E-0-4: Motor Over Temperature: The Motor's Thermistor circuit has opened, indicating an overheat condition.
A Thermistor is a solid-state device that has a certain resistance to voltage flow at some designed nominal temperature. At the Motor's designed high temperature limit of 140 degrees Celsius (284 degrees Fahrenheit), the Thermistor’s decreased resistance triggers a fault circuit. When the motor cools below a designed limit, the resistance also rises within limits, allowing the fault circuit to reset.
A closed voltage loop exists; sourced at the Servo Amplifier (Drive), extending out through the encoder cable, into the windings of the motor, through the Thermistor, then back, through the encoder cable to the Drive. A completed circuit of this voltage indicates to the Servo Drive, that the motor is within operating temperature. However, a break in this loop, other than the Thermistor opening, causes the drive to assume the motor is in an Over Temperature state, when in fact the motor is cool.
-Broken encoder cable wiring, loose connections, or a disconnected motor can cause this error.
-Of course, a VERY hot motor can indicate the same error. If the Motor is too hot to touch, a very serious problem exists with excessive current or loading on the system. As a rule, P/A Servo Feed Motors do NOT run at very high temperature.
-If the drive is an older DDM-30 drive, the J4 Motor Encoder connector on the front of the drive is VERY delicate. If this connector is moved side to side, pins can be broken on the connector's header. This CANNOT be repaired. The drive must be replaced. Be VERY careful handling this J4 connector.
E-0-5: IPM Fault: This is a serious problem with the Servo Amplifier's IPM module. The Intelligent Power Module processes all current, and phasing requirements to the Stator (stationary windings) of the Motor. A maximum of thirty peak amperes is allow through any phase of the motor for a short duration. Continuous current of ten amperes is allowed. When either the Continuous, or the Peak Currents, are exceeded in both amplitude and time, an IPM Fault is generated.
-Axis, Feeder, or Material locked. Extreme mechanical binding, tooling problem, tight loop, pulled slug, etc. Basically, anything that can cause the motor to lock-up, or be difficult to turn.
-Incorrect Motor Phasing. The four Motor wires MUST be connected properly on the Amplifier and Military connector. (A)BROWN to U or R, (B)BLACK to V or S, (C)BLUE to W or T, the (D)GREEN with YELLOW to GROUND or GND,
-Short Circuit in the Motor wiring or windings. The motor's Phase to Phase resistance should be equal and at a value of about 100 ohms or less. Each phase to the green/ground should show infinite resistance. The cable should be checked for continuity and shorts.
E-1-0: Bus Over Voltage Error: The D.C Bus Voltage has exceeded the maximum threshold of 392 VDC. The nominal Voltage measured across DC Bus+ and DC Bus- is 375 VDC. This rectified voltage is based on a maximum incoming Line Voltage of 240 VAC.
-Check the Line voltage to be sure it is between 88 and 240 VAC.
-Make sure the feed supply is not shared with other regenerative drive equipment.
-Deceleration of large strips after a long feedlength (six+ feet), can cause excessive regenerated voltage that pushes the Bus Voltage above it's maximum threshold. Lower the deceleration parameter.
-Line voltage spikes can send the Bus Voltage over it's maximum threshold. Install a Three KVA, Single Phase, transformer as a Line buffer. Wire the Primary Coil to match the Line Voltage, and the Secondary Coil, to output 210-220VAC Single Phase to the feed control.
E-1-1: Illegal Hall State Error: Usually caused by poor encoder cable connections at the motor's military type encoder connector.
-Power down, remove both motor connectors, spray with contact cleaner, blow out excess until dry, reconnect, repower.
-Check encoder cable for damage. Replace if damaged.
-Motor's Hall effect encoder damaged. Replace motor.
E-1-8: Overspeed Fault Error: May be caused by incorrect speed entry in the tool. Verify that the SPEED setting for the tool is within the capabilities of the system. Refer to "Feeder Scale Value" help page for maximum velocity settings, at nominal line voltage, of different P/A Systems. May also be caused by defective encoder cable, or bad connections to encoder. See E-24 below.
E-1-9: Excess Position Error: Usually caused by defective encoder cable, or bad connections to encoder. Power down, remove connectors, spray with contact cleaner, blow out excess until dry, reconnect, repower.
-Check encoder cable for damage. Replace if damaged.
-Motor's encoder damaged. Replace motor.
E-2-2: Motor Thermal Protection Fault: This is a digital filter that protects the Servo Motor. Tripping of the filter limit is usually caused by increased mechanical resistance in the Feeder, the application, dips in Line voltage, etc. Look for pulled slugs, cambered material, tool binding, mechanical resistance of the feed rolls, proper line voltage, poor connections, etc. (See IPM & Motor Thermo Error Document).
E-2-3: IPM Thermal Protection Fault: This is a digital filter that protects the Intelligent Power Module. Tripping of the filter limit is usually caused by increased mechanical resistance in the Feeder, or the application. Look for pulled slugs, cambered material, tool binding, mechanical resistance of the feed rolls, etc. (See IPM & Motor Thermo Error Document).
E-2-4: Excess Velocity Error: Usually caused by defective encoder cable, or bad connections to encoder.
-Power down, remove connectors, spray with contact cleaner, blow out excess until dry, reconnect, repower.
-Check encoder cable for damage. Replace if damaged.
-Motor's encoder damaged. Replace motor.
Sync-Fault: This error is produced in the Motion Control algorithm. It is caused when the controller detects that the Feeder is still completing the index (moving), when the feed cam signal goes off/low. It is NOT a servo drive error.
-Check feed to press timing to assure feed length can be completed within the given feed cam window. See P/A Speed Chart.
-Check Feed Cam Input for bouncing contacts. The Digital Inputs on the P/A Servo Drive have Signal Propagation rates as low as 0.2 milliseconds (very fast acting). Relays or micro switches on the Press, can have contact bounce, which the Feeder may detect as a very small feed cam window.
-Increase the Debounce parameter under the Setup button of the Operator Terminal. Factory default is 1 millisecond, raise this parameter setting to 5 milliseconds.
Note: The Debounce parameter acts similar to a dwell, in that, the program stops, and waits for the Debounce period to elapse before continuing to scan. A very large Debounce time (+50 ms), can actually produce Sync-Faults in high speed applications (+350 SPM) where every millisecond is needed to feed the material up within the feed cam window. In general, if the Sync-Fault is not remedied by a Debounce setting of 20 ms or less, another cause should be investigated. |