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Troubleshooting Guide

1. Figure 2 Gate Driver Board f X TP8 2 SL d AN X TPS a ar Ned FGI TP6 FORCE 1 X Pg j gt 89 V J13 29 Not 85 a Used TP19 wc T J1 x m gp N Not M Used 5146 V J7 N 5 ER gt To Power Module 7 Y E Snubber Boards TP2 ER JB E X uU 2 2 M N s 4 To Power Module Pom Snubber Boards e co Cy my Q LZ TP10 E N X 7 118 FIR TB7 S To PE 118 TP1 x TP3 TP18 TP14 x 2 x 5 J10 811615 a Sy SE 202000 Not Used NotUsed Not Used To DC Bus Figure 3 Isolation Board To Main Control To Current To AC Line DC Bus To Board J12 Transducers LEMs
2. a TB4 1 Bret 1 1 R px 0000005000909000 11514141 41 PLC LP FD ILL A i J1 J2 SO er O TB2 oL Qll 666 note below TB1 2 swi 1O h 1 i 115V O TB6 TB5 9999999919999 1 2 Il ll IT Control Circuitry Note TB2 is only used in Series B RGUs or RGUs with 3 CT current feedback See Figure 7 Publication 2364F 5 05 February 2005 A 6 Reference Information Test Points Test Points TP1 TP2 TP3 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 TP14 TP15 TP16 TP17 TP18 TP19 TP20 TP21 TP22 TP23 TP24 TP25 TP26 TP27 TP28 TP29 TP30 TP31 TP32 TP33 TP34 TP35 TP36 TP37 Name AGND DGND DGND 5V DGND RESET DGND ANIN8 DESAT ABS DSP DAC3 AGND DSP DAC2 5VREF 5VREF 10VREF OCT REF EDC OVT REF 15V ISS 15V ANIN1 ANIN2 AGND ANOUT1 ANOUT2 VR VS VT BUS BUS BUS Table F Test Points Main Control Board Description Analog Ground Digital Ground Digital Ground 5V Power Supply
3. NOT USED NOTUSED NOT USED TO GATE INTERFACE BOARD Pe ee CONTACTOR x INTERFACE vM 250 20 so Jie a Pd a ei AmS 99 ao o A SE lt 7 22 222222 2 0 2 aaz alaz alaa OO 5 3 a X XX odl ob E 2215555 zzz gt gt gt 2 5 lt lt m m o gt 55 ul 23456 12 3 6 7 8 11 12 13 16 17 18 2 1 4 87 54321 1 3 5 6 1 4 J7 J8 J2 J10 J6 J5 TB6 _AC LINE CHARGE 1 AC FAND COMMON gt 120VAC 15V TBS 120RTN NOT 15V 49 j 24V OUT 6 Gate Driver Board an SMPS SMPS J1 TB4 TB7 123 4 5 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 12 12 20 fr zz 141 141 1 151 515 4 gy go on gt 00 0 gt 2 Qo C 0000 22 202000 gt 282920 0 06 alr SS ad TE 28888885 22255555 he ee ey OS ele go o e Sap gt SPP gt gt z bzzz eee eo lt c 0 o ag 123 45 6 7 8 9 1011 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
4. O 5 2 Current Transducers TERA U E E 2127 Vae D P E E Publication 2364F 5 05 February 2005 Glossary 1336 FORCE Adjustable Frequency AC Drive An adjustable frequency AC drive produced by Rockwell Automation Most of the construction and components of the RGU power structure are equivalent to the 1336 FORCE drive Control Power Filter A filter used to reduce harmonics and noise in the 115V AC control power Digital Signal Processor DSP The digital signal processor which 1s located on the main control board of the RGU This component processes current commands for the RGU Disable When a unit 15 disabled the control logic is not directing current flow operations A unit is typically disabled by a disable command or by a fault condition Disconnect A circuit breaking device Enable When a unit is enabled the control logic is directing the motoring or regenerative current by modulating its hardware IGBTs Feedback signals from the hardware which indicate the hardware status to the control logic Gate Driver Board The RGU gate driver board is responsible for modulating the power modules and supplying power to the control boards The gate driver board is interfaced with the
5. Publication 2364F 5 05 February 2005 4 18 Testing Components Terminal Blocks Power Transformer Grounded Wye Secondary The RGU includes two terminal blocks which are available for customer connections TB1 and TB2 shown in Figure 4 14 These terminal blocks are located in the leftmost bay of the unit The RGU also has an analog I O terminal block available for customer connections TB1 on the main control board Details for connecting programming and using analog I O can be found in publication 2364F 5 01 N code RGUs also include an additional terminal block TB3 This terminal block is dedicated for motor operated circuit breaker wiring Figure 4 14 Terminal Blocks TB1 and TB2 TB2 1500 typ He jal 1 TBI 222 Controls 757 en m o oj 69 Fault Relay CR2 M Unit Not Faulted Pilot Light PL2 Used ARE exc pel er p Monitoring Deis e FE 612 oj eL er marl hlep er we oO es iiio 2 i p 1 ontrols 71 EE Devices 1 a Io 115V AC To Control Circuitry Publication 2364F 5 05 February 2005 Contents Specifications Appendix A Reference Information This appendix includes reference information for the RGU as indicated below Reference Information in This Chapter Specifications Printed Circuit Boards Test
6. 1 4 Troubleshooting The RGU RGU GONGWIONS Ji 37352 27 ate 2 1 Handling Unresolved Conditions 2 1 Unit Will Not 2 2 Unit Will Not 2 3 Unit Overvoltage Overcurrent Trips 2 4 Troubleshooting Faults and Warnings 3 1 Faults and WarningS 0 0 eee eee eee eee 3 1 How to Check the Warning and Fault Queues 3 2 Resetting the 3 4 Troubleshooting Faults and Warnings 3 5 Publication 2364F 5 05 February 2005 toc ii Chapter 4 Appendix A Glossary Index Publication 2364F 5 05 February 2005 Testing Components COMDONCING 24 aida dul aed edd edo fo fece e dete io do deo dede 4 1 Testing and Replacing Parts in the Power Structure 4 2 How the RGU Power Structure Differs From the 1336 FORCE 4 2 Testing the Main Control Board 4 3 Replacing the Battery for the Battery Backed Memory on the Main xou deumque eere Dv ee PPS 4 6 Testing the Gate Driver Board 4 7 Testing the Isolation Board 4 10 Testing the Control Power 4 12 T
7. Tic 13 BRAM Chksum 42 No Fast Task 15 DSP Timeout 43 No Bgnd Task 28 DualPort TO 44 Addr Bus Err 31 DSP Fault 45 Data Bus Err Publication 2364F 5 05 February 2005 4 6 Testing Components Replacing the Battery for the Battery Backed Memory on the Main Control Board Replacing the battery on the main control board U11 will erase all modified parameters Record parameters before replacing the battery 1 Push the disconnect lever to off and wait for voltage to discharge from the unit Do not continue until all voltage has dissipated from the DC bus Verify that there is no voltage across the DC bus see Figure 4 12 and Figure 4 13 for check points Verify that there is no voltage across the terminals and subcomponents of the main control board Put on an electrostatic discharge ESD protective strap and connect the strap to one of the door latches Grasp the battery from the top and bottom and gently pull the battery off of Ull as shown in Figure 4 3 note the orientation of the battery Gently press the new battery into place the battery can only be installed in one orientation Properly dispose of the lithium battery according to your local ordinances and company procedures Figure 4 3 Replacing the Battery for the Battery Backed Memory See publication 1756 5 68 for guidelines concerning lithium battery disposal Publication 2364F 5 05 Battery Backed _ Memor
8. Allen Bradley Regenerative DC Tro D es h ooti n 0 Bus Supply Unit d RGU Guide Bulletin 2364F Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or part without written permission of Rockwell Automation 1s prohibited Throughout this manual we
9. In addition to RGU publications the 1336 FORCE service manuals shown in Figure 1 1 provide information for testing and replacing components within the RGU power structure See chapter 4 for more information Figure 1 1 1336 FORCE Service Manuals 1336 FORCE 6 12 1336 FORCE 6 13 1336 FORCE 6 14 1336 FORCE 6 15 Not Available at Time of Printing J code RGUs For K code RGUs ForL code RGUs For M code RGUs For N code RGUS Note Most of the construction and components of the N code power structure are equivalent to the M code power structure Publication 1336 FORCE 6 15 has sufficient information for servicing the N code power structure Publication 2364F 5 05 February 2005 1 2 Introduction Basic Troubleshooting Techniques Data Nameplates Publication 2364F 5 05 February 2005 When troubleshooting refer to the system schematics and determine the components that are critical to the process Test each of the critical components to determine the problem Also consider how the RGU s programming parameters may be affecting the situation Consider upgrading to the latest version of firmware available When a damaged component has been found always try to determine the cause of the problem rather than just replacing the component Verify that equipment is connected and being used properly verify that the parameters are properly set for the particul
10. Terminal blocks 4 18 Troubleshooting 1 2 2 1 3 1 4 1 A 1 Control power filter 4 12 Damaged components 2 5 DC bus suppressor 4 14 Faults and warnings 2 6 3 2 3 3 3 5 3 6 3 7 3 8 3 9 3 10 Gate driver board 4 7 4 8 4 9 IGBTs power modules 4 16 Isolation board 4 10 4 11 Line RC suppressor 4 13 Main control board 4 3 4 4 4 5 MOVs 4 15 Precharge resistors 4 15 Unit overvoltage overcurrent trips 2 4 Unit will not enable 2 3 Unit will not start 2 2 U Unit overvoltage overcurrent trips 2 4 Unit will not enable 2 3 Unit will not start 2 2 Publication 2364F 5 05 February 2005 Index 1 3 Publication 2364F 5 05 February 2005 Reach us now at www rockwellautomation com Wherever you need us Rockwell Automation brings together leading brands in industrial automation including Allen Bradley controls Reliance Electric power transmission products Dodge mechanical power transmission components and Rockwell Software Rockwell Automation s unique flexible approach to helping customers achieve a competitive advantage is supported by thousands of authorized partners distributors and system integrators around the world Americas Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Roc kwell European Headquarters SA NV avenue Herrmann Debroux 46 1160 Brussels Belgium Tel 32 2 663 06 00 Fax 32 2 663 06 40 Asia Pacific Headquarters 27 F Citico
11. Ji oo 1 TP4 42 IE Digital Signal Processor DSP Flash Memory g UM J6 e B 90 5 Host 145 x Processor TP6 x TP7 J7 ne 18 1 TP8 TP9 TP10 x TP14 TP11 TP12 TP13 X X 19 TP15 1 x TP16 17 TP18 19 TP21 TP22 x x x x o J10 TP27 TP28 TP29 TP30 TP31 TP32 TP33 TP34 TP35 TP36 TP37 24 TP25 x x x x x X X X O Q J14 1 ooOooO000O000Q0 QR SE UR GUT SU SA SOUL 1128 Available for To Isolation Board User Connections J2 Analog 1 0 To NTC Bridge Thermal Sensor To SCANport Device To SCANport Device To Laptop PC Used Only for Upgrading Firmware Reference Information A 5 To Main Control Board J3
