1352C-Plus 5.1 VECTOR Troubleshooting Guide
LED Indicators
Card Location
Name
LED Identification
A2
Control Card
H1
A3
Power Supply
V58
A4
Pulse Amplifier
H101
H201
H301
H401
H501
H601
A4 - A6
Pulse Amplifier
A7
Chopper Card
H1 (Positive)
H2 (Negative)
V42
A9
Power Supply
V40
CBU-A1
Capacitor Supv. Card
V27
V28
V29
V30
Indication
Drive Size
ON = Ready
OFF = Not Ready or Running (GTO)
FLASHING = Processor Fault
ON = Power Supply OK
OFF = Power Supply Low
ON = Positive U Phase OK
ON = Positive V Phase OK
ON = Positive W Phase OK
ON = Negative U Phase OK
ON = Negative V Phase OK
ON = Negative W Phase OK
OFF = Device Fault
ON = Normal Operation
OFF = GTO Fault
ON = Aux. Voltage OK
OFF = Aux. Voltage Low
ON = Power Supply OK
OFF = Power Supply Low
ON = Normal Voltage
OFF = Low Voltage or Bypassed
All
30-115 kVA
30-115 kVA
30-115 kVA
30-115 kVA
30-115 kVA
30-115 kVA
30-115 kVA
140 kVA & Above
140 kVA 8 Above
140 kVA & Above
140 kVA & Above
140 kVA & Above
140 kVA & Above
Troubleshooting Guide Cont.
Diagnostic Display
Symptom
Probable Cause
Recommended Solutions/Comments
None
Drive Dead.
Main Contactor will not
close.
A. Main Disconnect not
closed .
A. Close Disconnect.
B. Maintained Emergency
Stop depressed.
B. Reset Emergency Stop.
C. Low or no voltage at
supply to Drive.
C. Provide correct voltage. Voltage of all three
phases must be + 10% of nameplate rating
& within 5% of the other phases.
D. Blown Fuses.
D. Check or replace LSU fuses F1 through F8.
E. Control voltages
missing.
E. If applicable, check for 115V AC between
terminals TB1-24 and TB1-25. Check for
215 VAC between TB1-9 and TB1-12.
F. Fault Interlock open
F. If applicable, check for Interlock or jumper
continuity at:
Terminals TB1-20 & 21
Terminals TB1-21 & 22
Terminals TB1-22 & 23
Terminals TB1-15 & 16
Check that LSU-K1 has picked up.
Check that LSU-K2 has picked up.
G. Reset Breaker F51 in LCU.
Check fan for free rotation.
Check heatsink thermostats S51 and S52 for
open circuit.
G. 210 kVA units and
above only. LCU
cooling fan circuit
breaker is off or
tripped.
None
None
CP1 Panel Blank. Drive
seems to be dead, but
cooling fans run.
CP1 Panel Blank.
Drive seems to be dead,
cooling fans do not run.
A. Maintained Emergency
Stop depressed.
B. Blown fuses.
A. Reset Emergency Stop.
C. Control voltages
missing.
C. If applicable, check for 115V AC between
LSU Terminals TB 1-24 and TB 1-25.
Check for 215V AC between LSU Terminals
TB1-9 and TB1-12.
Check for 215V AC between INU Terminals
X1.1, 101 and 102.
Cooling fan circuit breakers
are off or tripped.
B. Check or replace LSU fuses F1 through F8.
Reset breakers.
F2 in INU (30 to 115 kVA)
F11 in INU ( 140 to 870 kVA)
F51 in LCU (210 to 870 kVA)
If breaker trips again, check fans for free
rotation.
If INU fan breaker continues to trip, temporarily
remove jumper on INU X1 (103-104). (Run at no
load) If breaker trips, replace A3 Power Supply
on units 115 kVA and smaller.
On larger units, replace A9 Auxiliary Power
Supply. If breaker doesn't trip, replace the
cooling fan.
Troubleshooting Guide Cont.
Diagnostic Display
Symptom
Any Display
Drive stopped but
appears to be running.
Electronic noise
Verify that grounding practices have been
followed. (Section 2)
Display Character
•
Displays are strange.
Drive doesn't operate as
programmed.
All memory appears to
be lost.
Electronic noise has erased
EEPROM.
