QCPort Cover Control Trouble Shooting Guide

QCPort Cover Control Trouble Shooting Guide Technical Document Feb. 2006 Page 1 of 14

QCPort Cover Control Description Door Defeater Address/Options Bucket Latch Breaker Actuator Hasp Lock Keypad Overlay Page 2 of 14

Table of Contents QCPort Cover Control Description...2 Table of Contents...3 Supporting Documentation...3 LED Function Matrix...4 Trouble Shooting Guide...5 General Troubleshooting Hints...5 Communication Troubleshooting...8 Explanation of LED duty cycle states...8 Communication Hints...9 Field IO Wiring Information...11 Default IO Data...12 Input Data...12 Motor Control Faults...12 % FLA Word...12 % Thermal Memory...12 Motor Control Status...13 Output Data...14 3-Wire Control Output Data...14 Motor Control:...14 Supporting Documentation Manual Name QCPort Cover Control Programmer Guide D77D-DNA Users Manual D77D-EMA Users Manual D77D-PNA Users Manual D77D-EIP Users Manual NEMA IT Starter User Manual Reference Number MN05009001E MN05004002E MN05002002E MN05008001E MN05008003E MN03305001E Link to search Eaton Electrical Web site www.eatonelectrical.com Page 3 of 14

LED Function Matrix LED State LED Condition Off On SLOW FLASH FAST FLASH OFF Running Stopped E-Stop asserted FWD Running Forward Commanded to run and has not received status from aux contact that starter is pulled in FWD & OFF Stopped, hand, hard wired R1 enabled REV Running Reverse Commanded to run and has not received status from aux contact that starter is pulled in REV & OFF Stopped, hand, hard wired R2 enabled AUTO Hand mode Auto mode HAND Auto mode Hand mode 3 TRIP 3 Warning/fault OL TRIP High Temp fault Phase Loss fault Phase Imbalance fault Thermal Capacity fault Test Trip OL TRIP Reset asserted Resetting OL Trip GND FLT Ground Fault Warning or Fault GND FLT Reset asserted Ground Fault Warning Resetting Ground Fault trip 3 TRIP OL TRIP GND FLT 3 TRIP OL TRIP GND FLT All (7) LEDs Alternating FWD / REV Reset asserted Power up, Reset, or manual LED Test ON momentarily Application Communication Fault Press Rest button to clear Illegal Motor Direction Command Resetting Application Communication Fault Status No power Mostly On OK and is being actively scanned OFF & RUN & HAND Alerting the user that the unit is capable of running, however something is not allowing the starter to run such as the handle being in the OFF position. Mostly Off OK and is ready to be scanned 50% duty cycle device is faulted Strobe Undiscovered or Identify Page 4 of 14

Trouble Shooting Guide General Troubleshooting Hints Problem The STOP led is flashing Solution The E-Stop circuit is open. Refer to the wiring section of MN05009001E for proper wiring guidelines of the E-Stop circuit or the wiring diagram supplied with MCOVER CONTROL. Check that the terminal block located inside the bucket on the Interface Module labeled E1, E2, +, E is installed properly with the two jumpers from E1 to + and E2 to E. All three fault LEDs are flashing Check the 11 pin terminal block of the Interface Module in wire way has the jumper installed between E1 and E2 and that the terminal block is seated properly. This represents a loss of communication between the Cover Control and the starter. Verify that the harness between the Cover Control and the starter is correctly installed and all the wires are tight into the 8 pin terminal block on the IT starter. Verify that the aux contact is properly installed on the starter and that the harness is properly connected to both the aux and the Cover Control. Verify that the starter has power by pressing the test button for a short period of time; the status LED on the starter will illuminate. If the Cover Control was moved from one starter to another with a different OL range, a reset will be required to rematch the Cover Control and the starter. For version 1.5 and prior, to reset the Cover Control with out affecting the input and output data tables is to perform an Application Parameters Reset. This is performed by setting all the DIP switches on the Cover Control to the left, and toggling the second from the bottom (Group ID 2 or Switch 7) 5 times from off to on. When you have toggled the switch enough times all the LEDs on the Cover Control will pulse on. This will re-associate the Cover Control to the starter. Make sure to rest the DIP switches back to the original configuration. For version 1.61 and greater simply press the reset button. The Cover Control may have a board failure and will need to be replaced. The starter may be damaged and need to be replaced. Page 5 of 14

