8510 Troubleshooting Guide
Contents
1. Malfunctioning Power Unit Motor is overloaded by existing duty cycle Motor fan not operating Adjust taps on transformer or add step up transformer to keep AC line voltage above 180V AC 50 60 Hz Increase kVA rating of supply transformer to proper rating for drive size especially if fault occurs during accel or when the motor is running under heavy load With drive operating in motoring or accel if possible check phase to phase line voltages for balanced conditions and verify that voltage is above 180V AC Check all incoming line connections for tightness Refer to fault condition 4 With drive operating in motoring or accel if possible check phase to phase line voltages for balanced conditions Check all incoming line connections for tightness If a three phase motor is connected to the AC line a lost phase may not be detected by a voltage test on a lightly loaded 8510 system Increase kVA rating of supply transformer to proper rating for drive size Especially if fault occurs during accel or when the motor is running under heavy load Check IGBT modules M4 5 and or IGBT2 in A04 A06 drive according to procedure later in this chapter Replace Power Unit if IGBT is malfunctioning Replace the Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 If problems were not found with other tests replace the Power Unit When the motor cools the thermal switc2. Roclawell sviomation Allen Bradley 8510 Diagnostic Table 1 D Problems that Occur when AC Power is Applied No Problem Probable Cause 1 Display does not illuminate Loss of incoming AC power and drive and motor cooling fans do not start Loose power connection in Power Unit 2 Drive and motor cooling Malfunctioning AC control power fans do not start fuse Loose or disconnected fan wiring 3 Drive programming Malfunctioning AC control power diagnostics display does not 7 fuse or 5 DC power supply illuminate fuse Display intensity or contrast is misadjusted Logic power supply has malfunctioned Display has malfunctioned Possible Solutions Measure AC voltage between terminals R S and T on the bottom of the drive to verify that the line to line voltage is 180 253V AC at 60 Hz or 180 242V AC at 50 Hz Check and tighten screws that connect the Power Board to the power terminal block Check for other loose screws or connectors in Power Unit Check fuses FU2R FU2S and on 22 only FU2T and replace malfunctioning fuse 1 Verify that drive cooling fan cables are plugged into Power Board 2 Verify that motor cooling fan is properly wired to drive and motor terminal blocks 1 Check fuses FUIR and FUIS and replace malfunctioning fuse 2 Check 5V DC power supply fuse F7 or F13 on A04 A06 size unit and replace malfunctioning fuse Intensity and contrast adjustment pots are direct
3. continued Possible Solutions Measure all phase to phase voltages Check all incoming line connections for tightness Check fuses FU3R FU3S and FU3T 1 Check seating of Interconnect Board into board connector CN8 CN16 on A04 A06 drives 2 Remove Interconnect Board from CN8 and inspect contacts in both connectors to assure that they are making proper contact with the Interconnect Board Make certain it is plugged back in correctly so that blank side if any is towards outside of drive 3 Remove Control Boards and check tightness of incoming power connections to Power Board Check for other loose power interconnects If problems were not found with other tests replace Main Control Board Gate Drive Board on A04 A06 drive If problems were not found with other tests replace main Power Unit 1 Check 5V test point on Main Control Board Should be 4 75V to 5 25V Note test point is before the 5 0A fuse in the circuit 2 Check 15 test point on Main Control Board Should be 14 25V to 15 75V 3 Check 15V test point on Main Control Board Should be 14 25V to 15 75V 4 If any voltages are out of tolerance or missing replace Main Control Board Gate Drive Board on A04 A06 drive 1 Verify that the resolver feedback cable is plugged into connector CN3 2 Verify that the resolver connector in the motor terminal box is properly inserted 3 Check each connector to verify that
4. If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drive 22 23 continued Spd Error Hi displayed A motor stall condition or an unexpected motor acceleration or deceleration was detected If during startup the motor runs at a constant low speed or reverses direction frequently the motor versus resolver phasing is incorrect Incorrect motor selected in MOTOR SELECT Catalog Num parameter Load requires a torque that exceeds motor torque limit setting Motor phase is open When using 1327AD series dual winding motors Malfunctioning winding change contactor Resolver or resolver wiring is malfunctioning Malfunctioning Power Unit Malfunctioning printed circuit boards Use the parameter PARAMETER SET ELECT CONFIG Motor Phasing to reverse the relative phasing of the motor to the resolver Check Catalog Num setting to verify that it matches the motor nameplate Incorrect parameter setting can cause torque loss 1 Change duty cycle to reduce required motor torque 2 Turn Low Torque Limit Select input Off or increase setting of Low Torq Lmt parameter to allow sufficient torque to drive the load Increase rating of motor drive system if necessary to drive the load Check all power wiring to the motor for continuity and tight connections Use an ohmmeter to verify phase to phase continuity for each moto
