Error: Motor turns in neither direction of rotation
Cause no. 1: Soldered fuse of surge limiter BN 1778. 715 is open.
Indication: All LED in order, bimetal clip open
Error cause: Mains transformer badly connected on the primary side ?
Excessive intermediate circuit voltage, caused by feedback of excessive braking energy, for example by constant braking action of motor.
Surge limiter defective?
Elimination: Re-establish soldered fuse connection by soldering. When doing so, make sure to retain the spring force of the bimetal.
Check: under normal operational conditions the red LED of the surge limiter p.c. board must be OFF. It may only light up briefly when the motor is reversed.
Cause no. 2: Short-to-ground responds
Indication: Yellow LED (front panel) lights up; red LED on ground plate, or on older devices, red LED on additional board HL 6454.1439 on the first slot of the motherboard lights up.
Error cause: Accidental ground of one or both motor lines to the motor housing.
Caused by parting of cable in the motor line and resulting accidental ground to the cable shield. By a worn-through motor cable. By dust of the brushes which caused arcing to the motor housing.
Elimination: In case of parting of cable install a new motor cable, check the motor, take measurement with an ohmmeter or high-voltage tester between motor housing and one motor cable.
While doing so turn the motor shaft manually in order to detect a short over an entire rotation of the motor. In case of accidental ground, replace the motor.
Important! For these measurements, the device must be turned off and the motor disconnected. In order to reset the stored display messages, the yellow and red LED on the device, turn the mains voltage off and re-connect it.
Check: Under normal operational conditions the red LED on the motherboard or on supplementary board HL 6454.1439 as well as the yellow LED on the front panel must be OFF.
Cause no. 3: Connection error or defective supply line Indication: Yellow LED (ESR front side) lights up.
Error cause: - Enable input is open (terminal 15)
- Limit switch input is open (terminals 6 and 7) - Line break at these inputs
- Short-to-ground, simultaneously the red LED lights up.
Elimination: Measure the inputs (terminals 6, 7 and 15) to 0V (terminal 20) with voltmeter. The inputs must be at 0V, in case of a malfunction the inputs go up to approx. +14V. Eliminate accidental ground in motor line.
Cause no. 4: Maladjustment or fault in motor circuit Indication: Red LED (ESR front side) lights up.
Error cause: - Current limit set too low - Motor locked
- Motor connection lines short-circuited one against the other
Elimination: Check motor lines for short circuit. Switch ammeter into motor line. Current limit was too low and must be redefined. To do so, lock the motor. The pulse current will flow for some seconds. After that the devices switches back to constant current and the red LED lights up. In this condition the current is adjusted to the nominal current of the motor by means of the current limit potentiometer (front panel).
Check: The ammeter should be monitored for some time throughout the intended operation of the machine. In any case the mean current must be sufficiently below the adjusted current limit.
Cause no. 5: Interruption in motor circuit Indication: All LEDs (ESR front side) are in order Error cause: - Motor line interrupted
- Defective motor - Defective output stage
Elimination: - Measure nominal value input (terminals 11 and 12)
- Check carbon brushes of motor, use new ones, if necessary, or replace motor.
- In case of defective output stage, replace entire plug-in section.
Cause no. 6: Power supply error
Indication: Green LED in ESR front panel does not light Error cause: - device is not switched on
- no mains voltage
- +/- 14V Reference voltage short-circuited Elimination: - Check back-up fuses of device
- Verify mains voltage at transformer of device (under left-hand side cover)
- Measure reference voltage + / - 14V ( terminals 13 and 14 ) to 0V ( terminal 20 ) Cause no. 7: Activation error
Indication: All LEDs ( ESR front side ) are in order. Motor is at a standstill at the moment or is drifting slowly into one direction
Error cause: No nominal value available
Elimination: Measure nominal value input (terminal 11 compared to 12) Error: Motor runs without any control
Error cause: - Tachometer generator of motor badly poled - Tachometer line of motor broken
- Superimposed control circuit does not coincide with the direction of rotation of the motor
- Servo board jumper plugged incorrectly Elimination: - Check connection of motor cable
- Measure tachometer voltage again (terminal 4 to 5)
- Interrupt any superimposed bearing control circuit (disconnect transmitter signals) If the motor still does not run with speed control, exchange the connections of the tachometer or the motor. If the direction of rotation is correct, the bearing control circuit, if available, can be switched on again. If the motor runs without control, exchange the transmitter signals of channel 1 and 2.
Error: Motor is running rough and uneven
Error cause: - Switches of reversible PI wiring are maladjusted or not closed - Potentiometer of feedback is badly adjusted (ESR front side)
Elimination: - Verify switch position of PI wiring and set according to preset values
- Adjust potentiometer of feedback. Turn counter clockwise, until the motor runs perceptibly rough, then turn slowly clockwise until the motor runs smoothly over the complete speed range. Finally check brake afterrun and drift.
Error: Zero point cannot be set Error cause: - Zero loop in the wiring.
- There is still one nominal value from the control system.
Elimination: - Check wiring.
- Check activation of differential amplifier in the device (white colored wire on motherboard) must be separated or removed).
Verify nominal value at input (terminals 11 and 12).
Check: Disconnect nominal value from device and bridge terminals 11 and 12. Then adjust the zero point. To do so, watch the motor shaft or measure the tachometer voltage.