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Warnings:
- Use specified incoming line fuses to guard against equipment damage and hazards due to failure of Electrolytic Capacitors.
- Hazardous voltage levels exist on the Control Printed Circuit Board. Disconnect power, open guard and remove board for servicing.
- Always remove power from the drive when wires are being connected or reconnected or fuses are replaced. The removal should be done by means of an external disconnect switch. (The STOP push button switch on the door will not remove AC power from the drive.)
- Do not change adjustments set by the factory.
- If the procedures detailed here have been completed, or you do not feel you are qualified or comfortable working with high voltage, and the difficulty has not been corrected, consult your nearest Allen-Bradley office.
| Symptom | Step | Diagnostic Procedure | Probably Failure or Indication | Repair Procedure | |||||||||||||||||||||||||
| A. Unit does not turn on when the ON button is pressed (Contactor K1 does NOT pull in). | 1 | Measure input line voltage. Line voltage should be between 207 and 253V AC. | Voltage not present or insufficient. | Check and correct external voltage source. | |||||||||||||||||||||||||
| 2 | Turn off input power at the disconnect switch and check for blown fuses at fuse locations F1, F2, F3, & F4 | One or more fuses blown. | Replace blown fuse(s). Perform step A3 before reapplying power. | ||||||||||||||||||||||||||
| 3 | If 1 or more fuses are blown, check the following before reapplying AC power. | ||||||||||||||||||||||||||||
a) Set Ohmmeter on X1 scale. Check Rectifier Assembly A10 as follows
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a1) A low ohmmeter reading on any but not all connections indicates a shorted diode on A10. a2) If all ohmmeter connection cause a low reading. |
a1) Replace Rectifier Assembly A10. a2)Go to step 3b. |
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| 3 | b) Disconnect the (+) lead to the (+) bus BB1 on Capacitor Assembly A7. Connect the (+) ohmmeter lead to E1C and the (-) ohmmeter lead to E2A. | b1) An infinite ohmmeter reading indicates that the fault is in the A7 assembly. b2) A low ohmmeter reading indicates either diode CR7 in Rectifier Assembly A10 is shorted or electrolytic capacitor C4 in Rectifier Assembly A10 has failed. |
b1) Go to step 3c. b2) Replace Rectifier Assembly A10. |
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| 3 | c) Connect the (+) ohmmeter lead to the (+) Bus BB1 on A7 and the (-) ohmmeter lead to the (-) Bus BB3 on A7. Disconnect one electrolytic capacitor at a time. | c1) The ohmmeter will indicate an infinite reading when the shorted capacitor is disconnected. c2) If the ohmmeter continues to indicate low ohms when all electrolytic capacitors are disconnected, the fault is elsewhere. |
c1) Replace the shorted capacitor. c2) Go to step 3d. |
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| 3 | d) Connect the ohmmeter the same as in step 3c. Unplug P203 on Control Board A2. | d1) An infinite ohmmeter reading indicates a fault on Control Board A2. d2) A low ohmmeter reading indicates a fault elsewhere. |
d1) Replace Control Board A2. d2) Go to step 3e. |
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| 3 | e) If the drive is equipped with a Brake option disconnect the brake resistor at TB3 and unplug connector P801 on the Brake Board. Leave the ohmmeter connected as in 3C. | e1) An infinite ohmmeter reading indicates a fault on Brake Assembly A8. e2) A low ohmmeter reading indicates two or more A6 Switching Modules have failed. |
e1) Replace Brake assembly A8 (Brake Board 50280-002 and Brake Board Transistor Assembly 41308). e2) Go to step 3f. |
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| 3 | f) Checking one module at a time, unplug connector P601 and disconnect all three Switching Module Leads at the (+) and (-) Bus on A7. On the three upper A6 modules (A6UA -A6UB - A6UC), connect the (+) ohmmeter lead to the Black (heavier) #10AWG lead. Connect the (-) ohmmeter lead to the White Lead. On the lower A6 modules(A6LA - A6LB - A6LC) connect the (+) ohmmeter lead to the White Lead and the (-) ohmmeter lead to the Black #10AWG Lead. | f1) An infinite ohmmeter reading indicates a good A6 module. | f1) Ohmmeter check each of the A6 modules. | ||||||||||||||||||||||||||
| 4 | a) Use the ohmmeter to test for blown fuses F5 on Transformer Assembly T1 and F6 and F7 on the chassis hinged panel. | a1) Blown fuse F5 indicates a shorted transformer. OR a2) A failed Converter Power Supply, A3. OR a3) A failed 1CR relay on Control Board A2. a4) Blown fuses F6 and F7 indicates a fault in the Bus circuit. |