5. Overspd Trip parameter was detected Bus Overvoltg displayed DC bus voltage that exceeded maximum allowable limits was detected continued malfunctioning MOTOR SELECT Catalog Num and or ELECT CONFIG Drive Cat Num programmed as NONE SELECTED when the Coast to Stop input is turned On Overspd Trip parameter set too low relative to commanded speed Motor disconnected from load while drive in torque mode Excess overhauling load Malfunctioning resolver or resolver signals Malfunctioning printed circuit board Incorrect motor selected in MOTOR SELECT Catalog Num parameter Incoming 3 phase voltage is out of tolerance If overvoltage is detected during regeneration incoming AC line impedance may be too high Malfunctioning regeneration control circuit Correctly program the MOTOR SELECT Catalog Num and ELECT CONFIG Drive Cat Num parameters before applying 24V DC to the Coast to stop input Increase setting of Overspd Trip parameter or reduce setting of Max Cmnd Spd parameter The overspeed trip point should be set about 10 higher than the maximum command speed to avoid nuisance trips Important If the Overspd Trip parameter is inadvertently set to zero this fault may occur as soon as the power is applied to the drive With a setting of zero even a one bit change from the resolver decoding circuit will cause this fault Never allow the motor to become dis
6. it is wired according to the 8510 User Manual Table 1 E Resolver waveforms not correct Problems That Occur when Drive Enable is Applied or during operation No 7 Problem No fault is indicated but the main contactor will not close and the Drive Ready output is not energized Probable Cause Improper command sequence has been applied Contactor coil circuit not completed via the Coast to Stop input Loose connections on contactor Malfunctioning pilot relay on I O Board Malfunctioning pilot relay on Power Board or malfunctioning contactor 1 On Main Control Board Gate Drive Board on A04 A06 drives check test points S1 and S2 for excitation sine waves these will not be smooth but will have a staircase look See Figure 1 3 for typical resolver waveforms If waveforms are not correct then unplug the resolver cable connector CN3 If the waveforms are now correct then the resolver cable is miswired or the resolver is malfunctioning If the waveforms are still not correct replace the Main Control Board or Gate Drive Board 2 Check test point R1 for a smooth clean feedback sine wave See Figure 1 3 for typical waveform If R1 waveform correct replace Main Control Board or Gate Drive Board 3 If R1 waveform is missing or incorrect check resolver wiring If wiring replace motor resolver Possible Solutions Assure that the Coast to Stop input is energized before any
7. not properly installed Verify that the EEPROM is properly installed in or malfunctioning the socket If problem remains replace I O Board 45 Bad EEPROM displayed EEPROM not properly installed Verify that the EEPROM is properly installed in The T O Board or malfunctioning the socket If problem remains replace I O Board microprocessor can not communicate with the EEPROM 46 Bad Optional A D This version of the I O Board If the drive catalog number does not end in either displayed The I O Board does not have the optional 14 bit Cx or Dx the optional A D converter 15 not microprocessor can not linear A D converter installed installed Either program drive to use standard communicate with or is A D converter or install I O Board that includes receiving bad data from the optional A D converter on the I O Board Malfunctioning A D converter or Replace I O Board Board the optional A D converter 47 48 49 50 51 Table 1 J Problems Caused by Programming Errors No 52 53 continued EEPROM Sumchk displayed The I O Board microprocessor has read an incorrect check sum value from the EEPROM which indicates corrupted data in the EEPROM H8 CPU RAM displayed The RAM that is internal to the H8 microprocessor will not pass a read write test T O DURM displayed The dual port RAM used to communicate to the Main Control Board will not pass a read write test LCD Timeout displayed Communicat
