Parker Compumotor 430 User manual

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Compumotor Division
Parker Hannifin Corporation
~ln 88-003360-03 C
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-, I Compumotor
Operator's manual^
430 TROUBLESHOOTING GUIDE
PIN: 88-006 107-0 1
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430 TROUBLESHOOTING GUIDE
1.0 INTRODUCTION
This guide
is intended to be helpful when experiencing problems with a model
430 indexer. The assunption has been made that the problem
is related to the
hardware of the 430 indexer, motor/drive, or any external devices interfaced
to the 430. If the problem you have
is related to programming the 430, refer
to Section 2.3.2 for assistance. Programing command
list is provided in
Figure 2-0 for an easy reference.
1.1 Test Equipment
Before you begin troubleshooting the 430, you should have the following
equipment available:
1. Small screwdriver
2. Model 431 programmer
3. Wire for jumpers
4. Voltmeter
The following equipment
is optional, but desirable:
5. Terminal with RS-232 transmission
6. Spare Model 430
7. Spare motorfdrive
8. Oscilloscope
-
...................
AC P3I;ER INPUT JUHPER BLOCK AND SHIELD STATUS INDICATION
Figure
1-1
1
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2.0 LED DIAGNOSTIC INDICATORS
The 430 has a tv~colorLED on the front panel (see Figure 1-1) vhich gives
you a quick visual indication of the indexer's condition. The LED can
be in
one of three possible States: LED OFF,
LED RED, or LED GREEN. Refer to Figure
1-2 for a pictorial representation of these conditions.
LED OFF
- Indicates that there is no power to the 430's power supply. See
Section 2.1 for a further description.
LED RED
- Indicates that power
is on and that the board monitor alarm has been
activated. This means that tho microprocessol:
is not executing its programs
properly. See Section 2.2 for further description.
LED
GREEN - Indicates that the power is on and that the microprocessor is
functioning properly. See Section 2.3 for a further description.
The following sections outline in further detail the possible causes and
solutions for each of the above conditons.
2.1 LED Off
'2.1.1
AC Power Missing
Check 430 power terminals for #correct
AC voltage as illustrated in Figure 1-3,
then check the wiring from
AC power source and reapply power. CAUTION: Be
sure to disconnect
AC voltage lbefore checking wiring. If
AC connections are
ccrrect, proceed to next section.
The 430 Operation Manuals
ui to and including Rev. C have indicated AC power
wiring configurations for 100
1J and 220 V. These configuratio..~ will damage
the power supply and should not be used.
2.1.2 Line Fuse Blown
Remove power from the 430 and check
AC line fuses for continuity. Refer to
Figure
1-1 for fuse location. If a fuse fs blown, replace and reapply power.
It is likely that a short exists in the 430 power supply if the replacement
fuse inmediately fails. If this occurs, retu~rnfaulty unit for repair. See
Section 3.0 for return materials assistance. If fuses are intact, continue to
next paragraph.
.
2.1.3 Faulty Power Supply
There
is also the possibility of a faulty power supply or some open circuitry.
Remove cover and verify that the two ramp-style connectors which carry power
from the two
5 volt power suppLies to the circuit board are attached. Refer to
Figure 1-4 for location of these connectors. If the connectors are in place
and the LED
is still off, retum unit for repair. See Section 3.0 for return
materials assistance.
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2.2 LED Red
2.2.1 Contact Bounce
Early versions of the 430 could experience intermittent faults if contact
bounce of a certain frequency was present on any strobe input, or on trigger
one. This can be eliminated by upgrading the 430 software to the latest
revision. As of May
1, 1986 the latest software revision for the 430 is
number 92-5012-11C/-01~. Refer to Figure 1-4 and for location of PROM's on
circuit board part numbers illostrated. When you are examining the PROM's.
check to ensure that the chips are installed ]properly. The chips have a
small
notch on one end. This notch 1;hould
be faciqz away from the screw terminal
connections. Also check the chips for proper insertion. If all of the legs
of the chips are not completelg inserted, the
PROM's will not perform as
required. Contact Compumotor's application engineering department at 1-800-
358-9068 for the most recent set of
PROM'S if new revision software is
required. If the PROM's are 92-5012A or later, proceed to next dipswitch and
jumper check.