a1) Replace Transformer Assembly T1. Replace fuses. a2) Replace Converter Power Supply A3. a3) Replace relay 1CR on Control Board A2. a4) Replace blown fuses and go back to step 3c before placing the drive into service. |
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| 5 | a) Reapply input power at the disconnect switch, press the"ON" pushbutton, and measure the AC voltage on Control Board A2 at connector P201 between pins 4 and 8. | a1) If the voltmeter does not indicate 120V AC while the "ON" pushbutton is depressed, there is faulty wiring in the external control circuits. a2) If the voltmeter does not indicate 120V AC after the "ON" pushbutton has been released, then relay 1CR on Control Board A2 has failed. |
a1) Repair control pushbutton circuits. a2) Replace relay 1 CR on Control Board A2. |
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| 5 | b) Measure the AC voltage on Converter Power Supply A3 at connector P301 between pins 5 and 7. | b1) Zero AC voltage indicates relay 7CR or F1 or F2 on Control Board A2 has failed. b2) If the voltmeter indicates 120V AC but the unit still does not operate. |
b1) Replace relay 7CR or F1 or F2 on Control Board A2.
b2) Go to step 5c. |
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| 5 | c) Measure the DC voltage on electrolytic capacitor C7. | c1) Zero DC voltage indicates Converter Power Supply A3 has failed. c2) If the voltmeter indicates 130V DC ± 5V. |
c1) Replace Converter Power Supply A3. c2) Go to step 5d. |
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| 5 | d) Measure the DC voltage on A3, at connector P302 between pins 9 and 5. | d1) If the voltmeter indicates less than 34V DC or greater than 40V DC. d2) If the voltmeter indicates 34-40V DC. |
d1) Replace Converter Power Supply A3. d2) Go to step 5e. |
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| 5 | e) Observe DS3 ("PRE-CHARGE") on Control Board A2. | e1) If DS3 is not lit, Logic Board A1 has failed. e2) If DS3 is lit. |
e1) Replace Logic Board A1.
CAUTION: When replacing the Logic Board, if there is a ribbon cable plugged into J10 and/or J11, PIN 1 on the plug must be lined up in the direction of the arrow. e2) Go to step 5f. |
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| 5 | f) Measure the AC voltage at 2CR on the chassis hinged panel between pins 7 and 9. | f1) Zero AC voltage indicates that relay 2CR has failed. f2) If the voltmeter reads 230V AC. |
f1) Replace relay 2CR on the hinged panel.
f2) Go to step 5g). |
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| 5 | g) Observe fault indicator light DS1 ("BUS") on Control Board A2. | g1) If DS1 is lit. g2) If DS2 is not lit. |
g1) Go to step 5h.
g2) Go to step 3c. |
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| 5 | h) Observe fault indicator light DS3 ("DC POWER") on Control Board A2. | h1) If DS3 is not lit. h2) If DS3 is lit. |
h1) Replace Logic Board A1.
h2) Go to step 5i. |
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| 5 | i) Measure the AC voltage on Control Board A2 between connector P202-PIN 14 and P203-PIN 1. | i1) If the voltmeter reads 115V AC Contactor Coil K1 has failed. i2) If the voltmeter reads zero volts,either relay 7CR or 3CR has failed. |
i1) Replace Contactor Coil K1.
i2) Replace relay 7CR on Control Board A2 or relay 3CR on the hinged panel. |
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| Symptom | Step | Diagnostic Procedure | Probable Failure or Indication | Repair Procedure |
| B. Contactor K1 energizes momentarily then unit trips off. | 1 | After the unit trips off, but before pressing the "OFF" push button, look at fault indicator lights DS2, 3 and 5 on Logic Board A1. If DS2 is lit, check the line voltage as in step A1. | DS2 is lit due to a high DC Bus voltage. | Check and correct external voltage source. |
| 2 | If DS3 is lit, set the speed control pot to zero, press "OFF," wait a moment, then press "ON." Proceed as follows: a) If DS3 is still lit. b) If DS3 is not lit. c) Disconnect the motor from the drive. Confirm that DS3 does not light when the speed control pot is turned up to 50% speed. |
a) Logic Board A1 has failed or switch S1 ("DC Boost") is set too high or too low. b) The original cause for DS3 to be lit is probably external to the drive. Probable cause: Motor overload, failed motor, or faulty wiring. c) Overload or failed motor or faulty wiring. |
a) Replace Logic Board A1 or reduce the DC boost - (See ADJUSTMENTS).