8. other input command is applied Assure that Drive Enable is energized before either run command or the orient command Assure that the jumper cable is connected between connector J3 in the lower left corner of the I O Board and the EM1 EM2 terminal block on the upper left of the power circuit board Remove control boards and tighten all connections to main contactor Remove power Remove the jumper cable from connector J3 on the I O Board Use a small piece of insulated wire to short between the terminals of the plug on the jumper cable Important 230V AC is present on this plug when AC power is applied If the contactor will now close when power is turned On and the Drive Enable is applied replace I O Board If problems were not found with other tests replace Power Unit continued No Precharge displayed the DC bus failed to achieve the necessary voltage level during the allowed bus precharge time and the main contactor is blocked from closing Convrtr Short displayed Current sensed by DC link current sensor CT R was too high Usually indicates problem converter bridge continued AC line voltage out of tolerance Malfunctioning drive interconnections Malfunctioning IGBT module in converter bridge Malfunctioning bus precharge 1 or bus discharge KM3 relay Malfunctioning printed circuit board Momentary power outage while motor is regenerating to a stop Malfunc
9. the drive Malfunctioning feedback device Malfunctioning printed circuit board The number of encoder lines has been incorrectly programmed Feedback device is incorrectly phased Feedback device not correctly connected to the drive The ORIENT TUNE Orient Start parameter value is much too low relative to the value of ORIENT TUNE Orient Speed parameter Malfunctioning feedback device Use the ORIENT SETUP FEEDBACK DEFN Encoder Lines parameter to set the correct encoder line count or number of teeth on the high resolution feedback gear 1 Verify that connector CN2 is connected to the drive 2 Verify the wiring of the connector at the drive and at the feedback device 1 If an optical encoder is used verify that the marker pulse is present and of proper amplitude and width relative to the A and B channel outputs 2 If the high resolution magnetic feedback is used verify the output signals per Figure 1 4 Adjust the sensor relative to the gear to obtain proper signals or replace the sensor head If problems were not found with other tests replace Main Control Board CPU Board on A04 A06 drives Use the ORIENT SETUP FEEDBACK DEFN Encoder Lines parameter to set the correct encoder line count or number of teeth on the high resolution feedback gear Use the ORIENT SETUP FEEDBACK DEFN Encdr Phasing parameter to reverse the phasing of the orient feedback device 1 Verify that c
10. ace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drives If problems were not found with other tests replace Power Unit sensor or circuit board Check for proper hookup of contactors motor contactor coils and auxiliary contacts Check Catalog Num setting to verify that it matches the motor nameplate Disconnect motor at the drive Use a megger high voltage ohmmeter to verify that the insulation resistance to ground for each phase is at least 5 megohm For dual winding type motors disconnect the power wires at the motor terminal box and use the megger to measure phase to phase insulation resistance Verify that the insulation resistance between U amp V V amp W and W amp U is at least 5 megohms For single winding motors use an ohmmeter to measure resistance between phases depending on motor size value measured should be from 0 1 1 0 ohms and should be approximately the same between each phase Phase to phase and internal winding shorts may not be detected with this test Verify that the motor power cable is securely fastened to the drive and motor terminal blocks and that no stray wire strands are shorting out any phases Replace the Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 If problems were not found with other tests replace the Power Unit See fault condition 10 Motor Short 1 Check seating of Interconnect Boards into board connect
11. arameter to set the correct encoder line count or number of teeth on the high resolution feedback gear If problems were not found with other tests replace Main Control Board CPU Board on A04 A06 drives Adjust SERVO MODE HI SPD RANGE P and I gains to obtain quick stopping without overshoot when the Run command is energized de energized The accel decel ramp rate setting limits the decel rate that can be obtained during orient and a slow decel rate can cause overshoot Reduce the value of the Acc Rate 1 or Acc Rate 2 parameter setting or select the quicker accel decel rate setting Reduce the value of the ORIENT TUNE Orient Speed parameter setting or increase the value of the ORIENT TUNE Orient Start parameter setting As explained in the 8510 Programming Manual publication 8510 5 2 these parameters control the orient position loop gain and define the required deceleration rate 26 27 continued Bad PG Marker displayed A correct marker pulse was not detected within one revolution of the feedback device as determined by the programmed number of lines on the feedback device Bad PG Count displayed An incorrect number of spindle position feedback counts was detected between two successive markers pulses as determined by the programmed number of lines on the feedback device The number of encoder lines has been incorrectly programmed Feedback device not correctly connected to
