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 Diagnostic Codes

George A. Shrokman, Jr. - The Industrial Door Geek

GS Control Systems LLC - Door Controls Engineering and Application

615-826-5559

 

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Door System Diagnostics Fault Codes

 

 

Fault outputs are currently available from three different sources on Shrokman Technologies control systems.

    1. Pilot Light output
    2. 4 line digital display
    3. Touch Screen (CRT)

We track two types of faults.

  1. Current Fault – This is a fault that is occurring while the fault reading is being taken. Limit switches tripped, overload tripped, etc are small examples of current faults.
  2. Historical Fault – These are faults that have occurred and have been recorded in history. There is a count available of how many times these faults have occurred. Depending on the processor used, a time stamp is available for these faults. A historical fault would be if a reversing edge were working intermittently, or how many times someone pressed a motor contactor manually.

We also track the amount of times inputs and outputs have been activated. This gives us a history of how many times a sensor has been tripped. This can be used in diagnosing hard to get at problems. The most common counter is the reversing edge counter. Theoretically, the reversing edge should never be used. But in many instances when the door is fully closed and the advanced closed and closed limits deactivate the reversing edge, the bottom edge can be sitting on an object. This can lead to early failure of the reversing edge. Without this count, you would never know that there is a problem.

It must be noted that each device must have it’s own input in order to do diagnostics. This is easy for control professionals to understand, but hard to explain to the door manufacturer who is trying to keep his costs down. The end user sees the benefits more because of their close link to the actual doors. Because industrial facilities that use diagnostics in their machinery are used to the extra cost, they do not balk at the price like door manufacturers.

Currently the count tracking is not available with the fault light. It is standard with the 4 line digital display and the touch screen.

There are various ways to activate the outputs on the codes.

For a Fault Light Code Reading, the most common way is to press the STOP button, and cycle the power, and then release the stop button. If the process does not start, we automatically know that we have a problem with the stop button.

The 4 line digital display fault code cycle is started by cycling the power as above, or holding in the stop button, pressing the open and close button at the same time.

With the digital display, just press the "Fault Code" button.

Fault outputs are currently available from three different sources on Shrokman Technologies control systems.

    1. Pilot Light output
    2. 4 line digital display
    3. Touch Screen (CRT)

Pilot Light mode.

The diagnostic pilot light is installed on the face of the control panel and flashes a code that references a problem.

Light Code Basics and Fault Codes

 

FLASH GROUP 1. The first group designates the device having the fault. An example would be a Door, Dock Leveler, Truck Restraint, Air Shelter etc. The door would be 1 flash, dock leveler 2 flashes, Truck Restraint 3 flashed, Air Shelter 4 flashes.

FLASH GROUP 2. We break the codes down into groups.

FLASH GROUP 3. This group describes the problem detected.

First Group Second Flash Group[ Third Flash Group
Count Desc Count Desc Count Desc
1 Designates the unit number of the diagnostic code. 1 Motors 1 See Chart for individual codes
2 2 Limits 2
3 3 Buttons 3
4 4 Sensors 4
5 5 Mechanical 5
6 6 Timing 6
7 7 Special 1 7
8 8 Special 2 8
9 9 Special 3 9

Currently we have not had a need to use a fourth flash group. We have found that if the panel is getting that large, it is much better to go to a touch screen for a more user friendly output.

Motor Faults

1 Overload Tripped at rest Input opening while system was at rest
2 Overload Tripped while going open MO energized when overload tripped
3 Overload Tripped while going closed MC energized when overload tripped
4 Two Speed Overload Tripped at rest Input opening while system was at rest
5 Two Speed Overload Tripped Going Open MO energized when overload tripped
6 Two Speed Overload Tripped going closed. MC energized when overload tripped
7 VFD Voltage Trip – see VFD for fault Drive Input Faults
8 Manual Press The normally closed contact opens when the controller is not giving an output to the motor contactor.
9 Overload Reset Count available Used to inform that there is a count in the register.

 

 

Limits

1 Hand Chain Limit Open Input open
2 Full Open Limit Open Input Open
3 Advance Open Limit Open Input Open
4 Advance Close Limit Open Input Open
5 Full Close Limit Open Input Open
6 Open Limit Tripped while Motor Ran Closed Used to check reverse phasing or that a limit has been over traveled.
7 Closed Limit Tripped while Motor Ran Open Used to check reverse phasing or that a limit has been over traveled.
8    
9    

 

 

Push Buttons

1 Stop Button Circuit Open Timed Circuit detects that the button has been pressed for more than 1 minute.
2 Stop Button Circuit Interminttent Timed circuit. Counts the number of times the button has been pressed in a 15 second interval.
3 Open Button Pressed stuck Timed Circuit detects that the button has been pressed for more than 1 minute
4 Close Button Pressed Timed Circuit detects that the button has been pressed for more than 1 minute
5 Hand Auto Selector Problem Both Hand and Auto Inputs are made. There is problem with the switch.
6    
7    
8    
9    

 

Sensors

1 Inside Photo-Eye blocked Timed Circuit when door is open.

A Fault circuit when the door is closed.

