QCPort Cover Control Trouble Shooting Guide

Technical Document

Feb. 2006

Page 1 of 14

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QCPort Cover Control Description

Door Defeater

Bucket Latch

Breaker Actuator

Hasp Lock

Page 2 of 14

Address/Options

Keypad Overlay

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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

Reference Number

QCPort Cover Control Programmer Guide

MN05009001E

D77D-DNA Users Manual

MN05004002E

D77D-EMA Users Manual

MN05002002E

D77D-PNA Users Manual

MN05008001E

D77D-EIP Users Manual

MN05008003E

NEMA IT Starter User Manual

MN03305001E

Link to search Eaton Electrical Web site www.eatonelectrical.com

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LED Function Matrix

LED State
LED

Condition

OFF

Off
Running

On

SLOW FLASH

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

AUTO

Hand mode

Stopped, hand, hard wired

R1 enabled
Running Reverse
Commanded to run and has
not received status from aux
contact that starter is pulled in
Stopped, hand, hard wired
R2 enabled
Auto mode

HAND

Auto mode

Hand mode

REV

REV & OFF

TRIP

OL TRIP

Reset asserted

GND FLT

Reset asserted

Resetting OL Trip
Ground Fault Warning or
Fault
Ground Fault Warning

OFF & RUN &

HAND

Resetting Ground Fault

trip

Application Communication
Fault
Press Rest button to clear
Reset asserted

Resetting Application
Communication Fault

Power up,
Reset, or
manual LED
Test

ON momentarily

Alternating
FWD / REV
Status

Warning/fault
High Temp fault
Phase Loss fault
Phase Imbalance fault
Thermal Capacity fault
Test Trip

OL TRIP
GND FLT

3 TRIP
OL TRIP
GND FLT
3 TRIP
OL TRIP
GND FLT
All (7) LEDs

FAST FLASH

Illegal Motor Direction

Command
No power

Mostly On OK and is
being actively scanned

Mostly Off OK and is ready

to be scanned

50% duty cycle device

is faulted
Strobe Undiscovered
or Identify

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.

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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.

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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.

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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 LEDs 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.

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Communication Troubleshooting
Explanation of LED duty cycle states
Mostly Off
Mostly On
50%
Rapid Flash
Status LED
Mostly Off

One short blink ON every 2 seconds

One short blink OFF every 2 seconds
ON and OFF blinking same amount of time; second cycle
Strobe
Description
Offline and
configured

Explanation
The Cover Control has been acquired by the network
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

50% On

Faulted

Everything is OK with in the Cover Control and the Cover

Control is being scanned by the network adapter.
Internal memory fault (cycle power)
Verify that there are not any duplicate Group IDs
(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 Controls will have the
same behavior of the status LED. Perform an auto
configuration.

Solid On

Off

No Power

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.
The Cover Control is not powered or a memory fault in NV
RAM has occurred that will require the Cover Control to be
replaced.

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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.
Cycle power to the Network Adapter.

Are all the buckets

connected to one
Network Gateway with in
the MCC not
communicating? Are all
the Status LEDs either
Rapid Flash or 50% On

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.

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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 connectors 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.

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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

IM

+
E
E1
E2

Fault Output
Fault Output
Auto Output
Auto Output
+24/L2
Local/Remote
Run 1
Run 2
Reset
E-Stop
E-Stop

[9]
[8]
[7]
[6]
[5]
[4]
[3]
[2]
[1]
[E1]
[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

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Default IO Data
Input Data

Data
Motor Control Fault Word High Byte
Motor Control Fault Word Low Byte
% FLA High Byte
% FLA Low Byte
% Thermal Capacity
Motor Control Status

Byte
0
1
2
3
4
5

Motor Control Faults

Bit
0
1
2
3
4
5
6
7
8

9
10
11
12
13
14
15

Description
Phase Loss (Loss of one or more of the line phases or a Circuit Breaker Trip)
Phase Imbalance (current imbalance of greater than 50%)
Thermal Overload (starter trip due to thermal overload)
Reserved
Reserved
Ground Fault (trip due to a ground fault, separate ground fault sensor required)
Reserved
Reserved
Device Over Temperature (Device temperature limit exceeded, S751 only)
Reserved
Reserved
Motor Control E-Stop (Device is in the state of an Emergency Stop)
Reserved
Reserved
Reserved
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.

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Motor Control Status

Bit
0
1
2
3
4
5
6
7

Description
Running 1 (starter is commanded to run forward/fast)
Running 2 (starter is commanded to run reverse/slow)
Permissive
Reserved
Local Control
Faulted
Warning
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.

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Output Data
3-Wire Control Output Data

Data
Motor Control (byte)

Byte
0

Motor Control:

Bit
0
1
2
3
4
5
6
7

Description
Run 1 (command the primary contactor to energize)
Run 2 (command the secondary contactor to energize)
Permissive (permissive to energize the starter)
Reset
Reserved
Reserved
Reserved
Reserved

State
Momentary
Momentary
Maintained
Momentary
NA
NA
NA
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.

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