12. Testing MOVs Testing Precharge Resistors Testing IGBTs Terminal Blocks ATTENTION Do not attempt to alter or modify any printed circuit boards in the RGU Any attempt to alter or modify boards may result in personal injury or property damage Publication 2364F 5 05 February 2005 4 2 Testing Components Testing and Replacing Parts in the Power Structure Publication 2364F 5 05 February 2005 The RGU power structure design is based on the 1336 FORCE drive To test or replace parts in the power structure refer to the instructions in this publication and refer to the appropriate 1336 FORCE service manual listed in Table 4 A for additional details Table 4 A 1336 FORCE Service Manuals RGU Current Code Reference Publication J 1336 FORCE 6 12 K 1336 FORCE 6 13 L 1336 FORCE 6 14 M 1336 FORCE 6 15 N Not available at time of publishing Note Most of the construction and components of the N code power structure are equivalent to the M code power structure Publication 1336 FORCE 6 15 can be used to service N code power structures How the RGU Power Structure Differs From the 1336 FORCE When using the 1336 FORCE service manuals take note that the RGU power structure differs from the 1336 FORCE in the following regards e The power structure has an isolation board in place of the 1336 FORCE precharge board e The power structure has an RGU main control board in place of the 1336T main control board standar
13. 15 DSP Timeout The host processor did not receive data from P174 bit 15 the DSP The host assumes that the DSP is not running 16 Desaturizatn A power module was overloaded so severely P177 bit 0 that the power module was forced out of full turn on condition Publication 2364F 5 05 February 2005 Action Clear the fault and try resetting restarting the RGU Check all feedback wiring Verify that the door mounted start switch is turned on Check that timer relay TR1 is set to 3 seconds Check for any other fault activity that may be causing the M1 Open fault Verify that the SCANport device is connected properly Pull the plug out and reconnect If necessary try resetting or restarting the RGU Clear the fault and try resetting restarting the RGU Check the R2R board s and wiring connections Troubleshoot the board s and replace as necessary The boards receive power from the DC bus Check the wiring from the gate driver board J10 to the DC bus Check the ribbon cable connection between the gate driver board J1 and the main control board J3 Check the TE connection on main control board J11 and the gate driver board TB7 2 Troubleshoot the gate driver board and main control board and replace as necessary Check that the door fans are operating properly and verify that the RGU is operating at the appropriately derated current see the specifications appendix in 2364F 5 01 Verify that the RGU is not operating in
14. 4 7 Push the disconnect lever to off and wait for all voltage to discharge from the unit Do not continue until all voltage has dissipated from the DC bus Verify that there is no voltage across the DC bus see Figure 4 12 and Figure 4 13 for check points Verify that there is no voltage across the subcomponents of the control power filter Set meter for resistance and check the resistor For 4 KHz filters the resistance should be 0 8 1 4 ohms 1 ohm rating For 2 kHz filters the resistance should be 1 3 1 9 ohms 1 5 ohm rating Check the continuity between 1 1 and the connection point for the control power transformer PT1 If the filter has failed any of these tests it may be damaged Replace the filter and consider replacing any associated wiring or fuses as necessary Figure 4 7 Voltage Waveforms Ahead and After the Control Power Filter Typical Control Power Ahead of Filter Typical Control Power After Filter Testing Components 4 13 Testing the Line RC Suppressor The line RC suppressor discharges excess voltage from the AC lines 1 7 Push the disconnect lever to off and wait for voltage to discharge from the unit Do not continue until all voltage has dissipated from the DC bus Verify that there is no voltage across the DC bus see Figure 4 12 and Figure 4 13 for check points Verify that there is no voltage across the subcomponents of the suppressor Check the board fuses and an
15. 42 43 44 45 46 47 48 49 50 J3 FROM HEATSINK NTC J2 FROM HEATSINK NTC 111 TO TE GND Main Control Board J1 DSP BACKGROUND CONNECTOR J5 FLASH PROGRAM JUMPER 46 HOST BACKGROUND CONNECTOR USER DCD gt USER RECEIVE DATA USER TRANSMIT DATA USER DTE J43 5 SIGNAL GROUND USER DSR 7 USER RTS USER CTS o USER RING J8 2 3 4 5 6 7 8 9 10 11 12 13 14 ol gt gt 2 2 5555 B R2R RXDO u2 MASTER ROB 5 SCANPORT EXTENDER ID 6 120 V AC R2R RXD1 SLAVE 1 181 2 120 FROM R2R DUPLEX CONNECTORS R2R TXD1 us Aura U3 amp U4 SLAVE2 R2RRXD2 yg R2R TXD2 y R2R Communications SLAVE3 R2RRXD3 yg i ROR TXD3 6 Hub Board Optional FROM MASTER TIO LOCAL CONNECTOR U5 TIO LEADER FROM SLAVE 1 TIO REMOTE CONNECTOR U6 TIO SLAVE 1 FROM SLAVE 2 TIO REMOTE CONNECTOR U6 TIO SLAVE 2 FROM SLAVE 3 TIO REMOTE CONNECTOR U6 TIO SLAVE 3 U16 Publication 2364F 5 05 February 2005 10 Reference Information Firmware Diagrams Figure 5 Firmware Block Diagram Regulation Ref Change Rate 127 Bus Rate Ref Bus Reference A SE SB 2 121 lt 125 5 Min Bus Ref Max Bus Ref 20 Aux Volt Cmd Bus Volt Cmd Bus Ref Auto Ref Limit Bus Feedback 129 gt Calculator 4096 Base D
16. External Resistor Discharge Not Used Publication 2364F 5 05 February 2005 A 8 Reference Information Board to Board Schematics Figure 4 Board to Board Schematics F gt 2 Zz 2 2 2 2 or 5 2 5 gt 5 55 5 252 B e m m m m e 2 a 9 5 2 c NRE rm H a 2 a 0 2 gt 0 2 2 2 a 0 0 n 0 0 0 2 2 O 9 N d ITI ITI f yuy E d 4 a C fo 123 p 201918171615141312110987654321 1 1 3111 3 4 AUXILIARY RELAY COM J1 TB1 2 TBS CLEARANCE 5 J7 AUXILIARY RELAY NC LEM INTERLOCK AUXILIARY RELAY 2 15 PHASE CLEARANCE 5 3 PHASE RLEM BUS CONTROL RELAY COM isolation Board 2 _ 15V PHASE CLEARANCE x 5 15V PHASE S BUS CONTROL RELAY NC 5 PHASE LEM BUS CONTROL RELAY 15V PHASE S INPUT VOLTAGE 15V PHASE T TBS SELECT SW1 9 PHASE T LEM ENABLE 1 24V 10 15V PHASE T FAULT RESET 44 SPARE EXTERNAL MAIN 3 1 45v J2 42 LEM INTERLOCK INPUT COMMON OFF 12 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1
17. February 2005 Figure 1 4 shows the process that should be used to start a unit which has been serviced If the unit is set for local mode the unit will automatically enable when started Figure 1 4 Starting and Operating the RGU Setting Up Local Mode Startup and Parameter Check Unit Enables At Startup e Push disconnect to on e Set P8 Remote Local Selector to 0 e Check the line to ground voltage e Resetor restart the unit between F7 and ground should be about 120V A signal must be applied to TB5 1 isolation board for the unit to e Turn start switch to on enable i e by timer relay e Check the following parameters Setting Up Remote Mode P4 Frame Catalog Number Unit Enables By HIM GPT P10 Nominal AC Line Voltage P11 Rated AC Line Current P12 Line Reactor Inductance e Set P224 SCANport Port Enable P13 Utility AC Line Frequency Mask and P225 SCANport Enable P14 Measured AC Line Voltage Mask to 0100 0111 P143 Scaled Bus Feedback P203 External Capacitance e Set P8 Remote Local Selector to 1 Refer to publication 2364F 5 01 e Enable the unit with a HIM GPT or for programming details other connected SCANport device Chapter 2 Troubleshooting The RGU RGU Conditions This chapter provides troubleshooting instructions for the most common RGU conditions Choose the topic that most closely represents the condition of your unit Conditions Handled in This Chapter
18. RGU User Manual Figure 1 3 Data Nameplate Power Structure CAT 2364FA MNB gt CONSTANT TORQUE S VOLTS A PH apar ser es ra um Refer to user manual for installation instructions Basic Catalog String 2364 A Type Family Wiring Power Structure MNB Current Code M Regenerative DC Bus Supply Unit 460V AC Input Basic Catalog Strings 2364FA JNN J code RGU 380V AC 2364FA MNN M code RGU 380V AC 2364FA JNB J code RGU 460V AC 2364FA MNB M code RGU 460V AC 2364FA JNC J code RGU 575V AC 2364FA MNC M code RGU 575V AC 2364FA KNN K code RGU 380V AC 2364FA NNN N code RGU 380 2364FA KNB K code RGU 460V AC 2364FA NNB N code RGU 460V AC 2364FA KNC K code RGU 575V AC 2364FA NNC N code RGU 575V AC 2364FA LNN L code RGU 380V AC 2364FA LNB L code RGU 460V AC 2364FA LNC L code RGU 575V AC Publication 2364F 5 05 February 2005 1 4 Introduction Starting and Operating the RGU Prestart Inspection Verify that all tools and debris are out of the unit With disconnect off check the line to ground and line to line AC voltage in the unit should be zero Check the line to ground resistance before and after the main contactor should be high Check the bus to ground resistance for each DC bus should be high Check the line to line AC voltage ahead of the breaker should comply with the input rating of the unit Publication 2364F 5 05
19. The host processor was reset due to a P180 bit 1 memory access error The memory device was not responding in cycle 34 Watchdog W The host processor was reset due to a P180 bit 2 watchdog situation 3b EnatPwrUp The RGU enabled immediately at power up P180 bit 3 36 Battery Low W The lithium battery in the battery backed P180 bit 4 RAM is low If the RGU is powered down all setup parameters will be lost 37 101055 The slave RGU could not synchronize with the P180 bit 5 master RGU on power up since the TIO signal could not be found 38 R2R Dup Addr The CAN chip detected two nodes trying to P180 bit 6 use a duplicate address 39 Lost Master The slave RGU is not receiving data from the P180 bit 7 master unit seen only on a slave RGU ina master slave configuration Publication 2364F 5 05 February 2005 Action Clear the fault and try resetting restarting the RGU Verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved Clear the fault and try resetting restarting the RGU Verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If neces