Problem Pressed the HAND button and the HAND, RUN and OFF LED are illuminated. The Three Phase trip LED is flashing. The GF Trip LED is flashing. For the HOA overlay, when the Cover Control is in Hand, the starter cannot be energized. For Reset Only overlay the starter cannot be energized. Pressed the HAND button and the HAND, RUN and OFF LED are illuminated. Solution This indicates that the unit was commanded to run and that one or more permissive have not been met to allow the unit to run. For example, the unit is in field control, the HAND button is pressed and the field commands a RUN. The Handle is OFF and factory defaults for Breaker Off Run Disable is used which disables a run when the handle is OFF. Once the handle is changed from OFF to ON the starter will energize. This is signaling that the breaker has tripped and will need to be reset. After resetting the breaker, the Reset button on the overlay needs to be pressed. Refer to the wiring diagram for the bucket, if there is not an aux contact installed in the breaker the MM DIP Switch on the Cover Control needs to be disabled. Refer to D64 manual for operation of Ground Fault module for resetting of the module. Refer to the wiring diagram for the bucket, if there is not Ground Fault adapter installed in the breaker the GF DIP Switch on the Cover Control needs to be disabled. The jumper from 4 to 5 on the IM (interface module) in the wire way is not installed. This jumper is for switching from Local to Remote control while in hand. Local control (open) signals that control is from the terminals while Remote control (closed) signals that control is from the keypad. When the Local/Remote circuit is open, there needs to be a valid run command on the Run1 terminal, terminal 3, signaling that is OK to operate in Hand. If none of these solutions work, contact factory since Cover Control may not be properly configured. The jumper from 4 to 5 on the IM (interface module) in the wire way is not installed. This jumper is for switching from Hand to Auto control. Hand control (open) signals that control is from the terminals while Auto control (closed) signals that control is from the industrial network. When the Hand/Auto circuit is open, there needs to be a valid run command on the Run1 terminal, terminal 3, signaling that is OK to operate in Hand. If none of these solutions work, contact factory since Cover Control may not be properly configured. This indicates that the unit was commanded to run and that one or more permissive have not been met to allow the unit to run. For example, the unit is in field control, the HAND button is pressed and the field commands a RUN. The Handle is OFF and factory defaults for Breaker Off Run Disable is used which disables a run when the handle is OFF. Once the handle is changed from OFF to ON the starter will energize. Page 6 of 14

Problem The starter will periodically drop out while running. Solution Check the length and routing of the E-Stop wiring. It is possible that the length of the E-Stop circuit is too long. To test this place a jumper between E1 and E2 on the IM terminal in the vertical wire way and see if the problem goes away. If it does an interposing relay may need to be installed between the E-Stop circuit and the IM terminals. Verify that the control program is not dropping the starter out inadvertently. One or more of the Cover Control units are not communicating back to the D77D-DNA and the system controller or the data is not correct with in the system controller. Check the system controller to verify that the scan bit is set in the Network Adapter (bit 0 of byte 0 for CH_A and bit 0 of byte 1 for CH_B). Verify the offsets with in the memory map in the system controller for errors. Has a constant Fail to Open or Fail to Close warning. While On-Line with CH Studio the Network Adapter or the Cover Control disappears. While looking at the Cover Control it is noticed that the status LED (LED located near the Eaton) is solid on. Check the status LED for the selected devices for consistency with working devices. The auxiliary contact on the starter is damaged or missing. The jumper from JP2 to the auxiliary contact is damaged or unplugged. It may be that the controller is not allowing enough time for the CH Studio messages and the connection between CH Studio and the Network Adapter is timing out. You may have to take the system controller off-line to continue. If no other LED s are on it is possible the Cover Control was placed into a firmware download mode, cycle power to the Cover Control and see if the LED behaves properly. It is possible that you are looking at a non QCPort COVER CONTROL, for that type of Cover Control the status LED is a power indication and is always ON. Refer to the wiring diagram for the bucket to verify if the bucket is communicating or non-communicating. Page 7 of 14

Communication Troubleshooting Explanation of LED duty cycle states Mostly Off One short blink ON every 2 seconds Mostly On One short blink OFF every 2 seconds 50% ON and OFF blinking same amount of time; ½ second cycle Rapid Flash Strobe Status LED Description Explanation Mostly Off Offline and The Cover Control has been acquired by the network configured adapter and is not being scanned. Check that the network adapter is commanded to scan QCPort. This is done by setting bit 0 of byte 0, for channel A, in the output assembly. Mostly On Online Everything is OK with in the Cover Control and the Cover Control is being scanned by the network adapter. 50% On Faulted Internal memory fault (cycle power) Verify that there are not any duplicate Group ID s (address). Check that the address is unique for the QCPort system. The Group ID was changed and a reset is required Rapid Flash Unacquired Buss fault. All the devices on the QCPort will have the same status LED behavior. A buss fault is caused by an open or shorted buss. The Cover Control has not been discovered/acquired by the network adapter, verify that the node ID is set correctly for the system. The network adapter has not auto configured the QCPort system. In this case all the Cover Control s will have the same behavior of the status LED. Perform an auto configuration. Solid On CH Studio is identifying that bucket. When the bucket is highlighted in CH Studio this is a way to identify in the field which bucket is being highlighted. Remove the highlight from CH Studio and verify that the Rapid Flash disappears. It is possible the Cover Control is in firmware download mode, cycle power to exit that mode. If the LED stays solid On after the power cycle the Cover Control may be a non communicating Cover Control or the memory is corrupt. Off No Power The Cover Control is not powered or a memory fault in NV RAM has occurred that will require the Cover Control to be replaced. Page 8 of 14