12. connected from the load or the drive to be disconnected from an external control loop while the drive is operating in torque mode Reduce the overhauling load to a value that is less than the torque limit setting of the drive Check the resolver signals as defined under fault condition 6 If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drives Check Catalog Num setting to verify that it matches the motor nameplate Adjust taps on transformer or add step down transformer to keep AC line voltage below 253V AC 60 Hz or 242V AC 50 Hz Increase kVA rating of supply transformer to proper rating for drive size Replace Main Control Board Gate Drive Board on A04 A06 drives 18 20 Bus Undervolt displayed DC bus voltage less than the minimum allowable level was detected AC Phase Loss displayed Loss of one phase of incoming AC line detected by drive Motor Ovrtemp displayed The drive detected that the thermal switch in the motor has opened continued Incoming 3 phase voltage is out of tolerance Incoming AC line impedance is too high An incoming 3 phase line is open or has high impedance Refer to fault condition 4 An incoming 3 phase line is open or has high impedance Incoming AC line impedance is too high Malfunctioning IGBT module in converter bridge Malfunctioning printed circuit board
13. e of Tear dnd gear speed m 1 Poimi A s and Ground VPP Nx Lex where N Numhier of Teeth PI S Apeed opm Aumplitede ef AT H y i FF Mi 0 4 T Amplitude ol Z Y 45w V pope dy Test Point Z and maialn Face Senor install ihe gear amd sensor as shown The Specifications aboye choald be cet at CW rodadion when ihe weer is viewed from the Z phase gear cide lt Gear Pha Gear
14. e in the drive control software The gear and sensor must be installed in accordance with the mechanical tolerance specifications in the High Resolution Magnetic Feedback Instructions 8510 5 13 At test point A on the Main Control Board CPU Board of A04 A06 drive the amplitude modulation of the signal should be less then 0 1 volts when the gear is properly installed The magnitude of the signal can be changed by changing the gear to sensor airgap 1 Verify that proper signals are received from the sensor See Figure 1 4 for correct waveforms 2 If not correct check cables and connectors for continuity and proper connections 3 If cables and connections are OK replace sensor If problems were not found with other tests replace Main Control Board CPU Board on A04 A06 drives Table 1 H Other Faults that Indicate Control Hardware Malfunction No 29 Problem Probable Cause Possible Solutions Replace Main Control Board CPU Board on 30 Main RAM Err displayed RAM is malfunctioning A parity or functional error was detected in RAM on the Main Control Board CPU Board on A04 A06 drive T O Comm Err displayed Hardware malfunction on either A04 A06 drive 1 Verify that EPROMs on both the I O Board and Board or Main Control Board CPU Board on A04 A06 drive No communications occurring between microprocessor on Main Control Board CPU Board on A04 A06 drive and microprocess
15. erify that the selected motor and drive catalog numbers are a compatible set A 5 5 kW drive can be used with any motor rated 5 5 kW or smaller An 11 kW drive can be used with any motor rated from 5 5 kW through 11 kW A 22 kW drive can be used with any motor rated from 11 kW through 22 kW Verify that the SPINDL PRESET Overspd Trip parameter is set to a value other than zero 54 55 56 57 continued Op Dig Set Er displayed The drive has been programmed to use the optional 16 bit parallel inputs for two different functions simultaneously Orient Prm Er displayed One or more of the critical parameters for orient are not properly programmed Sp Mtr 1 P Er displayed An error was detected in the motor parameter table values Sp Mtr 2 P Er displayed error was detected in the motor parameter table values For the gear range selected the SPINDLE MODE Cmnd Source parameter has been set to either 4 DIGIT BCD or 16 BIT BINARY and the ORIENT TUNE Position Data parameter has been set to either BCD INPUT or BINARY INPUT For the gear range selected one or more of the following parameters has a programmed value of zero SET RATIOS Spindle Revs SET RATIOS Motor Revs ORIENT TUNE Orient Speed ORIENT TUNE Orient Start For the gear range selected the motor type selected by the MOTOR SELECT Catalog Num parameter has been set to NON STD MTR 1 and thi