20. Unit Will Not Start Unit Will Not Enable Unit Overvoltage Overcurrent Trips Damaged Components Handling Unresolved If a condition cannot be resolved by the troubleshooting instructions in this Conditions manual contact your local Rockwell Automation office for additional support Publication 2364F 5 05 February 2005 2 2 Troubleshooting The RGU Unit Will Not Start After the disconnect lever and start switch have been turned on the RGU should power any connected HIM or GPT devices and perform its precharge routine to raise the voltage of the capacitors on the DC bus Check the following items if the unit will not operate Is power available to the unit No Make power available to the unit Yes across the DC bus before testing the following items Are the line fuses in good condition No Replace all the AC line fuses Yes N ATTENTION Push the disconnect lever to off and verify zero volts Are the primary fuses F4 F6 in good No Replace both of the primary fuses condition Yes Is the control power F7 good No Replace the control power fuse condition Yes the precharge fuses F2 F4 in good No Replace both of the precharge fuses condition F9 F10 for J code RGU Yes Test the precharge resistors as instructed No Replace the damaged precharge
21. a resistance of 26 5 28 0 ohms 27 ohm rating This resistor is shown in Figure 4 10 Replace any damaged components and associated wiring as necessary Figure 4 10 Precharge Resistors 27 ohm 6 ohm Precharge d Precharge Resistor N Resistor 0 Used only in older J code RGUs Publication 2364F 5 05 February 2005 4 16 Testing Components Testing IGBTs Publication 2364F 5 05 February 2005 IGBTs can be checked by testing the resistance of the AC terminals with respect to the DC busbars 1 Push the disconnect lever to off and wait for all voltage to discharge from the unit Do not continue until all voltage has dissipated from the DC bus 2 Verify that there 18 no voltage across the DC bus see Figure 4 12 and Figure 4 13 for check points 3 Test the resistance between L1 and DC Bust J K and L code RGUs should show a high resistance over 500 k ohms M and N code RGUs should indicate a resistance of 5 to 10 k ohms since two IGBTs are installed parallel Test the other two lines L2 and L3 with respect to DC Bust 4 Test the resistance of L1 L2 and L3 with respect to DC Bus Again 7 K and L code RGUs should read over 500 k ohms while M and N code RGUs should read 5 to 10 k ohms 5 Set meter to check diodes Take a reading of L1 to DC Bus with negative lead on
22. avoid the hazard of electrical shock verify that all voltage on capacitors has been discharged before attempting to service repair or remove a drive system or its components You should only attempt the procedures this manual if you are qualified to do so and are familiar with solid state control equipment and the safety procedures in publication NFPA 70E ATTENTION An incorrectly applied or installed drive system can result in component damage and or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply and excessive ambient temperatures can result in the malfunction of the drive equipment ATTENTION The drive system contains ESD electrostatic discharge sensitive parts and assemblies Static control precautions are required when installing testing or repairing the RGU Component damage can result in ESD control procedures are not followed If you are not familiar with static control procedures refer to Allen Bradley publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook To reduce the risk of ESD damage to circuit boards wear a grounding wrist strap when handling circuit boards Store circuit boards in conductive packets Preface P 3 Contents of this Manual Chapter Title Contents Preface Information concerning safety support and reference documentation 1 Introduction Introduction to manu
23. processor A watchdog error has been detected in a background task of the host processor An address bus error has been detected on the main control board A data bus error has been detected on the main control board The input line voltage has fallen below the minimum threshold as defined in P26 The input line voltage has exceeded the maximum threshold as defined in P27 The 121 wire protection has evaluated the heatsink to power module junction temperatures and is indicating that the temperature is at half of the trip point Troubleshooting Faults and Warnings 3 9 Action Clear the fault and try resetting restarting the RGU Verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved The unit switches to the internal timer but synchonization between the host processor and the DSP is lost Try restarting the RGU verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware Replace the board and or send the board in for repair if the problem cannot be resolved Clear the fault and
24. try resetting restarting the RGU Verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved Clear the fault and try resetting restarting the RGU Verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved Clear the fault and try resetting restarting the RGU verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved Clear the fault and try resetting restarting the RGU verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware Replac
25. 005 2 6 Troubleshooting The RGU Handling Fault Conditions Typically a fault condition can be resolved through the process shown in flowchart below See chapter 3 for details on handling specific faults and warnings Clear the fault OK gt Resume normal operation Not OK Send enable command by HIM GPT SCANport device OK Not OK OK Reset or restart the unit 4 Not OK Troubleshoot hardware and firmware OK conditions Not OK Reinstall upgrade firmware replace parts OK Publication 2364F 5 05 February 2005 Contents Faults and Warnings Chapter 3 Troubleshooting Faults and Warnings This chapter covers the faults and warnings which may indicate troubled conditions in the RGU When the RGU indicates a warning fault or status condition you may need to take remedial action as stated in this chapter Topics in this chapter Faults and Warnings How to Check the Warning and Fault Queues Resetting the RGU Troubleshooting Faults and Warnings A fault situation will typically cause the RGU to report the condition and disable A warning situation will cause the RGU to report the condition but the RGU will continue normal operation with regard to the condition The RGU will indicate a situation as either a fault or warning according to the configuration of the fault warning select parameters
26. 22 33 47 68 135 135 215 430 645 645 900 1200 1200 1500 2070 2070 1500 2400 Table D Typical Capacitor Bank Values per Drive in uf 10 For 575V AC Lineups Frame Size gt A B NNI 15 200 350 300 700 1336 FORCE SA3100 90 140 290 400 600 900 1500 1800 2400 2400 1336 IMPACT 75 140 290 400 600 900 1500 1800 2400 2400 1336 PLUS 1336 PLUS II 75 75 290 400 600 900 1500 1800 2400 Table E Typical Gapacitor Bank Values for each SA3000 Inverter in uf 10 56A 70A 112A 140A 192A 240A 534A 972A 380 470 760 940 1330 1645 3200 6400 1457 12800 Inverter Publication 2364F 5 05 February 2005 A 4 Reference Information Printed Circuit Boards To Gate Driver Board J1 Publication 2364F 5 05 February 2005 Figure 1 Main Control Board 20 x TP23 x TP26 x lu To TE TP1 TP2 X mw ow own mi m ND Hi 15V 15 Host DSP Enable SCANport R2R Fault Fault OK OK C
27. 5 4 Preface Rockwell Automation Support Publication 2364F 5 05 February 2005 Rockwell Automation offers support services worldwide with Sales Support offices authorized distributors and authorized Systems Integrators located throughout the United States plus Rockwell Automation representatives in every major country in the world Local Product Support Please contact your local Rockwell Automation representative for e sales and order support e product technical training e warranty support e support service agreements Technical Product Assistance If you need to contact us for technical assistance please review the appropriate product manuals and the troubleshooting information in this manual first For the quickest possible response please have the catalog numbers of your products ready when you call Using This Manual 1336 FORCE Service Manuals Chapter 1 Introduction This manual provides information to help service personnel troubleshoot and correct the most common RGU conditions This troubleshooting guide is laid out with the following topics e Troubleshooting RGU Conditions e Troubleshooting Warnings and Faults e Testing Components e Reference Information This manual is to be used in conjunction with publication 2364F 5 01 Regenerative DC Bus Supply Unit RGU User Manual which provides component information schematics installation instructions specifications and a parameter list
28. 5 Communications Module User Manual Information for installing configuring programming and 1336 FORCE Adjustable Frequency AC Drive 1336 FORCE 5 12 troubleshooting the 1336 FORCE adjustable frequency AC drive User Manual Information for installing configuring programming and 1336 PLUS Adjustable Frequency AC Drive User 1336 PLUS 5 0 troubleshooting the 1336 PLUS adjustable frequency AC drive Manual Instructions for properly handling and moving motor control Receiving Handling and Storing Motor Control 2100 5 5 centers MCCs Centers Instructions Instructions for installing Bulletin 2300 motor control centers Bulletin 2300 Family of Drive Systems 2300 5 1 MCCs splicing busbars and removing roll out units Installation Manual Information for installing configuring and programming the SA3000 Binder 9 3001 833000 AC drive Information for installing configuring and programming the SA3100 Binder 9 3053 833100 AC drive Instructions for testing and replacing components in the RGU 1336 FORCE Adjustable Frequency Drive 1336 FORCE 6 12 power structure Service Manuals to 6 15 Information for wire sizes grounding and other electrical topics National Electrical Code ANSI NFPA70 A list of all the documentation available through Allen Bradley Allen Bradley Publication Index 50499 glossary of industrial automation terms and abbreviations Industrial Automation Glossary AG 7 1 Publication 2364F 5 05 February 200
29. 5 to 2 15V AC at full load 1 75 to 2 15V AC at full load 1 75 to 2 15V AC at full load 14 4 to 15 4V DC 10 to 10V DC see parameter P36 in pub 2364F 5 01 10 to 10V DC see parameter P37 in pub 2364F 5 01 10 to 10V DC see parameter P47 in pub 2364F 5 01 10 to 10V DC see parameter P48 in pub 2364F 5 01 1 14 1 38 1 71V AC depending on rated line voltage 1 14 1 38 1 71V AC depending on rated line voltage 1 14 1 38 1 71V AC depending on rated line voltage 1 25 1 51 1 89V AC depending on rated line voltage 1 25 1 51 1 89V AC depending on rated line voltage 1 25 1 51 1 89V AC depending on rated line voltage gt gt gt gt Reference Information 7 Table G Test Points Gate Driver Board Test Points Name Description Scale Typical Range TP1 BUS Positive Bus Input 1 1 1 rated DC bus voltage TP2 BUS Negative Bus Input 1 1 1 rated DC bus voltage TP3 24V 24V Power Supply 1 1 23 7 to 24 3V DC TP4 5V 5V Reference 1 1 4 8 to 5 4V DC TP5 15V 15V Reference 1 1 14 4 to 15 4V DC TP6 15V 15V Reference 1 1 14 4 to 15 4V DC TP7 DGND Digital Ground TP8 IS012 Tachometer Encoder Not Used TP9 ISO12RTN Tachometer Encoder Not Used TP10 PS IN Power Supply In 1 1 1 rated DC bus voltage TP14 EXT External Resistor Discharge Not Used TP16 PS IN Power Supply In 1 1 1 rated DC bus voltage TP17 24V 24V Power Supply 1 1 23 7 to 24 4V DC TP18 DGND Digital Ground TP19 EXT
