Rockwell Automation FlexPak Plus NRG DC Drive User Manual

Page 22

TABLE 5.A - TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER (Continued)

Symptom

Probable Cause

Recommended Procedures

4. In reversing conĆ

trollers only . . .

Controller's M

contactor not

picking up when

FORWARD/REVERSE

switch malfunction,

V Examine Remote Operator Adapter on Regulator Module for firm seating and proper

wiring and pin connections.

V Test FORWARD/REVERSE switch. Use basic technique outlined above for the

START/STOP switch.

picking up when

START switch is

pressed (closed).

M contactor malfuncĆ

tioning.

V On the Auxiliary M pins located on the Regulator Module, connect an ohmmeter.

Place it on the pin 39 and pin 67.

V Place the FORWARD/REVERSE switch in the FORWARD position. The reading should

be approximately 150 to 1000 ohms if it is operating properly.

V Without changing test points, place the switch in the REVERSE position. The reading

should be between 150 to 1000 ohms. if it is operating properly. If a short is observed,

remove jumper J9 and repeat the test.

V If a 150 Ć1000 ohm resistance reading cannot be obtained when the switches are

open, the M contactor is malfunctioning and must be replaced.

5. M contactor picks

up but remains in

only when START

RUN/JOG switch is in

JOG position.

V Place the RUN/JOG switch in the RUN position.

only when START

pushbutton is

pressed and held

in.

CR relay not picking

up.

V Connect a voltĆohmmeter on the Remote Operator Adapter. Place it on terminal 35.

V Connect the second probe to connection 139 connected to the FlexPak Plus M

contactor.

V The reading should be +24 VDC for normal operation.

V Next, shift the probe from terminal 35 to terminal 38 on the same terminal board.

However, leave the second probe where it is.

V Press the START switch, The reading should be approximately 24 VDC for normal

operation.

V Press the START/STOP switch to STOP, and then START. A 24 VDC (approximately)

reading should continue to appear. If it does not, the CR relay is not picking up. In this

case, replace the Regulator Module.

6. Drive motor does

not run, but M

contactor and CR

pull up.

(Use this proceĆ

dure only if conĆ

troller does not

have optional Test

Meter Adapter

Kit.)

No input signal from

SPEED potentiometer

on Control Station.

V If the controller does not have an optional AUTO/MANUAL switch, inspect the

Regulator Module to determine that jumper J4 is In place. (The jumper is removed

when the AUTO/ MANUAL switch is installed.)

V Check the SPEED potentiometer on the Control Station. First, open the power

disconnect switch.

V Connect a voltĆohmmeter to the Regulator Module Remote Operator Adapter inputs,

Connect one lead to terminal 28. Connect the other to terminal 20. (Refer to Figure

3.4 for a Remote Station,)

V For proper operation, the reading should be 5K ohms,

V Disconnect the VOM lead from terminal 20. Connect it to terminal 426.

V Turn the SPEED potentiometer from 10 to 0. The resistance should vary from 5K to 0

ohms. If it does not, replace the potentiometer.

7. Drive motor does

not run, but M

contactor and CR

Pull up.

(Use this proceĆ

dure only if conĆ

troller has optionĆ

al Test Meter

Adapter Kit. )

No input signal from

SPEED pot.

V First check the main power supplies. This must be done with power applied to the

FlexPak Plus controller,

V Connect one lead of voltĆohmmeter to test pin 357 on the Test Meter Adapter Module.

V Connect the second lead to test pin 356 on the Module.

V The reading should be within the range of 10.8 to 11.5 VDC for normal operation.

N t

th l d f

i 356 Pl

i 456

V The reading should be within the range of 10.8 to 11.5 VDC for normal operation.

V Next, remove the lead from pin 356. Place it on pin 456.

V The reading should be within the range of +16 to +28 VDC for normal operation.

V Next, remove the lead from pin 456. Place it on pin 471.

V The reading should be within the range of Ć16 to Ć28 VDC for normal operation.

V If the proper readings are obtained, the power supplies may be assumed to be

operating correctly,

V If incorrect reading are obtained, replace the Regulator Module.

V Next, check the reference voltage input signal. (This changes in direct proportion to

an increase of SPEED potentiometer voltage caused by a turning of the dial.)

V Connect one lead of a voltĆohmmeter to pin 357 on the Test Meter Adapter Module.

V Connect the other lead to pin 826. Readings vary from 0 to +8.2 VDC, depending on

the set point of the SPEED potentiometer dial.

V If no voltage is noted between pins 357 and 826, check to see if jumper J4 on the

Regulator Module is properly placed/removed for the specific controller. (It is to be in

place, as factoryĆshipped, if there is no AUTO/MANUAL switch. It is to be removed if

there is an AUTO/MANUAL switch.)

V If the SPEED potentiometer is functioning normally, and if the J4 jumper is

placed/removed, as necessary, replace the Regulator Module.

DANGER

THE PROCEDURE DESCRIBED HERE IS PERFORMED WITH

LIVE AĆC VOLTAGE APPLIED TO THE CONTROLLER. USE ONLY

ONE HAND TO APPLY VOM LEADS/PROBES. KEEP YOUR

OTHER HAND BEHIND YOU AT ALL TIMES. DO NOT HOLD ONTO

THE CONTROLLER FOR SUPPORT. PERSONAL INJURY MAY

RESULT IF THESE PRECAUTIONS ARE NOT TAKEN.