16. h will close and the fault will clear Reduce duty cycle loading or increase size of motor drive system 1 Measure voltage at fan terminal block in motor terminal box If voltage not 200 to 230V AC when AC power is applied to the drive check fuses FU2R FU2S and FU2T on A22 drive only and wiring to fan N If voltage is present and fan is not operating check for obstructions Otherwise replace motor or cooling fan 21 Drive Ovrtemp displayed The drive detected that the thermal switch on the drive heat sink has opened Insufficient air flow through motor cooling passages Incorrect motor selected in MOTOR SELECT Catalog Num parameter Motor thermal switch or wiring through resolver cable has malfunctioned Malfunctioning printed circuit board Drive is overloaded by existing duty cycle Drive cooling fan not operative Insufficient air flow over heat sink or poor heat transfer Incorrect motor selected in MOTOR SELECT Catalog Num parameter Malfunctioning printed circuit board Clean motor fan protective grill and fan Use pressurized air to clean cooling passages in each corner of the motor frame Check Catalog Num setting to verify that it matches the motor nameplate Incorrect parameter setting or oversized drive can result in excitation currents that exceed motor rating 1 Measure motor case temperature Thermal switch should open at 140 5 Case tem
17. ions between the I O Board microprocessor and the programming display module did not occur in the allowed time Any other Fault I O Board fault message displayed Indication of firmware or hardware malfunction on I O Board Problem Bad Comb M amp D displayed The motor and drive catalog numbers that are selected are not compatible with one another Max Spd None displayed The microprocessor can not find a value programmed for the SPINDL PRESET Overspd Trip parameter Data has become corrupted due to noise or some other means EEPROM is malfunctioning The microprocessor on the I O Board is malfunctioning The dual port RAM on the I O Board is malfunctioning The I O Board is malfunctioning Some hardware or firmware on the I O Board is malfunctioning Probable Cause For the gear range selected the MOTOR SELECT Catalog Num and the ELECT CONFIG Drive Cat Num parameter values not compatible or are not defined For the gear range selected the value for the SPINDL PRESET Overspd Trip parameter is set to ZeTO Perform the complete drive setup programming procedure as described in the 8510 Programming Manual publication 8510 5 2 Replace the EEPROM or complete I O Board Replace I O Board Replace I O Board Replace I O Board Replace the I O Board Possible Solutions Verify that motor and drive catalog numbers have been programmed for the selected gear range V
18. ly below the display on the I O Board below and right on A04 A06 size unit Turn CCW to increase intensity and contrast Measure voltage at 5V DC test point to verify proper power supply operation If no 5 DC remove AC power and then remove cover from board connector CN8 CN15 on A04 A06 drive Reapply AC power and using a voltmeter verify voltage between pins 3 and 4 pins 1 and 32 on A04 A06 drive is 255 355V DC If supply voltage is OK replace Main Control Board or Gate Drive Board on A04 A06 drive If no 255 355V DC verify Interconnect Boards are properly seated in connectors Inspect contacts in both connectors to assure that they are making proper contact with the Interconnect Boards Replace drive Power Unit if 255 355V DC can not be obtained Replace I O Board and display assembly Table 1 D Continued Problems that Occur when AC Power is Applied No 4 Problem Probable Cause AC Phase Loss displayed An incoming 3 phase line is open Loss of one phase of incoming AC line detected by drive Malfunctioning AC control power fuse Malfunctioning drive interconnections or hardware Malfunctioning printed circuit board Faulty Power Unit Power Supply displayed Low voltage power supply An internal power is malfunction missing or out of tolerance was detected Resolver Loss displayed Incorrect wiring to resolver Improper or no signals from motor resolver have been detected
19. onnector CN2 is connected to the drive 2 Verify the wiring of the connector at the drive and at the feedback device Either increase the value of ORIENT TUNE Orient Start or decrease the value of ORIENT TUNE Orient Speed 1 If an optical encoder is used verify that the A B and Z channel outputs are present and have proper amplitude phase relationships and that the signals are relatively free of electrical noise 2 If the high resolution magnetic feedback is used follow the procedure shown in Figure 1 4 to verify the output signals Adjust the mounting of the gear and the position of the sensor relative to the gear to obtain proper signals or replace the sensor head 28 continued Malfunctioning printed circuit board If problems were not found with other tests replace Main Control Board CPU Board on A04 A06 drives If an optical encoder is being used the ORIENT Bad PG Output displayed Wrong type of feedback device The electrical signals from the high resolution magnetic feedback device are has been specified abnormal The gear or sensor are not correctly installed Interconnecting cable or sensor are defective Malfunctioning printed circuit board SETUP FEEDBACK DEFN Encoder Type parameter must be set to OPTICAL PULSE When this parameter is changed and then stored in EEPROM AC power must be removed from the drive and then reapplied to reset this parameter valu