Communication Hints Problem Solution Check the Network Adapter, is the ST LED Green? If the LED is green, then perform an auto configuration of the Network Adapter and see if the problem goes away. There may be a damaged Cover Control or a shorted blue communication rail that is prohibiting QCPort from working. Unrack all the Cover Control s so the 24Vdc is no longer on the buckets; pull out approximately 1 inch. Unplug the Network Adapter from the industrial network. Are all the buckets connected to one Network Gateway with in the MCC not communicating? Are all the Status LED s either Rapid Flash or 50% On Cycle power to the Network Adapter. One by one rack the buckets and verify that the status LED is mostly off as they are racked. When the bucket the causes the structure to fail is plugged in, the Cover Control s status LED will rapid flash or 50% flash only. Remove the bucket and verify that the blue rail connector is not damaged. This can be done by using a flashlight to view if the tabs inside the connector are damaged. If the connector is damaged that bucket cannot be used at that location until the rail is replaced. If the connector is not damaged, replace the Cover Control. When all the buckets are online, plug the Network Adapter into the industrial Network. It is possible that the terminating resistors are damaged, replace the terminating resistors located in the power supply buckets at both ends of QCPort (blue rail) system. Page 9 of 14

Problem Is there a single bucket in the MCC that is not communicating? During auto configuration the Network Adapter will not detect any of the buckets. Solution The problem may be that the single bucket has a fixable internal communication failure. To reset the Cover Control with out affecting the input and output data tables is to perform an Application Parameters Reset. This is performed by setting all the DIP switches on the Cover Control to the left, and toggling the second from the bottom (Group ID 2 or Switch 7) 5 times from off to on. When you have toggled the switch enough times all the LEDs on the Cover Control will pulse on. This will re-associate the Cover Control to the starter. Make sure to rest the DIP switches back to the original configuration. It is also possible the Group ID DIP switches were changed after auto configuration. Check the DIP switches and verify that they are in the correct position for that address. Physically move the DIP switch from one position to another to verify that it is in the correct position (there will be a snap when it reaches the ON or OFF state). Unrack the bucket to remove 24Vdc from the bucket only and then rerack the bucket and check that the problem disappears. It is possible that the communication jack is damaged or unplugged; replace the cable between the Cover Control and the blue communication rail. It will be necessary to remove the bucket to check the plug that connects the bucket to the blue rail. It is possible that the connector s C clip is no longer holding the connector in place. It is possible that the Network Adapter is damaged, replace the Network Adapter. It is possible that the terminating resistors are damaged, replace the terminating resistors located in the power supply buckets at both ends of QCPort (blue rail) system. Check the status LEDs on the Cover Control units, if the LEDs are rapid flashing or 50% On refer to the above problem for a solution. If the status LEDs on the Cover Control units are all slow flashing, the Network Adapter has already connected to the Cover Control units and the problem is that the CH Studio software is not displaying the Cover Control units. This can be because the scanner is not allowing CH Studio to send long messages. The Network Adapter cannot perform an auto configuration if the system controller is scanning the Network Adapter. Disconnect the Network Adapter from the industrial network and reattempt the auto configuration. Page 10 of 14

Field IO Wiring Information The interface module terminals are broken into 3 basic functions. Terminals +, E, E1, and E2 on the unit's side of the input module and terminals E1 and E2 on the wireway side of the input module are used for E-Stop circuits. By default the E-Stop is jumpered from E1 to E2, it is up to the customer to connect the external E-Stop wiring and remove the jumper if one is required. Terminals 1, 2, 3, 4 & 5 on the wireway side of the input module are used for control inputs from field devices. These inputs have an internal 250 ms debounce which will remove any false starts or stops due to bounce from an external input. Depending on the voltage style of the interface module, terminal 5 will source 24Vdc (DC version) or be the neutral for the 120Vac (AC version). Terminal 6, 7, 8 & 9 on the wireway side of the input module are N.O. relay outputs for indication of unit status. These relays are isolated and are suitable for AC or DC. 9 NO Fault Relay 8 NO Fault Relay 7 NO Auto Relay 6 NO Auto Relay 5 - +24Vdc or neutral for 1-4 4 Local (field wiring) = open, Remote (keypad or auto) = closed 3 Run/Forward when 4 = open 2 Reverse when 4 = open 1 Remote reset + E E1 E2 IM Fault Output [9] Fault Output [8] Auto Output [7] Auto Output [6] +24/L2 [5] Local/Remote [4] Run 1 [3] Run 2 [2] Reset [1] E-Stop [E1] E-Stop [E2] Wire distances measured in total wire (out and back) for E-Stop and control circuits. Wire Gauge E1, E2 Control Inputs 12 700 ft 4600 ft 14 450 ft 3000 ft 16 280 ft 1800 ft Page 11 of 14