2.2.2 Dipswitch and Jumper Settings
On 430's with internal CPU circuit cards labeled 'PCA 71-003270-01/-02",
dipswitch SW9 positions
5 and 6 must be ON fo3r boards to operate properly,
. while positions 7 and 8 must be OFF. Refer to Figure 1-4 for the location of
switches and jumpers on the 430's circuit board. Refer to Figure 1-5 and for
proper dipswitch and jumper settings.
On CPU circuit cards labeled 'PCA
71-003270-03", switch SW9 is a four position switch with two jumpers.
JU9 and
JU10, added. Make sure these jwmpers are on the left side of the circuit board
when viewing the screw terminal end of 430. When checking dipswitches and
jumpers, make sure each settiqz
is either completely ON or OFF. Be careful
not to set a dipswitch to a halfway oN/OFF setting. If jumpers and
dipswitches are in th- correct positions, cycle power and ~roceedto the
following paragraph if red liglht
still exists. If a green light is now
present, proceed to Section 2.3.
2.2.3 Cold Start
If the Red LED came on imediately after p0we.r-up,
it may be due to a
malfunctioning clock chip on the 430. Some 430's were built with Fujitsu 8284
clock chips. Some of these ch:Lps fail to ope.rate properly with the 430 design
until they are on for approxim.ately 30 minutea. Malfunctioning 430's with
Fujitsu 8284 chips should be returned to the factory for repair.
A Fujitsu
chip has a big "F" stamped on
it for identification. This chip
is found near
the microprocessor.
If the Fujitsu chip is present on circuit board, we
suggest that the unit be sent back for update.
2.2.4 Electrical Noise
When the red
LED comes on intermittently, it usually indicates the presence of
extreme electrical noise. Check the connections from the 430 to the
motorldrive (terminals 53-66) to ensure that all cabling
is shielded and that
one end of the shield
is connected to earth ground. If intermittant failures
persist,
it may be necessary to identify and suppress possible sources of
noise (i.e. inductive loads such as relays, solenoids or motor starters). You
should always avoid routing 430 cabling in close proximity to high voltage
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wiring. Also, if
YOU are using a 430 output !to drive a relay type load, be
sure to shunt back-EMF from the relay with a diode. This
will prevent
excessive voltage from being fed back into the output and consequently blowing
the output. Continue to next paragraph if re<dLED condition
still exists.
NOTE:
All indexer grounds should be terminated at the same point.
2.2.5 Microprocessor Fault
The red LED indicates that the microprocessor
is not able to execute any
commands. This
is most likely due to sane sort of component failure. Cycle
the power or reset the 430 by pulling the reset terminal 24 to ground. If the
LED immediately turns red again, return faulty unit for repair. See Section
3.0 for return materials assistance.
2.3 LED Green
If the LED
is green and the system is not functioning properly, the problem is
not likely related to the 430's hardware. When this occurs, we need to
isolate the problem; the motor/drive or the user's interface.
At this time a
spare indexer and motorfdrive would
be useful in isolating the source of
trouble. The sections below provide a description for each of the two LED
.- green conditions and give possible solutions to the troubles being
experienced. If the LED
is green and there is no motion, see Section 2.3.1.
If the LED
is green and there is motion, see Section 2.3-2-
2.3.1 No Motion LED Green
2.3.1.1 Holding Torque
,
Attempt to turn motor shaft with power applied to determine if full torque is
present. If no holding torque! is present, check the AC power connections to
the drive. Also, check to assure that remote pover shutdovn (terminal 32) is
not grounded. Refer to the troubleshooting chart found in the motorfdrive
operations manual for help. 1.f a spare motorfdrive
is available, connect the
cable from the 430 to the spare drive and verify proper operation. If there
still is no holding torque, gc~to faulty drive section. Otherwise, proceed to
the next section.
2.3.1.2 Overtravel Limit Switches (EOT switches)
The
CW and CCW limits on the 430 must be pulled to ground for motion to occur.
Verify that these inputs are ]!ow with respect to ground with a voltmeter. If
you read
5 volts on either of terminals 42 or 43, check the wiring frm your
limit switches. For proper operation, normally closed
limit svitches must be
used for the motor to move. 1:f
limit switches are not installed, make sure
that terminals 42 and 43 are jumpered to ground (terminal 22).
