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Publication 1394-5.0 — May 2000
Chapter
9
Troubleshooting
Chapter Objectives
This chapter covers:
• Understanding how to detect a problem
• Understanding system and axis module LEDs
• Understanding system faults
• Understanding GMC Turbo and GMC controller faults
• Understanding Analog Servo system module faults
• Troubleshooting general system problems
• Replacing system and axis modules
• Checking for a blown fuse in the 1394-DCLM
• Replacing 1394 the shunt module fuse
• Replacing the AM50 and AM75 axis module fan
!
ATTENTION: This product contains stored energy
devices. To avoid hazard of electrical shock, verify that
all voltage on the capacitors has been discharged before
attempting to service, repair, or remove this unit. You
should only attempt the procedures in this chapter if
you are qualified to do so and familiar with solid-state
control equipment and the safety procedures in
publication NFPA 70E.
ATTENTION: Do not attempt to defeat or override
the drive fault circuits. You must determine the cause
of a fault and correct it before you attempt to operate
the system. If you do not correct a drive or system
malfunction, it could result in personal injury and/or
damage to equipment as a result of uncontrolled
machine system operation.
ATTENTION: If you use an oscilloscope (or chart
recorder) for troubleshooting, you must properly
ground it. The oscilloscope chassis can be at a
potentially fatal voltage if you do not properly ground
it. Always connect the oscilloscope chassis to an earth
ground.
- 1394 Digital AC 1
- Multi-Axis 1
- Motion Control 1
- Allen-Bradley 1
- Important User 2
- Information 2
- Table of Contents 3
- Chapter 3 4
- Modules, and Motors 4
- (for all systems) 4
- Chapter 4 5
- Chapter 5 5
- Specifications 7
- Appendix B 8
- Appendix C 8
- Appendix D 9
- Catalog Numbers 9
- Who Should Use this Manual 11
- Purpose of this Manual 11
- Contents of this Manual 12
- Related Documentation 13
- Module Series Designator 13
- 1394 Product Receiving and 14
- Storage Responsibility 14
- Allen-Bradley Support 14
- Overview 15
- Safety Precautions 16
- 1394 System Overview 17
- Figure 1.2 18
- -C and 1394C-SJT 18
- CNC Interface System 19
- SERCOS System 20
- Analog Servo System 21
- 9/440 CNC System 22
- Terminal type connection 23
- Optical signal cable 23
- 1326AB Motors 26
- 1326AS Motors 26
- 1326AH Motors 27
- Standard Features of the 1394 29
- 1-16 Overview 30
- Installing Your 1394 31
- Before Mounting Your System 32
- Unpacking Modules 33
- System Mounting Requirements 33
- Figure 2.1 34
- Figure 2.2 35
- 1394 Mounting Hole Layout 35
- Bonding Your System 36
- Figure 2.4 37
- Bonding Examples 37
- Mounting Your 1394 System 38
- Engaged alignment tab 39
- Slide-and-Lock 40
- Mechanism 40
- Attach the 40
- Power Plug 41
- Incorrect Shunt Placement 42
- Figure 2.13 43
- Figure 2.14 44
- Mounting the Shunt Module 45
- Figure 2.15 46
- Understanding Basic Wiring 48
- Requirements 48
- Figure 3.1 49
- System Module Wire Sizes 50
- Shielding 50
- EMI/RFI Shielding 50
- EMI/RFI Bonding 50
- Input Power Conditioning 51
- Grounded Power Configuration 52
- Figure 3.3 53
- Figure 3.4 55
- Figure 3.5 56
- Figure 3.6 56
- Figure 3.7 57
- Grounding Your 1394 System 58
- Ground grid or power 59
- Always follow NEC and 59
- Figure 3.11 61
- Figure 3.12 62
- Required Tools and Equipment 63
- (Series C) 64
- Figure 3.13 66