Default IO Data Input Data Data Byte Motor Control Fault Word High Byte 0 Motor Control Fault Word Low Byte 1 % FLA High Byte 2 % FLA Low Byte 3 % Thermal Capacity 4 Motor Control Status 5 Motor Control Faults Bit Description 0 Phase Loss (Loss of one or more of the line phases or a Circuit Breaker Trip) 1 Phase Imbalance (current imbalance of greater than 50%) 2 Thermal Overload (starter trip due to thermal overload) 3 Reserved 4 Reserved 5 Ground Fault (trip due to a ground fault, separate ground fault sensor required) 6 Reserved 7 Reserved 8 Device Over Temperature (Device temperature limit exceeded, S751 only) 9 Reserved 10 Reserved 11 Motor Control E-Stop (Device is in the state of an Emergency Stop) 12 Reserved 13 Reserved 14 Reserved 15 Other, refer to Application Status (0x0004) and Fault Queue (0x001A) % FLA Word The % FLA word is a real number of 0 to 65535 that indicates the % of FLA that the motor is running at. The % FLA is the running current divided by the FLA setting on the overload. For example, %FLA of 100 equals the RMS average current equal to the FLA setting on the overload. % Thermal Memory The % thermal memory is a byte that models the temperature of the motor. When the % thermal memory reaches 100%, the overload will trip on thermal overload. Page 12 of 14

Motor Control Status Bit Description 0 Running 1 (starter is commanded to run forward/fast) 1 Running 2 (starter is commanded to run reverse/slow) 2 Permissive 3 Reserved 4 Local Control 5 Faulted 6 Warning 7 At Reference Running 1, if this bit is set, it means that the Cover Control is commanding the starter to run (fwd) and has applied 24V to both the permissive and the run1 (FWD) terminals of the starter. It does not mean that the unit has energized, only that it has been commanded to. Running 2, if this bit is set, it means that the Cover Control is commanding the starter to run (rev) and has applied 24V to both the permissive and the run2 (REV) terminals of the device. It does not mean that the unit has energized, only that it has been commanded to. Permissive, if this bit is set it means that the Motor Control permissive is set. Local Control, if this bit is set, the motor controller is being controlled by the key pad or by the field wiring. When this bit is not set, rick the cover control is being controlled by QCPort and is in auto. This bit is set by the action of the HAND or STOP button only on the Cover Control. Fault, this bit is set when a fault has occurred. This could be any of the faults listed. It is latched and requires a reset to clear the bit. Warning, this bit is set when a warning is present. This could be any of the warnings listed on page Error! Bookmark not defined. Error! Reference source not found.. It is not latched and will automatically clear when the warning clears. A reset has no affect on a warning. At reference, this bit indicates the state of the auxiliary cross bar sensors located on the motor controller. When the contactor is pulled in this bit is true, when the contactor has dropped out, this bit is false. A contactor that failed to open, for example, will show up as the At Reference bit being true, the Run1 (or Run2) being false and a warning bit that is true. The warning will be a failed to open warning. For a S751 softstart, this bit will represent when the S751 is in bypass. Page 13 of 14

Output Data 3-Wire Control Output Data Motor Control: Data Byte Motor Control (byte) 0 Bit Description State 0 Run 1 (command the primary contactor to energize) Momentary 1 Run 2 (command the secondary contactor to energize) Momentary 2 Permissive (permissive to energize the starter) Maintained 3 Reset Momentary 4 Reserved NA 5 Reserved NA 6 Reserved NA 7 Reserved NA Run1, this bit and the permissive must be true for the motor controller to energize in the forward direction. Once the motor controller is running, this bit is not required to be true to continue running. Run2, this bit and the permissive must be true for the motor controller to energize in the reverse direction. Once the motor controller is running, this bit is not required to be true to continue running. Permissive, this bit is required to be set any time the motor controller is expected to be running. If the permissive is not set, the motor controller can not run. The internal logic is a 3 wire control circuit, permissive has to be true and maintained to energize the starter (and keep it energized). The Run 1 ad Run 2 commands are momentary, though one can keep this maintained with the Permissive and drop both the bits (Run1 and Permissive or Run2 and Permissive) when a stop is required. Page 14 of 14