2.3.1.3 Jog Inputs
If overtravel
limits are in place, use a jumper wire from ground to terminal
25 or terminal 26 inputs to see if the 430 causes the motor to jog
in each
direction. If the motor jogs in each direction, proceed to section 2.3.2. If
the motor
still does not move, reset the 430 by pulling terminal 24 to ground.
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Now try the jog process again. If motors still do not jog, proceed to the
folloving section.
2.3.1.4 Test Move
Connect a Model 431 programmer to the 430. Remove the screv terminal block
from pins
1 through 22 and place the screv tenainal block connected to the 431
in
its place. If you do not have a Model 431, contact your local distributor
or Compumotor's application eqgineering department at 1-800-358-9068. See
Figure 1-6 for location of switches on 431. This device should
be connected
to the lov true end for proper interface vith the 430 unless the 430 has been
changed to operate on high true signals. Nov place a 0255 on the thumbvheels
and activate the command strobe (switch labelled
MD STB). This will cause the
430 to command the motor/drive to perform a one revolution move in the
CW
direction, and then a one revo:lution move in ,the CCW direction. The
CW and
CCW motor rotation is the movernent direction when viewing the front end of the
motor's mounting flange. After the
CCW move is completed, the LED will turn
red. When this occurs, simply reset the 430 lby grounding terminal 24. If the
above motlon does not occur, connect 431 interface to 430 to the high true end
and repeat the above proceedure. If the overtravel
limits are not in place no
motion
will occur and the LED will turn red irmediately. If the LED does not
turn red immediately, but the motor does not move, the indexer/drive cable may
be faulty. Repeat this test v:Lth a spare cable (refer to Section 2.3.1.2).
If the 0255 move does not occur vith 431 connected on lov or high true, go to
431 functional test. Otherwist?, see Section 2.3.2.3.
2.3.1.5 431 Functional Test
To check this, set the 431 pn the low true end and put a 9999 on the
rhumbwheels. Now check the 430 bits 0-15 vit'h a voltmeter for proper values.
Eae Figure 1-7 for proper voltage readings on each bit. Repeat this
proceedure vith a 6666 setting on the thumbvheels. If voltages shovn in the
figure correspond to measured values, the 431 is fuctioning properly. If your
430 is configured to operate
on high true signals, the voltages will be
opposite from what
is shovn (i.e.. 0 volts vill be 5 volts and so on). If the
voltages correspond nov, proceted to the jog inputs section. However,
if the
voltages do not check, examine the wiring from the 431 to the 430 for proper
connections and continuity. Now attempt the test move process again and
proceed to next paragraph if no motion occurs.
2..3.1.6 Faulty Drive
If the motor has no holding torque, this
is a good indication that the drive
is faulty. The easiest way to determine this is to connect a spare drive to
the 430, or monitor the pulse output with an oscilloscope. To check with a
spare drive, disconnect the cable from the existing drive and connect
it to
the spare motor/drive. Check to see
if this drive nov has holding torque
present. If the new motor/drive vorks, return faulty unit for repair. See
Section 3.0 for return materials assistance. Make sure when you are
connecting the new motor/drive that the cable is shielded and one end
is
connected to earth ground. If new drive functions properly, proceed to the
next paragraph. If spare drive also does not function, go to pulse output
failure.
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2.3.1.7 Pulse Output Failure
A spare indexer can be used to check the existing drive, or the step output on
the 430 may be checked with an oscilloscope. If you have a spare 430 indexer
available, connect
it to the existing motorldrive to see if it operates
properly. To check with a scope, first disconmect the rnotor/drive wiring from
the STEP+ and STEP- terminals
59 and 60. Isolate your scope from AC ground.
With your scope probes connected to terminals
59 and 60, you should see 5 volt
positive going pulses. These pulses should be approximately one microsecond
wide when the 430
is operating. If the system
is operating properly, go to
next section for programming assistance if desired. If the 430
is not sending
pulses, return the unit for repair. See Sectlon 3.0 for return materials
assistance.
2.3.2 Improper Motion
LED Green
This section
Is designed as a @de in troubleshooting the system when there
is motion at the motor, but for some reason the system is not functioning
properly.
It makes the assumption that the problem is now related to
programming the 430 indexer.