- Locating TB1 and TB2 66
- Figure 3.14 68
- Resistor 72
- Figure 3.15 73
- Figure 3.16 73
- 1394 bottom view 74
- Remove jumper 74
- Wiring the Shunt Module Power 75
- Figure 3.18 76
- Figure 3.19 77
- Connected to COL on the 78
- 22 kW System Module 78
- Connected to DC + on the 78
- Wiring Shunt Module Fan Power 79
- Wiring the fan for 115V 80
- To power supply 80
- Figure 4.1 82
- Input Wiring Board for 1394 82
- -C, -C-RL and -T, -T-RL 82
- Figure 4.2 83
- -L and -L-RL 83
- Figure 4.4 85
- Typical Registration Inputs 87
- Figure 4.6 88
- Encoder Feedback Wiring 90
- Serial Communications 91
- Data Highway Connection 92
- AxisLink 94
- GMC Turbo System 95
- Remote I/O 96
- Flex I/O 96
- SLC Interface 97
- Figure 4.17 98
- Axis connections 99
- 1394-DIM with 1398-DDM 100
- System Example 100
- 1394-DIM Configurations 101
- Configuration Examples 102
- Figure 4.24 103
- Figure 4.23 103
- Understanding DIM Signals 104
- Drive Enable Output 105
- Analog Output 105
- Belden 8163 106
- DIM cable connector 106
- Terminal open 107
- Terminal closed 107
- Insert cable wires into the 108
- Figure 4.32 109
- 1394-GE15 Cable Connections 109
- Chapter Objectives 111
- Finding Additional Wiring 111
- Information for 1394 Systems 111
- Understanding Analog Servo 111
- Wiring and Connections 111
- Input Wiring Board Layout 112
- Flat tab 113
- Insert wire 113
- Connecting AQB and SCANport 115
- Figure 5.4 116
- SCANport Adapter 117
- Turbo Systems 119
- Applying Power to the System 120
- Commander 121
- Preparing the System 122
- Before You Begin 123
- Servo System 125
- Setting Up Analog Test Points 129
- Defining Your Motor 129
- Ax:Mode Sel 130
- Anlg Vel 130
- Ax:Current Limit 132
- +8.43 amps 132
- Ax:Vel Ref Whole 132
- <204 > <---352 132
- Defining Limits 134
- Performing the Auto Tune 135
- Troubleshooting 135
- GML Programming Manual 137
- System Parameters 139
- [100% Torq Vel] 140
- [300%Torq Vel] 140
- [Anlg Vel Ofst] 140
- [Anlg Vel Scal] 140
- [ATune Current] 140
- Appendix A 141
- [Axis Type] 142
- [Bridge Lim] 142
- [Bus Voltage] 142
- [CCW OvSpd Vel] 142
- [CCW Vel Lim] 142
- [Command Mask] 143
- [Cur Fbk Rated] 143
- [Cur Fbk Scale] 143
- [Cur Lim Cause] 143
- [Cur Preload] 143
- [Cur Rate Lim] 144
- [Current Limit] 144
- [CW OvSpd Vel] 144
- [CW Vel Lim] 144
- [D/A #x Gain] 144
- [D/A #x Value] 145
- [DC Link Setup] 145
- [Desired BW] 145
- [Dig Cmd Mode] 145
- [Dig Torq Ref] 145
- [Disp-D/A Monitor] 146
- [Drive OK Mode] 146
- [Enabled Days] 147
- [Enabled Minutes] 147
- [Fdbk Pole Cnt] 147
- [Language Sel] 150
- [Ld/Lg Degrees] 150
- [Ld/Lg Freq] 150
- [Line Voltage] 150
- [Max Bandwidth] 150
- [Mod Rng Data] 151
- [Mode Sel] 151
- [Module Size] 151
- [Mt Power Usage] 152
- [Motor Type] 152
- [Mtr Inertia] 153
- [Mtr Peak Cur] 153
- [Mtr Pole Cnt] 153
- [Mtr Rated Cur] 153
- [Neg Cur Lim] 153
- [Shunt P] 156
- [Shunt Peak Usage] 156
- [Shunt R] 156
- [Shunt Type] 156
- [Shunt Usage] 156
- [Sys Mod Data] 159
- [Sys Mod Status 2] 159
- [System Type] 159
- [Test Mode Sel] 159
- [Torq Source] 160
- [Typ 1 Logic Axis] 161
- [Type 1 Status] 161
- [Type 2 Status] 161
- [Units Sel] 161
- [Up To Spd Tol] 161
- Underdamped 162
- Critically Damped 162
- Overdamped 162
- [Vel Rate Lim] 163
- [Vel Ref Fract] 163
- [Vel Ref Whole] 163
- [Vel Source] 163
- 1394 Analog Servo Software 164
- Diagrams 164
- Figure 8.2 165
- Module LEDs 168
- Axis Module Status 170
- Understanding System Faults 171