20. or on I O Board Main Control Board are inserted correctly 2 Verify that the I O Board connectors are fully seated into the Main Control Board or CPU Board connectors 3 If problem remains replace I O Board 4 If problem remains replace Main Control Board CPU Board on A04 A06 drive 31 32 33 34 35 36 37 38 continued Main CPU Loss displayed CPU on Main Control Board CPU Board on A04 A06 drive unable to complete calculations during allotted time cycle Main Comm Err displayed No communications occurring between master and slave processors on Main Control Board CPU Board on A04 A06 drive Main Watchdog displayed The watchdog timer on the Main Control Board CPU Board On A04 A06 drive tripped out Main A D Conv displayed The A D converter on the main control board CPU Board on A04 A06 drive faulted or sensed excessive offset Main CPU1 Err displayed The master cpu on the Main Control Board CPU Board on A04 A06 drive malfunctioned Main CPU2 Err displayed The slave cpu on the Main Control Board CPU Board on A04 A06 drive malfunctioned Main RAM Init displayed Functional error detected in RAM on Main Control Board CPU Board on A04 A06 drive Main CPU Ovfl displayed CPU on Main Control Board CPU Board on A04 A06 drive ran out of execution time Firmware problem or hardware malfunction on Main Control Board CPU Board on A04 A06 dri
21. ors CN7 and CN8 CN15 and CN16 on A04 A06 drives 2 Remove Interconnect Board from CN7 and 12 13 14 Table 1 F Need Parameter displayed A required parameter programmed into the EEPROM before attempting to enable the drive Parameter Err displayed Two programmed parameter values conflict with one another Data Conflict displayed Programmed parameter values conflict with one another Possible malfunctioning IGBT driver fuse on Main Control Board Gate Drive Board on A04 A06 Drive Malfunctioning IGBT module in inverter bridge Malfunctioning printed circuit board Malfunctioning Power Unit current sensor or circuit board Drive programming not completed Parameters are incorrectly programmed Parameters are incorrectly programmed Problems that Occur while the Drive is Operating No 15 Problem Motor runs in a random or uncontrolled manner or with excessive vibration when either the Forward Reverse Run command is energized continued Probable Cause Resolver phasing is incorrect Motor phase is open Resolver or resolver wiring is CN8 and inspect contacts in both connectors to assure that they are making proper contact with the Interconnect Board Make certain it is inserted correctly so that blank side if any is towards outside of drive Remove all twelve 0 3A fuses and check with ohmmeter Replace any bad fuses Important Be certain to p
22. perature should be in excess of 110 C at this time 2 If motor case is below 110 C use an ohmmeter to check the thermal switch Approximately zero ohms should be measured between pins 15 amp 16 on the resolver connector in 1327AB series motor terminal box For 1327AD motors measure pins 9 amp 10 If an open circuit or high resistance is measured replace the motor 3 If thermal switch is OK check cable to drive and connectors for proper connection and continuity Repair or replace as required If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drive When drive cools the thermal switch will close and the fault will clear Reduce duty cycle loading or increase size of motor drive system Check fuses FU2R and FU2S Verify that fan power cable is plugged into the Power Board The 11 uses connector XB10 in top left corner of Power Board The A22 uses connector XB9 in the upper right corner and XB10 in the lower right corner of the Power Board If fuses OK and fans inserted then cooling fan malfunctioning Replace Power Unit Thoroughly clean the heat sink using pressurized air Assure that there is sufficient clearance above and below heat sink to allow adequate air flow Check Catalog Num setting to verify that it matches the motor nameplate Incorrect parameter setting can cause current oscillation that exceeds drive rating
23. r phase Check the contactors to assure they are making proper connections at all times Replace contactors if necessary Refer to fault condition 6 for solutions If problems were not found with other tests replace Power Unit If problems were not found with other tests replace Main Control Board gate drive and CPU Boards on 04 06 drives Mtr Windg Chg displayed The auxiliary contacts on the winding change contactors did not cycle as expected during the winding change operation Whenever the Motor Winding Select Low High input is Off the auxiliary contact on the Low Speed Contactor should be closed Whenever the Motor Winding Select Low High input is On the auxiliary contact on the High Speed Contactor should be closed This fault is monitored only when a 1327AD series dual winding motor has been selected with the MOTOR SELECT Catalog Num parameter Interconnection problem between contactors One of the winding change contactors are malfunctioning 1 Verify that connector CN1 is properly connected to the drive 2 Verify that the connector CN1 and the contactors are correctly wired 3 Check the cable for continuity Check the contactors to verify that they operate properly Verify the operation of the auxiliary contacts Table 1 G continued Malfunctioning printed circuit board Problems that Occur during Spindle Orient Operation No 24 25 Problem Motor runs continuously a