CAUTION: When replacing the Logic Board, if there is a ribbon cable plugged into J10 and/or J11, PIN 1 on the plug must be lined up in the direction of the arrow. b) Go to step 2c). c) Repair/replace motor, faulty wiring, or remove overload. |
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| 3 | If DS5 is lit, use procedure A3f) to locate the faulty Switching Module(s). | Failed Switching Module(s). | Replace faulty Switching Module(s). | |
| 4 | None of the DS1-5 fault indicator lights are lit. | Failed bus discharge circuit on Control Board A2. | Replace Control Board A2. |
| Symptom | Step | Diagnostic Procedure | Probable Failure or Indication | Repair Procedure |
| C. The unit trips off during normal operation | 1 | After the unit trips off, but before pressing the "OFF" push button, look at fault indicator lights DS1, 2 and 4 on Logic Assembly A1. If DS1 is lit, check the input line voltage as in Step A1. | DS1 is lit due to a low external voltage or previous low line voltage transients. | Check and correct external voltage source. |
| Overvoltage | 2 | If DS2 is lit, proceed as follows: a) Measure the input line voltage. Line voltage should not be greater than 253V AC. b) Restart the unit by pressing "OFF," then the "ON" push button. Rotate the speed control pot until the desired motor speed is achieved. Now rapidly rotate the speed CCW to zero. |
a) Line voltage is marginally high or a utility surge has occurred. b) If the unit trips off, switch S3 ("Deceleration") is set too high for the motor/ load inertia. |
a) Check and correct external voltage source. b) Do one or both of the following: 1) Decrease the deceleration rate - (See ADJUSTMENTS). 2) Install a dynamic brake. |
| Line Out | 3 | If DS4 lights momentarily when the unit trips off, proceed as follows: a) Examine the "OFF" pushbutton and its associated wiring b) Monitor the drives input line voltage. |
a) Loose connection in the "OFF" pushbutton circuitry. b) A drop in utility voltage has occurred. |
a) Repair loose connection. b) Check and correct external voltage source. |
| 4 | None of the DS1-5 fault indicator lights are lit. | A failed bus discharge circuit on Control Board A2. | Replace Control Board A2. | |
| 5 | If DS3 is lit. | A momentary motor overload has occurred. | Correct the overload condition and restart the drive. | |
| 6 | If DS5 is lit. | A failed A6 Switching Module or a failed motor. | Go back to step A3f to isolate the failed Switching Module or repair/replace the motor. |
| Symptom | Step | Diagnostic Procedure | Probable Failure or Indication | Repair Procedure |
| D. Unit turns on but the motor will not turn | 1 | Measure the line-line voltage across each motor lead. The voltage should be approximately 230V AC for each phase with the speed control pot fully CW. | Open motor leads or a failed motor. | Repair/Replace the motor. If voltage is zero, replace Logic Board A1. |
| E. The motor slows down or stops when loaded. | 1 | Visually check S4 and S5 switch settings on Logic Board A1. | The Volts/Hz is set too low. | Set switches for desired Volts/Hz - See Adjustments |
| F. The motor will not turn until the speed pot is fully CW. | 1 | Visually check the setting of switch S1 ("DC Boost") on Logic Board A1. | Motor breakaway torque is set too high for the amount of DC Boost set. | Set switch S1 to a higher setting until the motor turns at low speed pot positions. |
| G. The motor will not reach full speed when fully loaded | 1 | Slowly turn R19 ("Acceleration Limit") on Logic Board A1 clockwise. | Acceleration current limit set too low. | Slowly turn R19 until motor reaches full speed at full load during acceleration. |
| H. Unit will not restart after cycling (pressing the "OFF" then "ON" push buttons). | 1 | Allow unit to cool for 5 minutes; press the "OFF" then the "ON" push buttons. Unit should restart. | Cycle rate too rapid for dynamic brake. | Consult your local AB office. |