30. 8 19 20 21 22 23 24 25 26 2728 29 30 31 32 33 34 x x d 38 ER gt gt gt AJAS ii EE E 999 2 2230320530 daz ua ymas eaa d S d S5 gt Vine 2 2012 5 52090 E E 2 I 1010095050 Oo jj oo lt X G au gt 2 2 lt 9 0 0 H H HOOO 5 x EE EF ED 2 2 E 2 2 lt w lt uj lt x m o Z z Z Zo Q 22 Ta I a Im i I 3t amp gt zadao gt oo a A OOoO0 m 5 a hu 0 amp a 9 ag lt am x lt I 1 A 1 2 345 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 2728 29 30 31 32 33 34 J12 TB1 ANALOG IN 1 ANALOG IN 1 5 ANALOG IN 1 COMMON ANALOG IN 2 ANALOG IN 2 5 ANALOG IN 2 MMON 6 ANALOG OUT 1 ANALOG OUT 1 COMMON ANALOG OUT 2 g ANALOG OUT 2 COMMON J7 J10 49 12345678 1 2 3 4 5 6 7 8 9 123456789 z z Q au 85 4594859 283542594289 2 2 ou Zo 2 18381808 49229229 lt lt 102935329535 039529535 HP 1 2 3 4 5 6 7 8 d SCAN PORT ID 1 SCAN PORT ID 2 Communications Board Optional U3 U4 U5 U6 Publication 2364F 5 05 February 2005 R2R RXD R2R TXD TIO LOCAL TIO REMOTE Reference Information A 9
31. C Bus Volt Line Voltage Nom Line Voltage 14 10 Base DC Bus Volt AutoRef Tracking 16 14 Bit A D Chan2 m 38 l Base DC Bus Volt scaled Bus Fok Bus Prefil Fdbk DSP DC Bus jul NT lt 143 gt lt 140 gt 60 7 EXE l 144 Feedback DSP avg DC Bus us 0 Scaling 1 4 61 Dar Sim Bus Fdbk 139 lt 218 gt 219 Bus Volt Sel Feedback Select Leadlag Freq wn iq Reference Leadlag Gain kn 96 217 215 Simulator pu Gap Simulator Rate 216 Simulator Load Publication 2364F 5 05 February 2005 Reference Information A 11 pi Error Limit pi Err Lim Step pi Err Gain Lim 115 116 117 Err Limiter Bus Error 1735 5 11422 Marten iq Pos Limit C 38 AE Out Linearizer iq Command 4X 34 gt C121 lt 35 22 C94 2 Filtered iq Ref DE 2 TAN eu lt 96 7 100 Rated AC Current 5120 2 iq Change Rate iq Cmd Mode Se IT iq Intg Output Linear pi Out Net Neg Cur Lim Net Pos Cur Lim 5 98 _ Intg gain Neg Current Lim Pos Current Lim Abs Junct Temp lt 86 gt Heatsink Temp 10 87 2 Max Pos H S HighTemp lt 183 X2 5 Overtemp Ot lt 0 lt 174 X0 gen Only iq Foldback lt 35 lt 83 gt it FIdbk Cur Lim Aux iq Limit JC Temp Rise Aux Limit id Pos Limit id Neg Limit 0 Regen Only id Command id Reference id Mode Select Note The Id function block is notusedin slave units Publication 2364
32. Digital Ground Ground for Reset Digital Ground Analog In 8 Reference Power Desaturization Trip Absolute Value of Line Current DSP DAC 3 Output Analog Ground DSP DAC 2 Output 5V Reference 5V Reference 10V Reference Overcurrent Trip DC Bus Line Voltage Overvoltage Trip 15V Power Supply Simulated S Phase Current Line Current R Analog Ground Line Current T Line Current S 15V Power Supply Analog In 1 Analog In 2 Analog Ground Analog Out 1 Analog Out 2 Voltage R Voltage S Voltage T Bus Voltage to Ground Bus Voltage to Ground Bus Voltage Publication 2364F 5 05 February 2005 Scale 1 1 Factory Use Only 1 95V AC Rated Currnt Factory Use Only Factory Use Only 1 1 1 1 1 1 4 04V 200 5V DC 713V DC 5V DC 1125V DC 1 1 1 95V AC Rated Currnt 1 95V AC Rated Currnt 1 95V AC Rated Currnt 1 95V AC Rated Currnt 1 1 10V DC Full Scale 10V DC Full Scale 10V DC Full Scale 10V DC Full Scale 1 435V AC 277V 1 435V AC 277V 1 435V AC 277V 5V DC 1125V DC 5V DC 1125V DC 5V DC 1125V DC Typical Range 4 8 to 5 5V DC 10 to 10V DC see parameter P44 in pub 2364F 5 01 1 75 to 2 15V AC at full load 4 8 to 5 3V DC 5 3 to 4 8V DC 9 6 to 10 4V DC 225 of rated current 2 50 3 02 3 78V DC depending on rated line voltage 3 08 3 73 4 66V DC depending on rated line voltage 14 4 to 15 4V DC 1 75 to 2 15V AC at full load 1 7
33. F 5 05 February 2005 12 Reference Information Figure 6 shows the parameter settings that are made in response to a control mode selection Figure 6 RGU Control Mode Selection Stand RGU Mode m IEEE Name EE 5 RGU Control Mode lq Mode Select Slave setto Aux Command Current Loop Bandwidth RGU to RGU Transmit Address Master set to transmit RGU to RGU Receive 1 Address Slave set to receive RGU to RGU Transmit Indirect 1 Master set to transmit P96 Iq Reference RGU to RGU Transmit Indirect 2 Master set to transmit P20 Master Status RGU to RGU Receivel Indirect 1 Slave set to receive to P89 Aux Iq Command RGU to RGU Receive Indirect 2 Slave set to receive to P20 Master Status Figure 7 Line Sensing Current Transducers 3 Current Transducers m O O O
34. P8 0 then this fault can be suppressed or can be reported as a warning by reprogramming P181 and or P182 Replace the battery on the U11 RAM chip as indicated in chapter 4 or send the main control board in for repair Verify that the master unit is operating properly Check the R2R boards and fiber optic connections Secure all terminals If an R2R hub board is equipped verify the wiring arrangement Reset the RGUs Verify that only one unit is set as a master unit P5 Check the R2R boards and fiber optic connections Secure all terminals If an R2R hub board is equipped verify the wiring arrangement Reset the RGUs If necessary reinstall or upgrade the firmware Check the R2R boards and fiber optic connections Secure all terminals If an R2R hub board is equipped verify the wiring arrangement Verify that the master RGU is operating properly Reset the RGUs Number Fault 40 DPRAM Error P180 bit 8 41 No Tic P180 bit 9 42 No Fast Task P180 bit 10 43 NoBgnd Task P180 bit 11 44 Addr Bus Err P180 bit 12 45 Data Bus Err P180 bit 13 46 Line Low P180 bit 14 47 Line High P180 bit 15 48 12t Warnings P183 bit 0 W Indicates An error has been detected in the dual port RAM between the host processor and the DSP The primary clock for the host processor which is used to synchronize with the DSP is missing A watchdog error has been detected in the main control loop task of the host
35. Points Board to Board Schematics Firmware Diagrams Table A Functional Specifications Efficiency 97 AC Input Frequency Tolerance 45 to 65 Hz AC Input Voltage Tolerance 10 Motoring Output Current Overload 150 of rated current for 60 seconds Regenerating Output Current Overload 150 of rated current for 60 seconds 150 of rated current for 30 seconds 380 460V N code RGUs at 40 C or 575V AC N code RGUs at 30 C Output Voltage Variation 10 maximum for a 100 DC output current step load change Resolution of Output Voltage Selection 1 0V Voltage Regulator Bandwidth 200 radians sec maximum Current Regulator Bandwidth 800 radians sec for 2 kHz units 1200 radians sec for 4 kHz units Publication 2364F 5 05 February 2005 A 2 Reference Information Table B Electrical Specifications Part 1 Nominal Continuous Maximum Control Transformer Ratings Input AC Line Basic Standard Current Bus Voltage Bus Current Rated DC Capacity Capacity A AC V DC A DC Bus kW kVA kVA The continuous AC line current values apply to both motoring and regenerating operations Rated DC bus kW is the power available on the DC thru bus at rated voltage and current Publication 2364F 5 05 February 2005 Reference Information A 3 Electrical Specifications Part 2 Internal Overcurrent Overcurrent Overvoltage Overvoltage Burden Warning Current Voltage Capacitance Inductance Trip Trip Referenc
36. Voltage Acceptable Readings J 380 460 8 87 ohm 8 84 9 31 ohm J 575 11 0ohm 10 45 11 55 ohm K 380 460 575 7 50hm 7 12 7 88 ohm L 380 460 6 19 ohm 5 88 6 50 ohm L 575 7 15ohm 6 79 7 51 ohm M 380 460 4 02 3 82 4 22 ohm 575 4 53 4 30 4 76 ohm 380 460 3 01 ohm 2 86 3 16 ohm N 575 3 40 ohm 3 23 3 57 ohm e Check all wiring connections on the isolation board and verify that SW1 is set appropriately 115V AC SI Set meter to test AC voltage While applying power to the unit check the voltage across the bus control relay TB6 6 to TB6 9 The voltage should rise to 115V AC during precharge then drop to zero after precharge If the board has failed any of these tests or if the unit continually faults with the items shown in Table 4 H the board may be damaged Consider replacing the board and or sending the board to Rockwell Automation for repair Table 4 H Typical Faults Possibly Involving Isolation Board Fault Number Fault Name 17 Board Intlk 20 Zero Seq Err 21 Phase Lock Loop 22 Phase Loss 27 Offset Err Publication 2364F 5 05 February 2005 4 12 Testing Components Testing the Control Power Filter The control power filter reduces the noise in the control power The Publication 2364F 5 05 February 2005 effectiveness of the filter can be checked by viewing the waveforms before and after the filter there should be less noise seen after the filter as shown in Figure
37. When the RGU faults the HIM or GPT will immediately report the fault on screen Figure 3 1 Fault Announcement HIM Figure 3 2 Fault Announcement GPT Publication 2364F 5 05 February 2005 3 2 Troubleshooting Faults and Warnings How to Check the Warning and Fault Queues When a fault condition occurs the RGU will store the fault information in the fault queue The fault queue will indicate the fault condition the sequence number of the fault and will display Trip if the fault caused the RGU to trip To view the warning or fault queue with a HIM choose Control Status then choose either Fault Queue or Warning Queue then choose View Queue to open the queue as shown in Figure 3 3 Figure 3 3 Checking the Fault Queue HIM Condition Fault Fault Indicator Trip Point Item in Queue Typically the fault or fault queue will need to be cleared before the RGU can be enabled again To clear the fault queue choose Control Status then choose Fault Queue then choose Clear Queue as shown in Figure 3 4 The fault queue will clear and the unit can be enabled again a reset may be required to rectify any hardware or software conditions Figure 3 4 Clearing the Fault Queue HIM Publication 2364F 5 05 February 2005 Troubleshooting Faults and Warnings 3 3 To view the warning or fault queue with a GPT go to the main menu by pushing F1 then choose either Fault Queue or Warning Queue The fault queue should ap