24. roperly reseat all fuses to avoid possible damage to IGBTs Check IGBT modules M1 M2 and M3 or IGBT1 in A04 A06 drive according to procedure later in this chapter Replace Power Unit if IGBT is malfunctioning If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drives If problems were not found with other tests replace the Power Unit 1 Verify that the motor catalog number and drive catalog number are properly programmed 2 In orient mode verify proper feedback definition Re examine programmable parameters for compatibility start with the ones most recently changed Refer to the 8510 Programming Manual publication 8510 5 2 as needed Re examine programmable parameters for compatibility start with the ones most recently changed Refer to the 8510 Programming Manual publication 8510 5 2 as needed Possible Solutions Use the programming parameter ELECT CONFIG Motor Phasing to reverse the relative phasing of the motor to the resolver Check all power wiring to the motor for continuity and tight connections Use an ohmmeter to verify phase to phase continuity for each motor phase When 1327AD series dual winding motors are used check both winding change contactors for proper operation Refer to fault condition 6 for solutions 16 17 ADS Overspeed displayed Motor shaft speed exceeding the programmed value of the
25. s motor has not been defined or is incorrectly defined For the gear range selected the motor type selected by the MOTOR SELECT Catalog Num parameter has been set NON STD MTR 2 and this motor has not been defined or is incorrectly defined Within a given gear range the optional 16 bit digital command input can be used as either a spindle speed command or as an orient position command not both Verify that only one of these functions are programmed for the BCD or binary command input Verify that each of the parameters listed under Probable Cause is set to a valid value that must be greater than zero Change the MOTOR SELECT Catalog Num parameter setting to the correct catalog number for the motor connected to the system If this does not correct the problem contact the factory Change the MOTOR SELECT Catalog Num parameter setting to the correct catalog number for the motor connected to the system If this does not correct the problem contact the factory Figure 1 3 Resolver Signals Test Point 51 amp Ground Resolver Signal Approx SIN Wave 17 6V p p 32us Test Point 52 amp Ground Resolver Excitation 0V DC Approx Signal SIN Wave 17 6 p p Test Point R1 amp Ground Resolver Feedback Approx T 128us _ _ with motor stopped Y Figure 1 4 High Resolution Magnetic Feedback Signals T a 8 the per nels th
26. ssure that they are making proper contact with the Interconnect Board Make certain it is inserted correctly so that blank side if any is towards outside of drive Remove all twelve 0 3A fuses and check with ohmmeter Replace any bad fuses Important Be certain to properly reset all fuses to avoid possible damage to IGBTs Check IGBT modules M4 5 and M6 or IGBT2 in A04 A06 drive according to procedure provided later in this chapter Replace Power Unit if IGBT is malfunctioning 10 11 Motor Short displayed Current sensed by motor phase current sensors CT U or CT V was too high Usually indicates a problem with the motor or motor wiring Inv Mtr Short displayed Current sensed by DC link current sensor CT S was too high Usually indicates problem with motor or IGBTs in inverter bridge continued Malfunctioning printed circuit board Malfunctioning Power Unit current sensor or circuit board Improper connection of winding changeover contactors when a dual winding motor is being used Incorrect motor selected in MOTOR SELECT Catalog Num parameter Shorted or voltage breakdown of motor or motor cabling to ground or another phase Improper motor power connections Malfunctioning printed circuit board Malfunctioning Power Unit See fault condition 10 Motor Short Malfunctioning drive interconnections If problems were not found with other tests repl
