on Motor Connector
phase to ground test
phase to ground test

Connect Ohmmeter
Leads between Ohmmeter Shall
Pins D and A Read Inifinity
on Motor Connector (open circuit)
phase to ground test

Any Reading in the entire test

that does not fall within specified limits phase to phase
or meet the exact reading phase to ground
is to be considered failing the test

42
For motors not listed contact Control Techniques to obtain information.

D.C. Resistance
MOTOR (Ohms)
NT-207 11.1
NT-212 4.6
NT-320 1.5
NT-330 1.2
NT-345 1.3
NT-355 1.0
MG-205 18.5
MG-208 7.3
MG-316 3.9
MG-340 1.9
MG-455 1.1
MG-490 0.4
MG-4120 0.4

43
Appendix E: En and Epsilon Drives Physical Connections
Epsilon Eb/Ei Drives

AC Power Input

DC Bus Access
Status Display Motor Power
Connection
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 Auxiliary Logic Power, DC

(Located on top of drive) Bus access
(Located under plastic
FM Module Connector 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. To determine if you have this program installed follow these steps:

1. Click on the “Start” button on the Windows Desktop.

2. Select “Programs”, then “Accessories”, and then “Communications” from the popup menus.
3. If HyperTerminal is installed, you should see it in the “Communications” menu (See Figure 1).
Note that on some computers, HyperTerminal may appear in the “Accessories” menu instead.
4. If HyperTerminal is not installed, either install it from your Windows CD or consult with someone
who can help you with this process.

Figure 8

46
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.
Typical examples of programs that can cause problems would be any Fax software or Palm Pilot
software that may not be active and open, but yet are “poised and ready” in the Windows system
tray (See Figure 2). These programs “watch” the serial port for any activity and when they detect a
connection attempt will block access to the port. If you have any programs of this nature
(including Allen Bradley’s “RSLinx” software) close them at once by right clicking on their icons
in the system tray and then closing the programs.
Fax software icon
Palm Software icon

Figure 2
2. You have the serial cable plugged into the wrong port.
Ensure that the serial communications cable is plugged into the serial port on the En/Eb/Ei drive.
Refer to Appendix E for the location of the serial port on the drive.
3. The power is turned off.
In order to communicate with any En/Eb/Ei drive, the main AC power must be present.
4. The drive you are trying to communicate with is faulted.
There are certain faults that can cause communication failures. If you cannot reset the drive, it may
be that you will not be able to communicate with it either.
Serial Loopback Test

Step 1: Re-start your PC

For best results, shut down and restart your PC. If you have just turned on the PC, ignore this step. Please
refer to step 1 above if you see any Fax or Palm icons in the system tray after you restart your computer.

Step 2: Create a new HyperTerminal Connection

Open the HyperTerminal folder from the Windows start menu by clicking on it (See Figure 1). Once the
folder is open, double click on the “Hypertrm.exe” shortcut (See Figure 3) to begin a new connection.

47
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.

Figure 4

48
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. Ensure that your configuration matches
the picture in Figure 6 exactly.

Figure 6
Once the Port Settings are defined, click on the OK button and HyperTerminal will open the Com port
automatically. You can determine if the program is active by referring to Figure 7. HyperTerminal will
show “Connected” in the lower left corner of the Status bar.

49
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.
Disconnect the Com port by clicking on the Disconnect icon on HyperTerminal’s toolbar (see Figure 8).

Figure 8

50
To complete the settings for the new connection, Select “Properties” from the HyperTerminal “File” menu
as shown in Figure 9.

Figure 9

51
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.

52
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.

Figure 13
Using a metallic object such as a small screwdriver, short pins #2 and #3 together. The pin numbers will
correspond to the diagram in Figure 13. Be careful not to accidentally touch any other pins!
Open the HyperTerminal connection that you configured in step 2.

53
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.
Your choice is to have the port repaired, or switch to a different computer and try the procedure again.

Figure 14

54