38. al content information for data nameplates and startup operating procedures 2 Troubleshooting the RGU Procedures for troubleshooting and handling conditions in the RGU 3 Troubleshooting Faults and Warnings Introduction to faults and warnings on the RGU plus troubleshooting action to correct fault situations Testing Components Troubleshooting procedures for the main control board gate driver board isolation board and other components of the RGU A Reference Information Specifications board diagrams test point information board to board schematics and firmware block diagrams Glossary Listing of terms that are used in this manual Index Index of key topics in this manual A Related Documentation For Read This Document Document Number Layout diagrams specifications setup instructions and Regenerative DC Bus Supply Unit RGU User 2364F 5 01 schematics of the RGU Manual Information for operating and understanding the Graphic Bulletin 1201 Graphic Programming Terminal 1201 5 0 Programming Terminal User Manual Information for installing and configuring the Remote 1 0 RIO Bulletin 1203 Remote 10 Communications 1203 5 1 Communications Module Module Getting Started Manual Information for installing and configuring the DeviceNet Bulletin 1203 DeviceNet Communications 1203 5 3 Communications Module Module User Manual Information for installing and configuring the Serial Bulletin 1203 Serial Communications Module 1203 5
39. amage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved Check the power modules as indicated in chapter 4 Check the line fuses and DC bus fuse if equipped If the components are good clear the fault and reset restart the RGU Number Fault Indicates 17 Board Intlk plugged into the isolation board 18 HW Bus OverV P177 bit 2 over 810V DC 380 460V AC or 1000V DC 575V AC 19 HW Line The hardware has detected an AC line P177 bit 3 overcurrent 20 Zero Seq Err 2610 21 Phase Lock L P177 bit 5 lost power or have browned out 22 Phase Loss P177 bit 6 23 Not Used P177 bit 7 24 Not Used P177 bit 8 25 Not Used P177 bit 9 26 SW Line P177 bit 10 overcurrent 27 X lOffset Err P177 bit 11 during initial power up The voltage feedback connector J1 or the P177 bit 1 current feedback connector J7 is not The hardware has detected a DC bus voltage The 3 phase input to the unit is out of P177 bit 4 balance The current vector sum is not near One or more phases from the line have A phase from the line has lost power The software has detected an AC line An excessive line current has been detected Troubleshooting Faults and Warnings 3 7 Action Verify that the J1 and J7 connections on the isolation board are
40. ar application and so on Try to determine and resolve all underlying problems to avoid future component failures For significant or recurring problems contact your local Rockwell Automation office for support Rockwell Automation support personnel can provide technical assistance and can offer information about hardware and software updates as they are made available The data nameplate provides the electrical ratings for the RGU signifies the type of RGU and identifies the options that have been included in the unit The data nameplate shown in Figure 1 2 is located the input bay of the RGU and signifies the unit ratings catalog string and unique reference identifiers for the RGU Figure 1 2 Data Nameplate RGU BULLETIN 2300 MOTOR CONTROL CENTER UNIT u 2364FA MJB XX CM 6P 4EA 715P 14LSP 88GF 14G1 14HAPC POWER RATINGS 101 0001 SERIAL STATIC CONVERTOR NO AC _ INPUT VOLTS 460 AMPS 678 WIRING AOR101 0002 2 DIA DC OUTPUT VOLTS 683 AMPS 749 jJRe 1 MAXIMUM PERMISSIBLE AVAILABLE SHORT CIRCUIT AMPS 65000 63 Rockwell Automation MADE IN USA Introduction 1 3 The data nameplate shown in Figure 1 3 s located on the power structure and s gnifies the ratings and the catalog string for the power structure Figure 1 3 also shows the basic catalog string format Note For more catalog string information refer to publication 2364F 5 01 Regenerative DC Bus Supply
41. ation The NRU is typically used as a front end power supply on a drive system lineup Overload A condition where the unit is supplying current above its rated current For example operating a unit at 150 overload would indicate that the unit 15 supplying 150 of its rated current Most units can operate with an overload condition for a short period of time Power Factor 07 A measurement of the time phase difference between the voltage and current in an AC circuit Power Module A transistor used in the RGU and 1336 products to convert regulated power between AC and DC See also insulated gate bipolar transistor IGBT Power Structure A 3 phase power bridge built in the RGU which converts AC to DC motoring current and DC to PWM AC regenerative current The power structure includes control boards a precharge circuit a power bridge and a capacitor bank Regenerative DC Bus Supply Unit RGU A regenerative DC power supply unit produced by Rockwell Automation The RGU 1s typically used as a front end power supply to provide motoring and regenerative current for a drive system lineup Regenerating Current Current which is being driven back from the motors from motoring induction to the DC bus RGUs are able to place regenerating current back onto the AC line RGU to RGU R2R Communications A communication link used between master and slave RGUs In R2R communications the master RGU passes current commands status in
42. cable at J3 may need to be connected replaced or the gate driver board may need to be tested the gate driver board supplies power for the main control board and isolation board Publication 2364F 5 05 February 2005 Testing Components 4 5 3 Set meter for AC voltage Check the AC line feedback by testing the voltage of TP32 TP33 and TP34 with respect to AGND Table 4 C shows the typical voltages that should be seen for these test points Table 4 C AC Line Feedback Test Points Main Control Board Rated Line Voltage Typical Voltage at Test Points 380V AC 1 08 to 1 21V 460 1 28 to 1 42V 575V 1 62 to 1 76V Note If a low voltage is seen the ribbon cable at J12 may need to be connected replaced or the isolation board may need to be tested Consider checking the gate driver board and isolation board as necessary If there are firmware or SCANport problems try reinstalling or upgrading to the latest available firmware If the board has failed any of these tests or if the unit continually faults with the items shown in Table 4 D the board may be damaged Consider replacing the board and or sending the board to Rockwell Automation for repair Table 4 D AC Line Feedback Test Points Main Control Board Fault Number Fault Name Fault Number Fault Name 0 ROM Bad CRC 32 Clock Loss 1 RAM Error 33 Double Bus 2 BatRAM Err 34 Watchdog 3 DSP Load 36 Battery Low 4 FPGA Load 40 DPRAM Err 7 SCANport Err 41
43. check for shorts to ground PE If there is no actual phase loss check the AC line sensor fuses and the J1 connection to the isolation board The RGU can continue to operate on single phase power but may trip if the load becomes too great or may trip if the RGU is forced to regenerate If the phase does not return check the power source check the incoming AC line fuses F1 F2 F3 and check for shorts from the lost phase to ground PE If there is no actual phase loss check the AC line sensor fuses and the J1 connection to the isolation board Verify that the setup parameters are programmed appropriately see the setup chapter of 2364F 5 01 Check for any shorts to ground Also check the burden resistors on the isolation board Check the parameters for any unusual current settings Check for any shorts to ground Verify that the correct burden resistors are installed on the isolation board Note W indicates that the condition is normally reported as a warning rather than a fault Publication 2364F 5 05 February 2005 3 8 Troubleshooting Faults and Warnings Number Fault Indicates 28 DualPort TO The DSP did not receive any data from the P177 bit 12 host processor The DSP assumes that the host is not running 29 Not Used P177 bit 13 30 NotUsed P177 bit 14 31 DSP Fault DSP is in faulted state reason unknown P177 bit 15 32 Clock Loss W The host processor was reset due to a clock P180 bit 0 loss 33 Double Bus W
44. d adapter board and HIM mounting bracket e The power structure does not include SCRs SCR heatsinks SCR snubber boards or the SCR cooling fan e The power structure does not include a ground sense current transducer e The power structure does not include a DC bus inductor e The power structure can include an optional R2R communication board R2R hub board and or SCANport interface board e The power structure may include a third current transducer on phase L2 e The power structure may have a power supply filter board mounted below the gate driver board Testing Components 4 3 Testing the Main Control Board The main control board regulates the power structure operation and is capable of communication with external devices through SCANport and analog I O Figure 4 1 Main Control Board E cci O TP20 15V TP23 AGND fo 7 26 15V TP32 VR TP33 VS TP34 Note A full listing of test points and a detailed drawing of the main control board can be found in Appendix A Important Always record or store parameters before replacing the main control board upgrading firmware or replacing the battery for the battery backed memory parameters can be stored in the internal memory ofa GPT or Series B HIM or can b
45. e 4 4 Test fuses Fl and F3 on the gate driver board If a fuse is damaged replace the board the damaged board can be sent to Rockwell Automation for repair Secure all wiring to the gate driver board J1 J7 J8 J10 and TB7 Testing Components 4 9 7 Set meter s to test for DC voltage 8 Connect meter leads to the test points indicated n Table 4 E if necessary test only one set of test points at a time Table 4 E Power Supply Test Points Gate Driver Board Test Points Typical Voltage TP4 to DGND 4 7 to 5 3V DC TP5 to DGND 14 4 to 15 4V DC TB6 to DGND 14 4 to 15 4V DC 9 With the meter leads connected reattach the mounting panel for the main control board 10 Reconnect all wiring to the main control board J2 J3 J9 J10 J11 J12 and TBI 11 Push the disconnect lever to on and turn the start switch to on 12 Check the voltage readings If the readings do not comply with Table 4 E replace the gate driver board Note If the gate driver board is damaged IGBTs and snubber boards may also need to be tested If the board has failed any of these tests or if the unit continually faults with the items shown in Table 4 F the board may be damaged Consider replacing the board and or sending the board to Rockwell Automation for further testing and repair Table 4 F Typical Faults Possibly Involving the Gate Driver Board Fault Number Fault Name 9 Control Volt 16 Desaturization For additional te