27. t the Orient Speed parameter setting without faulting and without orienting The spindle over shoots the target position and oscillates several times before stopping Probable Cause Feedback device is incorrectly phased Wrong type of feedback device has been specified The number of encoder lines has been incorrectly programmed Malfunctioning printed circuit board Either the velocity loop or the orient position loop is not tuned correctly The accel decel ramp rate settings are too slow relative to the orient position loop settings The orient mode tuning requires a faster decel rate than the drive can provide If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drives Possible Solutions Use the ORIENT SETUP FEEDBACK DEFN Encdr Phasing parameter to reverse the phasing of the orient feedback device The ORIENT SETUP FEEDBACK DEFN Encoder Type parameter must be set to OPTICAL PULSE when an optical encoder is used and to MAGNET ANALOG when the high resolution magnetic feedback is used Change this parameter to the correct setting and store it in EEPROM by energizing the Drive Enable input After the correct setting is stored AC power must be removed from the drive and then reapplied to reset this parameter value in the drive control software Use the ORIENT SETUP FEEDBACK DEFN Encoder Lines p
28. tioning drive interconnections Possible blown IGBT driver fuse on Main Control Board Gate Drive Board on A04 A06 Drive Malfunctioning IGBT module in converter bridge Verify that AC line voltage is between 180 252V 1 Check seating of Interconnect Board into board connectors CN6 and CN7 CN14 on A04 A06 drives 2 Remove Interconnect Board from CN6 and CN7 CN 14 and inspect contacts in both connectors to assure that they are making proper contact with the Interconnect Board Make certain it is inserted correctly so that blank side if any is towards outside of drive 3 Remove Control Boards and check for any loose hardware on Power Board In particular check connections to the terminal block AC line inductor and IGBT modules M4 M5 and M6 or IGBT2 in A04 A06 drive Check IGBT modules M4 5 and M6 or IGBT2 in A04 A06 drive according to IGBT Test Procedure presented later in this chapter Replace Power Unit if IGBT is malfunctioning If problems were not found with other tests replace Power Unit If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drive Remove power to the drive and restart 1 Check seating of Interconnect Boards into board connectors CN7 and CN8 CN15 and CN16 on A04 A06 drives 2 Remove interconnect board from CN7 and CN8 and inspect contacts in both connectors to a
29. ve Hardware malfunction The microprocessor on Main Control Board ran out of execution time or stopped Hardware malfunction Hardware malfunction Hardware malfunction Hardware malfunction Firmware error or hardware malfunction 1 Verify that the EPROM on the Main Control Board is inserted correctly 2 If problem remains replace Main Control Board CPU Board on 3 If problem remains contact factory 1 Verify that the EPROM on the Main Control Board is inserted correctly 2 If problem remains replace Main Control Board CPU Board on A04 A06 drive 1 Verify that EPROMs on both the I O Board and the Main Control Board CPU Board on A04 A06 drive are inserted correctly 2 If problem remains replace Main Control Board 3 If problem recurs contact factory Replace Main Control Board CPU Board on A04 A06 drive 1 Verify that EPROM chip on Main Control Board CPU Board on A04 A06 drive is inserted correctly 2 If problem remains replace Main Control Board CPU Board on A04 A06 drive 1 Verify that EPROM chip on Main Control Board CPU Board on A04 A06 drive is inserted correctly 2 If problem remains replace Main Control Board CPU Board on A04 A06 drive Replace Main Control Board CPU Board on A04 A06 drive 1 Verify that both EPROMs on I O Board and Main Control Board are inserted correctly 2 If problem remains replace Main Control Board CPU Board on A04 A06 dri
30. ve If problem recurs contact Allen Bradley continued 39 Optical Intpt displayed A Bright flash of light triggered the 1 Assure that the rubber plug is installed in the system interrupt was sensed fiber optic input fiber optic connector on the Main Control system fiber optic Board CPU Board on A04 A06 drive The transducer fiber optic connector is located adjacent to connector CN2 2 If problem remains replace Main Control Board CPU Board on A04 A06 drive 40 Hi Accel Rate displayed Firmware error Reset drive If fault persists contact Allen Bradley 41 Hi Positn Cmd displayed Firmware error Reset drive If fault persists contact Allen Bradley 42 Hi Positn Err displayed Firmware error Reset drive If fault persists contact Allen Bradley 43 Hi Speed displayed Firmware error Reset drive If fault persists contact Allen Bradley T O Board Faults When problems occur with the I O Board the first line of the display will show either Fault I O Board or Warning I O Brd The second line provides more detailed information about the exact nature of the fault Table 1 1 Problems Specifically Related to the Board No Problem Probable Cause Possible Solutions 44 EEPROM No Data The drive was not programmed Perform the complete drive setup programming displayed The I O Board procedure as described in the 8510 Programming microprocessor could not Manual publication 8510 5 2 find the EEPROM EEPROM
Download Pdf Manuals
Related Search