Rockwell Automation FlexPak Plus NRG DC Drive - Manual (Page 21)

20
TABLE 5.A - TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER
Symptom Probable Cause Recommended Procedures
1. POWER ON/OFF
circuit breaker
trips or fuses clear
when power is apĆ
plied.
Incorrect wiring conĆ
nections to controller;
from controller to moĆ
tor; in motor.
V Connect ohmmeter from terminal 38 to 39 on TB.
V Remove aĆc power at the disconnect.
V Remove leads to L1, L2, L3, A1, A2 and F1, F2, on incoming side of controller's
respective location.
V Open the power disconnect switch.
V Check for a ground condition at L1/181, L2/182, L3/183, A1, A2, F1 and F2. Do this at
controller (internal) side of 1TB. If a ground is discovered, check wiring connections
on Power Cube and motor field terminals F1 and F2.
V If no ground exists, examine the controller chassis for loose wires and/or foreign
objects.
V If no ground exists and if no foreign objects are discovered, reconnect the incoming
conductors A1, A2 and F1 and F2. Then check for grounds at these terminals.
V If a ground is found, it is in the conductors to the motor or in the motor itself.
V Disconnect the motor from the conductors at the drive motor.
V Test A1, A2, F1 and F2 conductors for a ground. (If one exists, examine connections
and insulation for areas where shorts could occur.)
V If no grounds are found in the conductors, check the motor for a ground condition. If
a ground is located here, examine and/or replace the motor, as necessary.
Short in Power Cube. V Replace Power Cube.
Short in Field Supply. V Replace Field Supply.
2. Drive motor does
not start.
Main aĆc line disconĆ
nect not closed; or
fuse blown; or no
power applied ahead
of disconnect.
V Check disconnect switch, fuses in it, and voltage on line.
Drive interlocks preĆ
venting operation. 32
to 33 on TB
V Verify that all userĆinstalled interlocks are in a state (physical condition and wiring
connections) to allow a start.
Drive motor thermoĆ
stat wires not conĆ
nected on FlexPak
Plus controller termiĆ
nals 34 and 132 on
TB.
V Check connections to thermostat: at drive motor P1, P2; at controller 34, 132.
V Check for open thermostat inside motor. Make a resistance check of thermostat. (It
should read a short, or low resistance, if it is closed,
External overload
wires not connected
on FlexPak Plus conĆ
troller terminals 34
and 33 on TB.
V Check connections to external overload. (Blower Motor Starter O/L)
V Check for open overload, Make a resistance check to overload. (It should read a
short, or low resistance, if it is closed.)
Drive thermostat wires
not connected on
FlexPak Plus controlĆ
ler terminals 132 to
232
V Check connections to thermostat at drive power bridge heat sink, at controller 132 or
232.
V Check for open thermostat. Make a resistance check to the thermostat. (It should
read a short, or low resistance, if it is closed.
3. In nonĆreversing
controllers only . .
. Controller's M
contactor not
picking up when
START switch is
Faulty M contactor. V Open the power disconnect switch,
V Examine M contactor for firm seating.
V On the M contactor, connect an ohmmeter on 139 and 39 Wires, The reading should
be 150 to 1000 ohms
V If these readings cannot be obtained, replace the M contactor. (Refer to Table 6.A.)
START switch is
pressed (closed). Faulty start/Stop
switch.
V Check START/STOPswitch, but first remove aĆc line power at main disconnect.
V Connect ohmmeter to terminal 32 on the Remote Operator Adapter.
V Touch probe to terminal 38 on the Remote Operator Adapter.
V Place switch in the START (closed) position,
V If the switch is property functioning, a short will be seen on the meter.
V Check the STOPfunction. Place the RUN/JOG switch in the RUN position. Connect
the ohmmeter to terminals 32 and 35, Place the switch in the STOP position, which
should open it if it is functioning correctly. If there is a short, it will be seen on the
meter. If there is no short, the circuit is opened, and the switch is functioning correctly.
V Using similar techniques, test the RUN/JOG switch in the RUN position at terminals 32
and 35. When the switch is in the RUN position, a short should be read.
DANGER
IF CIRCUIT BREAKER HAS TRIPPED OR FUSES HAVE CLEARED,THE
FIELD SUPPLY AND ITS WIRING MUST BE INSPECTED FOR DAMAGE.
AFTER REĆAPPLYING POWER TO THE DRIVE, THE FIELD VOLTAGE
MUST BE REĆCHECKED FOR PROPER VOLTAGE AT MOTOR TERMIĆ
NALS F1, F2. IF THIS VOLTAGE IS BELOW 90% OF THE FIELD VOLTAGE
SPECIFIED ON THE MOTOR NAMEPLATE, THE DRIVE MUST NOT BE
STARTED UNTIL PROPER VOLTAGE IS OBTAINED. FAILURE TO
FOLLOW THIS PROCEDURE COULD RESULT IN OVERSPEEDING THE
MOTOR AND/OR THE MACHINERY COUPLED TO THE MOTOR SHAFT
AND POSSIBLE FATAL INJURY.