46. e Trip Reference Resistor Temperature Temperature uF Arms TP20 Volts TP22 Volts Ohms C J 380 6450 1193 173 455 80 375 887 80 10 K 380 1200 510 409 455 80 375 750 80 10 L 380 1500 317 743 455 80 375 619 80 10 M 380 2400 137 1526 455 820 375 402 80 t0 N 380 24000 102 2039 455 820 375 30 80 no J 460 6450 1193 173 455 80 375 887 80 10 K 460 1200 510 409 455 80 375 750 80 10 L 460 1500 317 743 455 80 375 619 80 10 M 460 24000 137 1528 455 820 375 402 80 10 N 460 2400 102 2039 455 820 375 30 80 no J 575 2860 1853 140 45 1025 469 110 80 100 K 575 600 832 409 455 1025 469 750 100 L 575 15000 404 644 455 1025 469 715 80 100 M 575 24000 191 1354 455 1025 469 453 80 no N 575 24000 144 1805 455 1025 469 340 80 no Table C Typical Capacitor Bank Values per Drive in uf 10 For 380 460V AC Lineups A __ je 1 5 1 5 15 300 300 700 1336 FORCE SA3100 16 33 135 215 430 645 645 900 1200 1200 1500 2070 1500 2400 2400 1336 IMPACT 16 22 33 47 68 135 215 430 645 645 0900 1200 1200 1500 2070 1500 2400 2400 1336 PLUS 1336 PLUSII 16
47. e stored on a PC using DriveTools Publication 2364F 5 05 February 2005 4 4 Testing Components 1 With power applied to the unit check the LED indicators on the main control board see Figure 4 2 Figure 4 2 LED Indicators Normal Operation x XN A x ZN AS 7 i ium IH The LEDs should be illuminated as shown when AEN pe m N Host DSP Enable SCANport ROR the unit is enabled Fault OK Fault LED s are Illuminated WN Ue Ix Check the fault queue if either of the fault LEDs 00 DO oD are illuminated see chapter 3 to troubleshoot 7 15 RS IL UMS rupe CANport R2R 0 Reinstall firmware if the host fault LED is flashing Fault Fault OK Power LEDs are not Illuminated or are weak S wx 4 Check the wiring connections on the man co To 0 control board and test the gate driver board if x 15V 15V 5V Host DSP Enable SCANport R2R OK the power LEDs are not illuminated or are weak Fault Fault OK 2 Set meter for DC voltage Check the power supply to the main control board by testing the voltage across the test points shown in Table 4 B Table 4 B Power Supply Test Points Main Control Board Test Points Typical Voltage TP4 to AGND 4 7 to 5 3V DC TP20 to AGND 14 4 to 15 4V DC TP26 to AGND 14 4 to 15 4V DC Note If a low voltage is seen the ribbon
48. e the board and or send the board in for repair if the problem cannot be resolved Verify the parameter setup Check the Frame Catalog Number P4 the Rated AC Line Current P11 and the AC Line Low Setting P26 Verify that the current feedback burden resistors on the isolation board are appropriately sized Verify the parameter setup Check the Frame Catalog Number P4 the Rated AC Line Current P11 and the AC Line High Setting P27 Check that the current feedback burden resistors on the isolation board are appropriately sized The internal wiring may be at risk of overheating Check that all the door fans are operating properly and verify that the RGU is operating at the appropriately derated current see the specification appendix of 2364F 5 01 Verify that the RGU is not operating in overload for an extended period of time Note W indicates that the condition is normally reported as a warning rather than a fault Publication 2364F 5 05 February 2005 3 10 Troubleshooting Faults and Warnings Number Fault 49 121 Overload P183 bit 1 50 H S Hightemp P183 bit 2 51 Reset Req d P183 bit 3 52 NIC Open P183 bit 4 53 NTC Short P183 bit 5 54 MSTR Faulted P183 bit 6 55 1 Phase Warn P183 bit 7 56 1 Phase Err P183 bit 8 W Indicates The 12t wire protection has tripped the unit since the heatsink to power module junction temperature has exceeded the maximum allowed The heatsink tempera
49. esting the Line RC 5 4 13 Testing the DC Bus 5 50 4 14 Testna MONS 24 23 12645545 4525565555525555 6 5850 ee 4 15 Testing Precharge 51510 5 4 15 linis ass an ee en ee en 4 16 Terminal 0 5 4 18 Reference Information 1 Specifications ed wx EE Ear boa oe 1 Printed Circuit Boards A 4 TESL POINIS ux A 6 Board to Board 5 lt A 8 Firmware Diagrams siiis usa a a 10 Contents Who Should Use This Manual Preface Preface The Regenerative DC Bus Supply Unit RGUTM is a regenerative front end unit used to supply acommon DC bus drive system This manual includes information for troubleshooting RGU failure conditions troubleshooting components and handling fault and warning conditions This preface supplies information on the following topics e who should use this manual e safety precautions e contents of this manual e related documentation e Rockwell Automation support This manual is intended for qualified personnel who are responsible for servicing the Bulletin 2364F Regenerative DC Bus Supply Unit RGU If y
50. formation and synchronization signals to the slave RGUs SCANport Communications technology which is used by many Rockwell Automation products HIMs PLCs and many drive systems products can communicate with one another through SCANport Publication 2364F 5 05 February 2005 Numerics 1336 FORCE 4 2 1336 FORCE service manuals 1 1 4 2 A Automatically enabling the RGU 1 4 B Battery backed RAM 3 5 3 8 4 6 Burden resistors 4 11 C Catalog numbers 1 3 Check points on AC line and DC bus 4 17 Control power filter 4 12 D Damaged components 2 5 Data nameplates 1 2 1 3 DC bus suppressor 4 14 E Enabling the RGU 2 3 2 6 F Fault queue 3 2 3 3 Faults and warnings 2 6 3 2 3 3 3 5 3 6 3 7 3 6 3 9 3 10 G Gate driver board 4 7 4 8 4 9 Graphic Programming Terminal GPT 2 3 3 1 3 3 3 4 H Human Interface Module HIM 2 3 3 1 3 2 3 4 Index IGBTs power modules 2 5 4 16 Isolation board 4 10 4 11 L LED indicators 4 4 Line RC suppressor 4 13 Local mode 1 4 2 3 Loud discharge 2 5 M 1 Open 3 6 Main control board 4 3 4 4 4 5 MOVs 4 15 P Power modules 2 5 Power structure 4 2 Precharge 3 6 Precharge resistors 4 15 Programming parameters 2 4 R Resetting the RGU 3 4 RGU to RGU R2R communcations 3 8 RGU to RGU R2R communications 3 8 3 10 8 Safety precautions 3 5 SCANport 2 3 Starting the RGU 1 4 Publication 2364F 5 05 February 2005 1 2 Index T
51. he NTC sensor Verify that the NTC wiring is in good condition Check the connection on the main control board J2 If necessary replace the NTC sensor Check the master RGU fault queue and correct the situation Shut down the RGUs in the system Restart all the RGUs after all the power has been discharged from the DC bus restart the master RGU first If the phase does not return check the power source check the incoming AC line fuses F1 F2 F3 and check for shorts from the lost phase to ground PE If there is no actual phase loss check the AC line sensor fuses and the J1 connection to the isolation board If the phase does not return check the power source check the incoming AC line fuses F1 F2 F3 and check for shorts from the lost phase to ground PE If there is no actual phase loss check the AC line sensor fuses and the J1 connection to the isolation board Note W indicates that the condition is normally reported as a warning rather than a fault Publication 2364F 5 05 February 2005 Components Chapter 4 Testing Gomponents This chapter provides instructions for testing RGU components The topics listed below are covered in this chapter Topics in this Chapter Testing and Replacing Parts in the Power Structure Testing the Main Control Board Testing the Gate Driver Board Testing the Isolation Board Testing the Control Power Filter Testing the Line RC Suppressor Testing the DC Bus Suppressor
52. istors on the isolation board No Replace the damaged burden resistors at their rated resistance N ATTENTION Push the disconnect lever to off and verify zero volts Yes Test the main control board gate driver board and isolation board as instructed in Chapter 4 Replace as necessary Publication 2364F 5 05 February 2005 Troubleshooting The RGU 2 5 Damaged Components Damaged components may be suspected if a loud discharge or melting smell has come from the RGU Check the following items to find damaged components ATTENTION Push the disconnect lever to off and verify zero volts across the DC bus before testing the following items Is th isibl to the MOVs Replace the MOVs s there any visible damage to the MOVs Yes eplace the S Are the line fuses good condition Replace all the AC line fuses re the AC line fuses in g iti No ine fu Yes Test the IGBTs as instructed in Chapter 4 Replace the damaged IGBTs Test and Are any IGBTs damaged tes replace the gate driver board and snubber boards as necessary 2 Are the DC bus fuse s in good condition No Replace the damaged fuses Yes Check the RGU for melted wiring Test the isolation board and gate driver board as instructed in Chapter 4 Replace as necessary Publication 2364F 5 05 February 2
53. main control board Graphic Programming Terminal GPT A programming terminal with a graphical LED display and a pushbutton keyboard which is used to program control and view the status of a unit The GPT 16 also able to load and store parameters in its local memory Host Processor The main processor on the main control board of the RGU This component processes feedback and controls most of the activities in the RGU Human Interface Module HIM A programming terminal used to program control and view the status of a unit Insulated Gate Bipolar Transistor IGBT A transistor which can be used to allow current to flow in two opposite directions Also known as power module Isolation Board The RGU isolation board receives direct feedback from the AC line DC bus and current transducers This board supplies scaled feedback to the main control board Publication 2364F 5 05 February 2005 0 2 The RGU main control board regulates the voltage and current oversees activities in the unit and processes I O This board is isolated from the power circuitry Metal Oxide Varistor MOV A component used to protect against voltage surges and excessively high line to line line to ground voltages Motoring Current Current which 15 being supplied to the inverters through the DC bus for motoring Non Regenerative DC Bus Supply Unit NRU A six pulse DC power supply produced by Rockwell Autom
