Chapter 6 - AutomationDirect
Contents
1. MAINTENANCE AND TROUBLESHOOTING Contents of this Chapter Maintenance and Inspection 0000 eee 6 2 Monthly INSPECCION o 2 2c 8524 550000 0858688 408008 2550804 6 2 Annual Inspection 0 1 40 06 cet rebeddddbteneeasaww ewe mmed ee sek 6 2 Recharge Capacitors for unused drives 0 cece eee ae 6 2 WROUBRIESIOOUNG ze vache eccercumcan oe eee eye ee dene cee RA 6 3 Fault Codes ss 255 5555 666555505o50000 05 RRSSeeoadege EER 6 3 Warming Messages a0 lt lt 26 sssaaa anaa Soe 8e8 6 5 Chapter 6 Maintenance and Troubleshooting ET Maintenance and Inspection Modern AC drives are based on solid state electronics technology Preventive maintenance is required to operate the AC drive in its optimal condition and to ensure a long life We recommend that a qualified technician perform a regular inspection of the AC drive Some items should be checked once a month and some items should be checked yearly Before the inspection always turn off the AC input power to the unit and wait at least two minutes after all display lamps have turned off ine If the drive is stored or is otherwise unused for more than a year the drive s internal DC link capacitors should be recharged before use O therwise the capacitors may be damaged when the drive starts to operate We recommend recharging the capacitors of any unused drive at least once per year WARNING Disconnect AC power and ensure that the internal capaci2. AeA WwW N 6 2 l GS1 Series AC Drive User Manual 2nd Edition 07 06 2011 Chapter 6 Maintenance and Troubleshooting Troubleshooting Fault Codes The AC drive has a comprehensive fault diagnostic system that includes several different alarms and fault messages Once a fault is detected the corresponding protective functions will be activated The fault codes are then displayed on the digital keypad display The six most recent faults can be read on the digital keypad display by viewing P 6 31 to P 6 36 l NOTE Faults can be cleared by a reset from the keypad or input terminal Fault Codes Fault Name Fault Descriptions Corrective Actions The AC drive detects an abnormal 1 Check whether the motor s horsepower corresponds increase in current to the AC drive output power 2 Check the wiring connections between the AC drive and motor for possible short circuits Increase the Acceleration time P 1 01 or P 1 05 Check for possible excessive loading conditions at the motor If there are any abnormal conditions when operating the AC drive after short circuit is removed the AC drive should be sent back to the manufacturer The AC drive detects that the DC Check whether the input voltage falls within the bus voltage has exceeded its rated AC drive input voltage maximum allowable value Check for possible voltage transients Bus over voltage may also be caused by motor regeneration Increase the decel time Check
3. whether the required braking power is within the specified limits The AC drive temperature sensor Ensure that the ambient temperature falls within the detects excessive heat specified temperature range Make sure that the ventilation holes are not obstructed 3 Remove any foreign objects on the heat sinks and check for possible dirty heat sink fins 4 Provide enough spacing for adequate ventilation The AC drive detects that the DC Check whether the input voltage falls within the AC bus voltage has fallen below its drive s rated input voltage minimum value The AC drive detects excessive 1 Check whether the motor is overloaded drive output current 2 Reduce torque compensation setting as set in P 2 03 Note The AC drive can withstand 3 Increase the AC drive s output capacity up to 150 of the rated current for a maximum of 60 seconds 2nd Edition 07 06 201 GS1 Series AC Drive User Manual l 6 3 Chapter 6 Maintenance and Troubleshooting ET Fault Codes continued Fault Name 6 4 l GS1 Series AC Drive User Manual Fault Descriptions Corrective Actions Internal electronic overload trip Check for possible motor overload Check electronic thermal overload setting Increase motor capacity Reduce the current level so that the AC drive output current does not exceed the value set by the M otor Rated Current P 0 01 M otor overload Check the pa