'2.3.2.1 One Limit Switch Floating
If one
limit switch is grounded and the other is not, the 430 will move the
motor in one direction but not the other. The motors
will be capable of
moving in the direction of the
limit
that is grounded, but will not move in
the direction of the ungrounded
limit.
If this seems to be the case, go to
the
limit switch section fof assistance on checking the limit switches
(Section 2.3.1). Aftel the
lirnits are checked, reset the 430 by pulling
terminal
24 to ground. If this does not help the situation, proceed to the
following paragraph.
2.3.2.2 Test Program
At this point, a terminal with RS-232 interface will be very helpful. If you
have a terminal available, connect the interface as shown in Figure 1-8.
A
model 431 can also be used to strobe the test program into the 430. Refer to
Figure 2-0 for the listing of all 430 programming commands as needed. If
detailed information
is needed, refer to the 430 Operator's Manual page number
referenced next to each command. Before you begin the test program, reset the
indexer by grounding terminal :!4. Refer to Flgure 1-6 for location of data
registers if you are using the Model 431 to program the test move. When using
Model 431 to strobe the information found below into each register, the 430
retains the most recently strohed data for eac:h register. If the data for a
given register does not change from one command to the next, the data does not
need to be re-strobed for that register.
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REGl
0000
0000
001
1
0013
0011
0000
0011
0006
0000
0000
0000
CHDSTB
0261
0262
0200
0217
0064.
0041
00641
001:1
0216
0292;
0291.
DESCRIPTION
Set acceleration to
50,000 stepslseclsec.
Set velocity to 50,000
stepslsec.
Define move 611.
Define sequence 613
beginning point.
Execute move 611.
Delay for
1 second.
Execute move 611.
Turn on both outputs.
Define sequence end.
Enable autorecall.
Save all parameters.
After you have entered this information, cycle power to the 430. Set the
thumbwheel switches to read 13 and pull terminal 27, labeled SPECIAL, to
ground terminal 22. This will cause the sequence you have entered to begin
execution. The move performed should be
8 one revolution move in CW
direction followed by a delay of one second, then one revolution move in CW
direction with both outputs enabled after this move is completed. Check. with
a voltmeter, terminals 30
& 31 for a 5 volt reading. If the entire program
checks out, you have programmed one move and one sequence successfully. This
also indicates that the 430's storage into memory and autorecall on power-up
is functioning properly. If you need to erase all contents in the EEPROM,
this
is acomplished by inputting the information below to the 430.
REGl REG2 REG3 REG4
(3?D STB DESCRIPTION
0000 0000 0000 0000 0293 Disable autorecall
0000 0000 0000 0000 0291 Save
The save program changes the entire contents of permanent memory to match the
contents of the working memory. If the working memory
is blank, the save
program
will blank the permanent memory. If the move was not executed as
described above, refer to next paragraph.
2.3.2.3 Error Terminal Status
Jumper the pullups, terminal 46, to 5 volts, terminal 45, then check the error
terminal, 23, with
a voltmeter. When this pin reads +5 volts, it indicates
that the indexer is functioning properly.
A low voltage reading (.6 V)
indicates a component failure in the 430. This; output will go low if there is
a failure in the EEPROM of in the static RAM.
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3.0 RETURN MATERIALS PROCEDURE
If your 430 indexer or motorfdriver requires repair, follow the proceedure
listed below for the most rapid turnaround.
1) Obtain the serial number of unit to be returned.
2) Obtain a purchase order number for returned units.
3) Contact the factory at 1-800-358-9068 for
a return
materials authorization number
(RMA number).
4)
Package unit in original package or equivalent protection for shipment.
Include
a note in the box stating the reason for return.
5) Write RMA number on the box before shipment.
6) Send boxed unit to:
COMPUMOTOR CORPORATION
1179
N. McDowell Blvd.
Petaluma,
CA 94952
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LED TROUBLESHOOTING FLg3W CHART WITH S:ECTION TOPICS
LED STATUS
: (See Section 2.0)
-r-------------^-------------&--------.-------- 7
LED GREEN LED RED LED OFF
:(See Section 2.3) (See Section 2.2) (See Section
2.1)
A) Contact bounce A) AC power missing
B) Switch settings B) Line fuse blown
C) Cold start-up C) Bad power supply
D) Electrical noise
D) Return unit
E) Processor fault
F) Return unit
...............................