54. ol P174 bit 2 board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved 3 DSP Load Error detected while loading DSP program Try restarting the RGU verify that all connections to the main control P174 bit 3 memory at startup board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved 4 FPGA Load Error detected while loading FPGA firmware Try restarting the RGU verify that all connections to the main control P174 bit 4 at startup board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved 5 Iq Foldback W The current is being limited due to high The internal wiring may be at risk of overheating Check that the P174 bit 5 heatsink temperatures door fans are operating properly and verify that the RGU is operating at the appropriatel
55. ou do not have a basic understanding of this unit please refer to the applicable documentation and system schematics or contact your local Rockwell Automation Drive Systems representative for more information before using this product Be sure to read through this manual and through publication 2364F 5 01 Regenerative DC Bus Supply Unit RGU User Manual before servicing the RGU Publication 2364F 5 05 February 2005 2 Preface Safety Precautions Publication 2364F 5 05 February 2005 The following general precautions apply to Bulletin 2364F RGUs and to drive systems lineups ATTENTION Only those familiar with the drive system the products used in the system and the associated machinery should plan or implement the installation startup and future maintenance of the system Failure to comply can result in personal injury and or equipment damage ATTENTION Only connect Rockwell Automation common DC bus AC drives to the RGU common DC bus output ATTENTION Do not connect any drives to the RGU common DC bus which have input voltage specifications greater than the maximum input voltages listed below Nominal Input Voltage Maximum DC Input of RGU V AC of Drive V DC 380 632 460 746 575 933 ATTENTION Verify that all sources of AC and DC power are deenergized and locked out or tagged out in accordance with the requirements of ANSI NFPA 70E Part II ATTENTION The system may contain stored energy devices To
56. overload for an extended period of time Check internal wiring and components for heat damage melted wiring or burn marks Verify the parameter setup Check the Frame Catalog Number P4 the Scaled Bus Feedback P143 the Bus Voltage Feedback Calibration P144 and the DC Bus Low Setting P28 Check the bus for shorts to ground PE Verify the parameter setup Check the Frame Catalog Number P4 the Scaled Bus Feedback P143 the Bus Voltage Feedback Calibration P144 and the DC Bus High Setting P29 Try restarting the RGU verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved There may be too many inverters attached to the DC bus the precharge routine can only accommodate a certain amount of external capacitance If necessary disconnect some of the inverters until the RGU has completed its precharge or contact Rockwell Automation for other solutions Check the precharge resistors the precharge fuses and the precharge contactor M2 Also check for shorts between the DC bus and ground PE Try restarting the RGU verify that all connections to the main control board are in place and check the main control board for any obvious d
57. pear as shown in Figure 3 5 The fault queue can be cleared by entering the fault queue and pressing Fl to clear the fault or F2 to clear the queue An individual fault can be cleared on a GPT by pressing the stop button on any screen Figure 3 5 Checking the Fault Queue GPT Select Item 3 Fault Queue io Fault Number Sequence Number and Fault Type o p pum LL Lui To clear the Fault Queue Date and Time Press F2 of Fault Publication 2364F 5 05 February 2005 3 4 Troubleshooting Faults and Warnings Resetting the RGU Publication 2364F 5 05 February 2005 If a fault is the result of a hardware or software failure the unit may need to be reset to reinitialize the hardware and software before the unit can be enabled The RGU can be reset by e Cycling power to the RGU e Sending a reset command through a HIM GPT or other SCANport device To reset the RGU with a HIM choose Control Status then choose Reset Drive Figure 3 6 Resetting the RGU HIM To reset the RGU with a GPT press F3 while in the fault queue Figure 3 7 Resetting the RGU GPT Press F3 to Reset To reset the RGU with other SCANport devices send a reset command through the Host Command Word P32 bit 7 Troubleshooting Faults and Warnings 3 5 Troubleshooting Faults and The following list provides information for understanding and trouble Wa
58. r resistors should read 14 7 15 8 ohms 15 ohm rating If the suppressor has failed any of the above tests it may be damaged Replace the suppressor and consider replacing any associated wiring as necessary Figure 4 9 DC Bus Suppressor 9 k ohm Resistors 41 15 onm PE Connection Testing MOVs Testing Precharge Resistors Testing Components 4 15 MOVs provide surge line to line and line to ground protection for the RGU 1 Push the disconnect lever to off and wait for all voltage to discharge from the unit Do not continue until all voltage has dissipated from the DC bus 2 Verify that there is no voltage across the DC bus see Figure 4 12 and Figure 4 13 for check points 3 Observe the MOVs typically located near the circuit breaker Replace any MOVs that are visibly damaged The precharge resistors help the RGU supply appropriate voltage to the internal capacitors during the precharge routine 1 Push the disconnect lever to off and wait for all voltage to discharge from the unit Do not continue until all voltage has dissipated from the DC bus 2 Verify that there is no voltage across the DC bus see Figure 4 12 and Figure 4 13 for check points 3 Check the precharge fuses 4 Set meter to check resistance Disconnect and check each of the precharge resistors Resistors should indicate a resistance of 5 6 6 8 ohms 6 ohm rating Note Older J code RGU resistors should have
59. resistors in Chapter 4 Are the precharge resistors m at their rated resistance Yes Test the IGBTs as instructed in Chapter 4 Replace the damaged IGBTs Test and Are any of the IGBTs damaged 2199 replace the gate driver board and snubber boards as necessary No the DC bus fuse s good condition No Replace the damaged bus fuses Yes Test the main control board isolation board and gate driver board see Chapter 4 Replace any damaged boards Publication 2364F 5 05 February 2005 Troubleshooting The RGU 2 3 Unit Will Not Enable After the disconnect lever and start switch have been turned on the RGU should power any connected HIM or GPT devices and perform its precharge routine to raise the voltage of the capacitors on the DC bus If the Remote Local Selector P8 is set to Local Only the RGU should automatically enable when the precharge routine finishes If the Remote Local Selector is set to Local Remote the RGU should enable when enable command is sent by a connected SCANport device HIM GPT etc Check the following items if the unit will not enable Did the unit th h tine Verify that the total capacitance on the DC bus s Mis d d a No x is within the precharge capability of the RGU Also check 203 External Capacitance Yes Is the HIM GPT screen illuminated No Check
60. rnings shooting each fault or warning condition in the RGU Parameters can be stored in the internal memory of a GPT or Series B HIM or can be stored and printed out using DriveTools software Important Always record or store parameters before upgrading firmware or replacing the main control board ATTENTION Do not attempt to alter or modify any printed circuit boards Any attempt to alter or modify boards may result in personal injury or property damage Number Fault Indicates Action 0 ROM Bad CRC Program memory error detected Try restarting the RGU verify that all connections to the main control P174 bit 0 board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved 1 RAM Error RAM error detected Try restarting the RGU verify that all connections to the main control P174 bit 1 board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved 2 BatRAM Err Battery backed RAM error detected Try restarting the RGU verify that all connections to the main contr
61. rp Centre 18 Whitfield Road Causeway Bay Hong Kona Tel 852 2887 4788 Fax 852 2508 1846 Automation PN 366075 P01 2005 Rockwell International Corporation Printed in the U S A Publication 2364F 5 05 February 2005 Supersedes Publication 2364F 5 05 March 1999
62. sary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved Try resetting restarting the RGU when possible Verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved Try resetting restarting the RGU when possible Verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved Try resetting restarting the RGU when possible Verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware Replace the board and or send the board in for repair if the problem cannot be resolved Verify that the parameters are programmed appropriately If the RGU is set to Local Mode Only
63. secure and that the wiring is in good condition Check the AC line sensor fuses F17 19 In an N code RGU check the LEM power supply located on the upper front of the power structure roll out unit Verify that the setup parameters are programmed appropriately see the setup chapter of 2364F 5 01 Also check the burden resistors on the isolation board Check the operation of other drives in the system Verify that the setup parameters are programmed appropriately see the setup chapter of 2364F 5 01 Check for any shorts to ground Also check the burden resistors on the isolation board Clear the fault and try resetting restarting the RGU Clear the fault and try resetting restarting the RGU Verify that all connections to the main control board are in place and check the main control board for any obvious damage or any debris which may be shorting circuitry If necessary try reinstalling the firmware or upgrade to the latest available firmware If the problem cannot be resolved contact Rockwell Automation for hardware updates If necessary replace the main control board and or send the board to Rockwell Automation for testing The RGU can continue to operate until power is lost from two phases or until power becomes too low for the RGU to compensate to load If the phase s do not return verify that the circuit breaker is closed check the power source check all AC connections check the incoming AC line fuses F1 F2 F3 and