4. he AC drive Communications W arning Illegal data address The data address received in the command message is not available for the AC drive The corrective action can be set with the Transmission Fault Treatment parameter P 9 03 The available settings are Communications W arning Illegal data value The data value received in the command message is not available for the AC drive 0 Display fault and continue operating 1 Display fault and RAMP to stop 2 Display fault and COAST to stop 3 No fault displayed and continue operating The default setting is 0 Communications W arning Slave device failure The AC drive is unable to perform the requested action Communications W arning Communication Time O ut 2nd Edition 07 06 201 GS1 Series AC Drive User Manual l 6 5 Chapter 6 Maintenance and Troubleshooting ET 6 6 l GS1 Series AC Drive User Manual 2nd Edition 07 06 2011
5. nnections between the main control board and the power board 2 Reset drive to factory defaults Hardware protection failure Return to the factory Software protection failure Return to the factory AC Drive s internal circuitry abnormal 1 Switch off power supply 2 Check whether the input voltage falls within the rated AC drive input voltage Switch on the AC drive The external terminal EF CM goes from OFF to ON When external terminal EF CM is closed the output will be turned off under N O E F 2nd Edition 07 06 2011 Chapter 6 Maintenance and Troubleshooting ee Fault Codes continued Fault Name Fault Descriptions Corrective Actions Auto accel decel failure Don t use the function of auto acceleration deceleration External Base Block AC drive output is turned off Warning Messages 1 When the external input terminal base block is active the AC drive output will be turned off 2 Disable this connection and the AC drive will begin to work again There are several Warning Messages that the GS1 AC Drive may give The GS1 AC Drive allows you to decide how it should respond to these messages The descriptions of the Warning Messages are listed below Warning Messages Warning Descriptions Corrective Actions Communications W arning Illegal command code The command code received in the command message is not available for t
6. rameter settings 6 07 to 6 09 Reduce the motor load Adjust the over torque detection setting to an appropriate level O ver current during acceleration 1 Short circuit at motor output 2 Torque boost too high 3 Acceleration time too short 4 AC drive output capacity is too small Check for possible poor insulation at the output line Decrease the torque boost setting in P 2 03 Increase the acceleration time Replace the AC drive with one that has a higher output capacity next HP size O ver current during deceleration 1 Short circuit at motor output 2 Deceleration time too short 3 AC drive output capacity is too small Check for possible poor insulation at the output line Increase the deceleration time Replace the AC drive with one that has a higher output capacity next HP size O ver current during steady state operation 1 Short circuit at motor output 2 Sudden increase in motor loading 3 AC drive output capacity is too small Check for possible poor insulation at the output line Check for possible motor stall Replace the AC drive with one that has a higher output capacity next HP size Internal memory IC cannot be programmed Switch off power supply Check whether the input voltage falls within the AC drive s rated input voltage Switch the AC drive back on Internal memory IC can not be read Check the co
7. tors have fully discharged before inspecting the AC drive Monthly Inspection Check the following items at least once a month 1 Make sure the motors are operating as expected Make sure the installation environment is normal Make sure the cooling system is operating as expected Check for irregular vibrations or sounds during operation Make sure the motors are not overheating during operation Check the input voltage of the AC drive and make sure the voltage is within the operating range Check the voltage with a voltmeter Annual Inspection Check the following items once annually 1 Tighten and reinforce the screws of the AC drive if necessary They may loosen due to vibration or changing temperatures Make sure the conductors and insulators are not corroded or damaged Check the resistance of the insulation with a megohmmeter Check the capacitors and relays and replace if necessary Clean off any dust and dirt with a vacuum cleaner Pay special attention to cleaning the ventilation ports and PCBs Always keep these areas clean Accumulation of dust and dirt in these areas can cause unforeseen failures 6 Recharge the capacitors of any drive that is in storage or is otherwise unused Recharge Capacitors for unused drives Recharge the DC link before using any drive that has not been operated within a year 1 Disconnect the motor from the drive 2 Apply input power to the drive for 2 hours OU BW NN U
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