- 9-6 Troubleshooting 172
- Fault Number 173
- Fault Name 173
- Hard Fault Indicator 173
- Source of Fault 173
- Finding CNC Interface Faults 174
- Understanding GMC Turbo and 175
- GMC Controller Faults 175
- System Module Faults 176
- Problems 179
- Motor does not respond to 180
- Presence of noise on 180
- Command or resolver 180
- Replacing System and Axis 182
- Removing an Axis Module 183
- 9-18 Troubleshooting 184
- Removing a System Module 185
- 9-20 Troubleshooting 186
- Troubleshooting 9-21 187
- 9-22 Troubleshooting 188
- Terminator 189
- Cable plug 189
- DCLM cable 189
- Figure 9.5 190
- Checking for a Blown Fuse 190
- Fuse holder 191
- 1394-SR36A/36AF 192
- 1394-SR9A/9AF 192
- Fuse Label 192
- Figure 9.8 193
- Figure 9.9 193
- Module Fan 194
- Fan Housing 195
- Fan Plug 195
- Fan Gasket 196
- Appendix 199
- System Modules 200
- Axis Modules 201
- Contact Ratings 201
- DC Link Module 202
- Drive Interface Module 202
- Circuit Breakers 204
- Figure A.1 205
- Figure A.2 205
- Environmental Specifications 207
- Power Dissipation 208
- Communication Specifications 209
- Serial I/O Specifications 210
- DH-485 Specifications 211
- Flex I/O Specifications 211
- GMC System Specifications 212
- AxisLink Specifications 214
- Dimensions 215
- Axis Module Dimensions 216
- Specifications A-19 217
- Filter Dimensions 218
- Figure A.10 219
- Figure A.11 219
- External Shunt Dimensions 220
- Figure A.13 221
- Figure A.14 221
- Figure A.15 222
- Figure A.16 222
- Motor Dimensions 223
- Figure A.18 224
- Figure A.19 225
- Name Plate Detail 226
- Figure A.23 229
- 1326AS-B8 Series Servo Motor 229
- Servo Motor Performance Data 230
- 1326AS Performance Data 231
- A-34 Specifications 232
- Interconnect and CE Diagrams 233
- GMC, Analog Servo, and CNC 234
- 1394 GMC Interconnections 235
- Figure B.2 236
- -C and -T) 236
- AXIS MODULE (TYPICAL) 237
- Figure B.3 238
- (1394C-SJT 238
- Left Side 240
- Right Side 240
- Left Side Right Side 241
- SUB PANEL 241
- Figure B.6 242
- CNC Input Wiring Board 244
- CNC Interface Board 244
- 9/SERIES CNC 244
- CNC SYSTEM MODULE 244
- Resolver 245
- Thermal Interconnect Diagrams 246
- 1394 GMC Systems (1394 247
- Axis 0 Axis 1 Axis 2 Axis 3 248
- Figure B.11 250
- 1394 GMC Systems (1394C-SJT 251
- Figure B.14 252
- Isolated Series E-Stop 252
- Figure B.15 252
- Axis 0 Axis 1 Axis 2 253
- Cable Pin-outs 255
- 1394 Cable Pin-outs 258
- 5V ENC PWR - AXIS 0 259
- M02AE - OK 259
- 1394-CFLAE 259
- 1756-M02AE 259
- Figure B.22 260
- Figure B.23 260
- 1394-GR04 Cable Connections 260
- Figure B.24 261
- 1394-SA15 Cable Connections 261
- Figure B.25 262
- 1394 CE Requirements 262
- Understanding HIM Keys 264
- Understanding HIM Operation 266
- Understanding HIM Modes 267
- Linking Parameters 268
- Using Copy Cat 269
- Auto Tuning 272
- OPERATOR LEVEL 274
- MODE LEVEL 274
- FILE LEVEL 274
- GROUP LEVEL 274
- PARAMETER LEVEL 274
- Removing the HIM 276
- 8520 C 280
- 9/Series Integration and 281
- External Shunt Modules 282
- Control Interface Cables 283
- Single Axis Flying Lead Cable 283
- Two-Axis Prewired Cable 283
- 1326AB Servo Motors 284
- Catalog Numbers D-7 285
- 1326AH Servo Motors 288
- Power and Feedback Cables 289
- Motor Feedback Cables 290
- Miscellaneous Accessories 291
- D-14 Catalog Numbers 292
- Numerics 293
- I–2 Index 294
- Index I–3 295
- I–4 Index 296
- Index I–5 297
- I–6 Index 298
- Index I–7 299
- I–8 Index 300
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