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FMH E-STOP FAULT DIAGNOSIS

Fuse Holders

 

Before condemning a Motor, please check inside the fuse holder. The collars on the cables can be insecure causing juddering motor symptoms.

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Speed Controllers

 

When fitting a new speed controller please transfer from the old unit the following-

  1. Horsepower Resistor

  2. Fuses (if not blown)
     

The unit will not function without the above items.

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Run Contactor (JB under master section)

 

The centre pole of the contactor is used to send a Run signal back to the plc.

 

If the section is running but showing on the HMI as stationary, it is likely this pole has failed.  Check the resistance across the pole.

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Master JB PSU

 

We have had these fail several times, the section will show as faulted on the HMI.

 

Check the LED is illuminated and confirm by checking for 24v DC on the output terminals

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Button Stations (Fingers & Inducts)

 

If the finger or induct will not start check the following-

 

  1. Red blocks for continuity when not pressed.

  2. Green blocks for continuity when depressed.

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Swap out as required.

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Harting Connections

 

  1. Check the Harting connections are fully home, and clips secured.

  2. If the cable shows signs of being pulled, please check the terminations internally.

  3. There must be an end of line Dummy plug in the last section to link the Stop signal.

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Estop Issue on Transverse

 

The situation shown with both A & B flashing is normal when an estop is pressed.  On releasing the Estop button B should stop flashing and A will stop flashing once the Reset button is pressed.

If this is not working please see below points 2b, 2c and 2d.

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If B does not stop flashing then this means the PLC thinks the button is still depressed.  This could be the N/O contact block in the button station is stuck (C) on the picture on the left.

 

A and B on the image are the two N/C channel contacts for the Estop button.

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If A is still flashing and no Estop buttons are depressed then you likely have a break in the Estop circuit.

 

Confirm by looking at the Estop unit-

Left image shows healthy ESR.

Right image shows Unhealthy ESR.

 

Refer to Estop diagnosis section of this guide.

Estop fault diagnosis.
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  • If the ESR IN and OUT LED`S are lit up and you still have the HMI showing an Estop fault then check the fuses F6 and F7 in circle A.  This is the control voltage fed to the panel devices when the ESR is healthy, this is where the PLC gets its healthy signal from also.

 

  • If the unit is not showing the IN and OUT LED`s then test both Channels of the circuit for Continuity across S11 – S12 and S21 – S22. Disconnect these from the ESR when doing so or you may pick up resistance from inside of the Unit.  If one Channel is O/C then use Estop circuit drawing overleaf to diagnose exactly where the break is.  The drawings may not be the same as the ones pictured so please use the onsite copy if different.

 

  • If both channels are ok but the ESR will not reset look at the reset circuit coming in to S14 on the ESR on the above drawing. If any of the contacts feeding the reset button are O/C then the unit wont reset.  Check the circuit for 24v DC when the reset button is depressed.

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Estop circuit schematic showing terminal numbers in the panel. Use this to split the circuit into smaller sections for testing purposes by going to the half way point on each channel and checking the resistance/continuity until you finally isolate one contact or cable at fault.

 

It is unlikely that you would loose both channels at once, if this occurs then double check all Estop buttons are released and all Harting connectors are plugged in securely.

 

If all Steps have been checked and the ESR will still not reset, the ESR itself may have failed.  When replacing please ensure the knob on the front is set to the same position as the original.

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This Schematic shows the N/0 contacts For the Estop identification on the HMI through the PLC.  Input I0.0 is the estop healthy signal fed from a pair of relays (KP1 & KP2) that are directly energized by the ESR.  If this input is not received by the PLC then you will not be able to start the system even with a healthy ESR.  Check the fuses F6 and F7 as per previous page.
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