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Troubleshooting the Motor Driver FAULT ERROR LED:
On the bottom right hand corner of the master controller, look on the motor driver
PCB for LED activity upon power up.
If the motor is connected properly, there will
ONLY be one LED that turns on right away on power up, it is the lower left Green
LED on the Motor driver board marked "PWR".
The PWR LED indicates that the
motor driver board has 24volts. If the RED FAULT LED (near the center of the Motor
Driver board) is ON right away at power ON, then there is a problem between the
master controller and the motor.
The problem may be that the CAT5 cable is
damaged or cross wired, or maybe connectors or wires are damaged on the
motor, etc. On the end of the motor, there are 5 wires that are associated with this
error: Black, Red, Blue, Green, and White. These wires have a 5 conductor plastic
connector attached that plug into the small circuit board on the motor. The order
of the colors are Black, Red, White, Green, Blue. Be sure that the CAT5 cable to the
motor is wired 'straight through', with no crossover. Keep all pairs together, do not
split any wires out of a pair. Each end of the CAT5 cable should be identical colors,
not mirrored colors.
When the connection problem is resolved, on power up the motor driver board will
only have the
Green PWR LED lit up. The master controller on bootup does several
diagnostic routines. If the FAULT LED is LIT immediately on Power ONs, the system will
never boot up and pass the diagnostics test. First check that the MOTOR LOGIC
cable is plugged between the master controller and the motor. It may be required
to plug in the connector on each end several times to insure the copper
connections are cleaned. A good rule of thumb is to plug in the cable on each
end 5 times to clean the copper contacts on the plug. Also, inspect that the 5
wires from the motor are secure in the plastic connector. Gently pull on each wire
to see if one may have been broken, in which case the wire may pull out of the
connector.
A Fault on the Motor Driver indicated by the RED LED being on immediately at
power up is not a problem that can be solved with settings in the Master Controller.
NOTE: On some earlier versions of the Motor Driver circuit board (prior to 2013) the
Fault LED near the center of the board may have been GREEN. All newer boards
use RED.
See Section on Advanced Details on the FAULT LED ERROR.