64. st procedures see the appropriate 1336 FORCE service manual see Table 4 A Publication 2364F 5 05 February 2005 4 10 Testing Components Testing the Isolation Board Publication 2364F 5 05 February 2005 The isolation board receives feedback from the AC line DC bus current transducers main contactor M1 and reset button This feedback 16 passed to the main control board for processing Figure 4 6 Isolation Board Isolation Board TBS Ag Burden BL Resistors TB 6 TBZ 18 TB6 9 Note TB2 is used only in Series B units Note A detailed illustration of the isolation board can be found in Appendix A 1 Push the disconnect lever to off and wait for all voltage to discharge from the unit Do not continue until all voltage has dissipated from the DC bus 2 Verify that there is no voltage across the DC bus see Figure 4 12 and Figure 4 13 for check points 3 Verify that there is no voltage across the terminals and subcomponents of the isolation board Testing Components 4 11 4 Set meter to test resistance 5 Check the resistance of each burden resistor Replace any burden resistors that do not comply with the specifications give in Table 4 G Table 4 G Burden Resistor Specifications Current Rated Input Rated Resistance Code
65. the DC bus A reading of 0 2 to 0 4 volts should be seen Test the other two lines with respect to DC Bust 6 Take a reading of L1 to DC Bus with positive lead on DC bus Again a reading of 0 2 to 0 4 volts should be seen Test the other two lines with respect to DC Bus Figure 4 11 Testing IGBTs DC Bus DC Bus If any of these tests have failed the particular IGBTs may be damaged opened or shorted Replace any damaged IGBTs and consider testing the gate driver board and snubber boards Additional test instructions for the IGBTS power modules can be seen in the 1336 FORCE service manuals see Table 4 Testing Components 4 17 Figure 4 12 Check Points on AC Line and DC Bus J K and L code RGUs 255 72241 E Sy 13 12 DC Bus DC Bus Figure 4 13 Check Points on AC Line and DC Bus and N code RGUs
66. the HIM GPT and the cable Test the main control board Replace as necessary Yes there faults indicated on screen or Yes Resolve the fault condition clear the fault in the fault queue and reset the RGU as necessary 7 Check the RGU control circuitry and Is a signal being applied to TB5 1 Enable No p athe isolation beard other associated circuitry with the system schematics Yes Set the Local Remote Selector to Local Only Do you want to enable the RGU with a HIM No P8 0 Verify the En at Pwr Up fault is GPT or other SCANport device disabled P180 bit 3 0 and reset the RGU Yes Set the Local Remote Selector to Local Remote P8 1 Set the appropriate Example bits in P224 and P225 to 1 see example To enable Ports 1 2 and 6 configure P224 SCANport Port Enable Mask and P225 SCANport Enable Mask as shown 0100 0111 a ort6 Note The RGU can also be enabled by setting the Enable Cmd bit to 1 in the Host Command Word P32 Publication 2364F 5 05 February 2005 2 4 Troubleshooting The RGU Unit Overvoltage Overcurrent Check the following items if the unit frequently has an overvoltage or Trips overcurrent trip Does the Frame Catalog Number P4 show No Set P4 to match the catalog number sho
67. ture has exceeded 80 C The RGU recognizes that a reset is required The RGU has detected that the circuit for the NTC bridge thermal sensor is open The RGU has detected that the NTC bridge thermal sensor wires are shorted together The slave RGU has received a faulted status from the master RGU through the R2R network The RGU has detected a single phase condition on the incoming AC power The threshold for detecting this condition is set by 1 Phase Threshold P147 The detected single phase condition has persisted beyond the time limit specified by 1 Phase Err Delay P148 Action The internal wiring may be at risk of overheating Check that the door fans are operating properly and verify that the RGU is operating at the appropriately derated current see the specifications appendix in 2364F 5 01 Verify that the RGU is not operating in overload for an extended period of time Check internal wiring and components for heat damage melted wiring or burn marks Check that the door fans are operating properly Verify that the RGU is operating at the appropriately derated current see the specifications appendix in 2364F 5 01 Verify that the RGU is not operating in overload for an extended period of time Reset the RGU Either shut down the RGU and restart or reset the RGU through a HIM or GPT Verify that the NTC wiring is in good condition Check the connection on the main control board J2 If necessary replace t
68. use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to e identify a hazard e avoid a hazard e recognize the consequences Important Identifies information that is critical for successful application and understanding of the product 1336 FORCE 1336 PLUS DriveTools RGU HIM GPT DriveTools and SCANport are trademarks of Rockwell Automation or its subsidiaries Preface Chapter 1 Chapter 2 Chapter 3 Table of Contents Preface COMEN P 1 Who Should Use This Manual 1 Safety Precautions P 2 Contents of this P 4 Related Documentation 5 Rockwell Automation Support P 6 Local Product SUDDOLL 2 2 P 6 Technical Product Assistance P 6 Introduction Using This 1 1 1336 FORCE Service 1 1 Basic Troubleshooting Techniques 1 2 Data 1 2 Starting and Operating the
69. wn the appropriate catalog number for the unit on the data nameplate see Chapter 1 Yes Does the AC Line Inductance P12 show the total line inductance provided to the No Calculate the total inductance and set P12 RGU including external components Yes Does the External Capacitance P203 show Calculate the total capacitance on the DC the total capacitance for all inverters I connected on DC bus bus and set P203 appropriately Yes Is the RGU being overloaded for extended Yes Adjust the period of overload application for periods of time beyond its rated capability the RGU No Are drives on the DC bus set to allow a very Yes Adjust the drives to an acceptable fast deceleration time faster than the voltage loop bandwidth of the RGU Is the current loop bandwidth P198 high No Adjust ds a Sd SUNG enough for the application 3 appropriately Tor the application see e setup chapter in publication 2364F 5 01 Yes Is the voltage loop bandwidth P205 set Yes Adjust a oo an appropriately for the application gt appropriately for the application see the setup chapter in publication 2364F 5 01 deceleration time No across the DC bus before testing the following items Are the burden res
70. y U11 February 2005 Lithium Battery and Crystal Package 2 8V 49mAh Testing Components 4 7 Testing the Gate Driver Board The gate driver board turns the IGBT gates on and off and supplies power to the main control board and isolation board Figure 4 4 Accessing the Gate Driver Board Remove screws and nuts Publication 2364F 5 05 February 2005 4 8 Testing Components Publication 2364F 5 05 February 2005 Figure 4 5 Gate Driver Board TP5 41 54 Gate Driver Board 7 0880 45V Fi Note A full listing of test points and a detailed illustration of the gate driver board can be found in Appendix A Push the disconnect lever to off and wait for all voltage to discharge from the unit Do not continue until all voltage has dissipated from the DC bus Verify that there is no voltage across the DC bus see Figure 4 12 and Figure 4 13 for check points Disconnect all wiring from the main control board J2 J3 J9 J10 J11 J12 and TBI Remove the mounting panel for the main control board see Figur
71. y associated wiring for visible damage burn marks or damaged subcomponents Remove fuses 14 F15 and F16 Set meter for resistance and test each resistor on the board Each resistor should read 670 700 k ohm 680 k ohm rating Reinstall fuses 14 F15 and 16 Check the fuses with a meter If the board has failed any of these tests the board may be damaged Replace the board and consider replacing any associated wiring or fuses as necessary Figure 4 8 Line RC Suppressor 680 k ohm Resistor Publication 2364F 5 05 February 2005 4 14 Testing Components Testing the DC Bus Suppressor Publication 2364F 5 05 February 2005 FE The DC bus suppressor discharges excess voltage from the DC bus Push the disconnect lever to off and wait for all voltage to discharge from the unit Do not continue until all voltage has dissipated from the DC bus Verify that there is no voltage across the DC bus see Figure 4 12 and Figure 4 13 for check points Verify that there is no voltage across the subcomponents of the suppressor Check the suppressor and any associated wiring for visible damage burn marks or damaged subcomponents Check the resistance between the top of each capacitor with respect to the PE terminal The meter should show 8 10 ohms Set meter for resistance and test each resistor The two middle resistors should read 8 5 9 5 k ohms 9 k ohm rating The two oute
72. y derated current see the specifications appendix in 2364F 5 01 Verify that the RGU is not operating in overload for an extended period of time Note W indicates that the condition is normally reported as a warning rather than a fault Publication 2364F 5 05 February 2005 3 6 Troubleshooting Faults and Warnings Number Fault Indicates 6 1 Open M1 contactor opened while the RGU is in P174 bit 6 ready or running state 7 SCANport Err W Error detected in SCANport controlling device P174 bit 7 or device missing 8 R2R HW Error Error detected in the R2R hardware by the P174 bit 8 CAN chip which is responsible for R2R communications 9 Control Volt W The voltage supplied to the main control P174 bit 9 board is too low for reliable operation 10 H S Overtemp The heatsink temperature has exceeded the P174 bit 10 prescribed temperature limit 100 C for J L codes 110 C for M and N codes 11 Bus Low W The DC bus voltage is under the DC Bus Low P174 bit 11 Setting P28 default 7190 of nominal 12 Bus High W The DC bus voltage has exceeded the DC Bus P174 bit 12 High Setting P29 default 114 of nominal 13 BRAM Chksum W The checksum of data in battery backed P174 bit 13 RAM was bad The data is deemed as unreliable 14 Prchrg Fail The DC bus voltage was high enough to P174 bit 14 power the control boards 200V DC but did not rise to the RMS value of the AC line to allow the main contactor M1 to close

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