2 Photo-Eye 2 Blocked
3 Inside Loop Tripped Timed circuit
4 Outside Loop Tripped
5 Inside Motion Sensor Tripped Timed circuit
6 Outside Motion Sensor Tripped
7    
8    
9    

 

Reversing Edge

1 Reversing Edge Circuit Open Timed Circuit
2 Reversing Edge Tripping Intermittently Timed Circuit – detects that the edge is faulting quickly within a 5 second time. Range is adjustable.
3 Reversing Edge Intermittent when opening Edge trips when the door is running open.
4 Edge hitting at door track curve Sectional Overhead Door – Edge trips when Advance Open Limit is tripped.
5 Edge pressed when door is fully closed. Shows that the down limit needs adjustment or blocks are off the end of the door edge. With sliding doors, there may be a problem with the binders.
6    
7    
8    
9    

 

Timing

1 Open Over Travel Timer Exceeded Timed Circuit
2 Close Over Travel Timer Exceeded Timed Circuit
3 Auto Close Missing Input The open limit is open, but the verification closed contact is not. Check the full open limit and brake operation.
4    
5    
6    
7    
8    
9

 

 

Special 1 – Megadoor

1 LS1 tripped  
2 LS2 tripped  
3 LS3 tripped  
4 LS4 tripped  
5 LS5 tripped  
6 LS6 tripped  
7 LS5 or LS6 fault LS5 or LS6 inputs open, and the full open verification limit is not closed, showing a problem with the open limit.
8 LS1 Reset LS3 is open, and then LS1 opens when the door has been at full rest. ( refer to Denver Airport)
9 LS2 Reset LS4 is open, and then LS2 opens when the door has been at full rest (refer to Denver Airport)

 

 

Special 2 – Megadoor

1 LB1 Open Plunger Sticking Timing Circuit. Motor starts closed and the corresponding open limit switch does not close within two seconds. Then the plunger releases and the limit goes closed. This is a history problem.
2 LB2 Open Plunger Sticking
3 LB1 Close Plunger Sticking Timing Circuit. Motor starts open and the close limit takes more than 3 seconds to close. Then after that it closes.
4 LB2 Close Plunger Sticking
5 Brake Not Operating properly and door is dropping Open limit trips, and then after the motor stops, closes within 1 second. This shows that the door drops after opening.
6 Door over traveled while running open MO energized and both open and over travel limit tripped.
7 Door over traveled while running closed. MC energized and both close and over travel limit tripped.
8 Belt Wound Backwards Motor running one way, and opposite limit trips.
9    

 

 

Special 1 – Dock Systems

1 Dock Leveler Raise PB pressed Input Closes
2 Lip Out PB Pressed Input Closes
3 Leveler Motor Overload Tripped Input Opens
4 Lip Stored Limit open while trying to unlock truck Input must be closed for truck to unlock. Restraint will not release truck unless this limit is closed.
5 Truck Locked PB Input Closes
6 Truck Unlock PB Input closes
7 Latch Down Open when lock is stored
8 Latch UP Open when lock over travels ICC bar
9 Vehicle Not Locked Fault output that is counted.

 

Special 2 – Dock Systems

1 Vehicle Bypass Mode Gives a count of how many times the bypass mode has been activated.
2 Air Shelter on Count for run on air shelter
3 Air Shelter Overload Overload Tripped
4    
5    
6    
7    
8    
9    

 

Special – Door Heaters

1 Heater Turned On  
2 Thermostat Closed  
3 Building Automation System Input 1 Varies per system
4 Building Automation System Input 2 Varies per system
5 Building Automation System Input 3 Varies per system
6 Burner On with no output Verifies that there is a problem in the heater internal system.
7 Pilot Gas Valve On with no verification output Verifies that there is a problem in the heater internal system.
8 Gas Train Flame Out Fault Gas train goes out while thermostat is not satisfied and heater is turned on.
9 Damper Fault Damper not fully open in allowable time

 

 

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Last modified: 08/10/13