NO MOTION IMPROPER MOTION
See Section 2.3.1) (See Section 2.3.2)
A) Limit switches
A) Test program
B) Rolding torque B) Error terminal status
C) Jog Inputs C) Obtain a new EEPROM
D) Test move
E) 431 test
F) Faulty drive
G) Pulse output failure
H) Return unit
Figure 1-2
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120 VAC .
LINE -
NEUT
G ND
AC LINE -240 VAC (BL
At NEUT (h'HITE)
AC CIiD (GREEN)
240 VAC
Figure 1-3
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ON
OFF
VIEW OF CIRCUIT BOARD SHOVING
INTERNAL DIP Sh'ITCHES Ah'D JUWERS
CIRCUIT BOARD
CONTAIKING
INTERKAL DIP
SVITmES Ah'D
0
0
0
AC PO~TR IKPUT JUHPER BLOCK/
Id
AC PROTECTIVE SHIEL /
[ STATUS INDICATOR
figure 1-4
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Table 3-1. Hodel 430 Factory DIP Switch and Jumper Settings
DIP Switcl
sv1-1
SW 1-2
SWl-3
SW1-4
SW1-5
..
sui-6
SW1-7
SWI-8
-
sw2-1
SW2-2 '
SW2-3
SW2-4
SW2-5
SW2-6
SW2-7
SW2-8
SW3-1
SW3-2
SW3-3
SW3-4
Su3-5
SW3-6
SW3-7
SV3-8
SW4-1
SW4-2
SW4-3
SW4-4
SW4-5
SW4-6
SW4-7
SU4-8
Settinl
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
OFF
OH
OFF
OFF
Setting
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
OFF
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
DIP Switch
SW9-1
SW9-2
SW9-3
SW9-'I
SW9-5
SW9-6
sw9-7
SW9-8
JU-
1
JU-2
JU-3
JU-4
JU-5
JU-6
JU-7
JU-8
Settin(
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Figure '1-5
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431 PRDGRARMER .FUNCTIONAL TEST
431 Settingi19999
L
BITS:
VOLTAGES:
431 Setting86666
I
- - - - - - - - - - -. -- - - - - - - -
BITS: 12 3 4r56 7 B 9 1C) 11 12 13 14 1
VOLTAGES: &JJ& Jlf~~~2J-2iJio~10~-3]f5~~], - - - - - - - - - --
Figure 1-6
Figure 1-7
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KALE
25 PIN-D
NOTES: 1. 1200 BAUD
8 DATA BITS
2 STOP BITS
0 PARITY
. .
- a3
.
i--E
2. LBSOLDIg AND
READY MY NEED
TO BE SWITCHED
.-
--I
HOST
>
I'igure 1-8
c--
-2 =
45 +5 VOLfS
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430 COM?III??) ALPHABETICAL LISTING
and
-
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[w25] mldu mvc TL)LICIIII~ w SIAU Bznn
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nn rcu wnlrm
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[WWI um w ucaos
10os31
w1n w mmru
toor11 urn ror
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1~161
93 rrnn ram rrno
[oout]
sn a610 Lm unn rm ZERO
(~181 sn TIQ rmmrmnm 1.5 rsvrvrr rrro
[00501 cum
mnrrwm mm
[w511 mmz rruoI.m AN nnrrenrL mvr
IWYI rucm ~LNMII u usarm mr
1~531mmrnmm-rm, rrel+cnrr mvr
,- ."<.,.,
10091 CQCLTC DDSPI-LW IIURVK KNC
f
.~~ ~~~ -~
100651mmr A ruocr~nr~s&ma
100721 COnI*YE
101t21
STU IOTlm
101l11 SusrrxD 1w
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lev'] rrrx*r rnr RATIO-6- mom srwr lo r~mtcasror
arrarn~prc~uran
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Figure 2-0
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Compumotor
Operator's Manual
ADDENDUM: 430 NEW COMMANDS
PIN: 88-006 140-02:
Rrlor Hannlfln Corpontion
Conpnmr Division
1179 N. MCcOaell Blvd.
Wuma C4 94952 US4
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Supplement to
Colapumotor Model 430
Operator's
Manual:
Nev Commands
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