Verify grounding. (Section 2) Replace D16 Chip
with another chip containing new software or
reload your program.
None
Main fuses blown
None
Main Fuses blow
periodically while
running.
Probable Cause
Recommended Solutions/Comments
A. Insufficient Precharge
time.
A. Verify precharge timer TR1 is set to value
shown on schematic diagram, but not less
than 0.5 seconds.
B. Precharge resistor
open.
B. Measure precharge resistor values (typically
10 ohms each) replace if necessary. Check
that K3 energizes during precharge time
and de-energizes after precharge time.
C. Malfunctioning Main
Contactor Unit. (K4)
C. Open Main Disconnect and verify contactor
operates freely.
D. Malfunctioning diode
rectifier.
D. Replace G1, G2, or G3 (30 to 180 kVA), G51,
G52, or G53 (210 to 340 kVA), or V41-V56, on
460 to 870 kVA units.
Check/replace bad diodes.
E. Cap. bank or inverter
shorted " +" to "-".
E. Inspect/measure capacitors and bus circuits.
F. Excessive voltage at
input to Drive
terminals.
F. Measure input voltage. Voltage must be
within ± 10% of nameplate rating (460V AC
or 575V AC) and within 5% of other phases.
A. Diode rectifier is weak
and malfunctioning.
A. Replace G1, G2, or G3 (30 to 115 kVA units).
G51, G52, or G53 (210 to 340 kVA).
Check/Replace bad Diodes V51-V56
(460 to 870 kVA).
B. Capacitor bank or
Inverter Intermittently
shorted " + " to " - ".
B. Inspect/measure capacitors and bus circuits.
Check for loose wires or material in bus
circuits.
Check for worn or cracked insulation on
main power conductors.
C. Excessive voltage at
input to Drive
terminals.
C. Check input voltage. Voltage must be
within ± 10% of nameplate rating (460V AC
or 575V AC).
D. Intermittent single
phasing of incoming
3-phase power.
D. Check supply network cables, termination's
and switches.
E. Phase voltage
unbalance greater than
6.5%.
E. Correct cause of voltage imbalance in supply
lines.
Troubleshooting Guide Cont.
Diagnostic Display
Symptom
Probable Cause
Recommended Solutions/Comments
None
DC Bus fuses blow while
running or starting
Inverter. (140 kVA and
above only)
A. Capacitor bank or
inverter intermittently
shorted " + " to " - "
A. Inspect/measure capacitors and bus circuits.
Check for loose wires or material in bus
circuits.
Check for worn or cracked insulation on
main power conductors.
None
DC fuses blow when
main contactor K4 is
closed.
A. Short circuit in the
inverter.
B. Misfiring of GTO
Thyristors
C. Inverter intermittently
shorted " + " to "-" or
to chassis.
A. Check for short circuit in semiconductor and
replace if necessary.
B. Check data of fault queue Parameters
176-181.
C. Inspect/measure capacitors and bus circuits.
Check for loose wires or material in main
circuits.
Check for worn or cracked insulation on
main power conductors.
FL01 (CP1)
C9 Capacitor circuit
voltage too low.
A. Loose connections
A. Verify solid connections at chopper bus bars.
Reseat connectors on INU A7 Chopper
Control Card.
Verify connections at Thyristor V17.
B. INU A7 Chopper
Control Card
malfunctioning
B. Inspect/Replace fuse F1 on A7 Chopper
Control Card.
Replace INU A7 Chopper Control Card
Verify that the INU Cooling Fan Breaker F11
and Temperature Sensor S1 are closed.
C. Short circuited
capacitors C9.1 - C9.N
C. Disconnect the chopper capacitors from the
circuits at the Bus Bars.
Inspect and measure capacitors for short
circuits.
D V17 Chopper Thyristor
malfunctioning
D. Replace V17 and V28 Thyristors.
Check/Replace INU A8 Snubber Card.
Check Chopper Snubber diodes.
E. INU A4 Pulse Amplifier
malfunction
E. Replace A4 Pulse Amplifier.
F. Chopper charge time
too short
F. Check that CHARGETIME 158EE is set to at
least 6.
A. Loose connections
A. Tighten connections at chopper bus bars.
Reseat connectors on INU A7 Chopper
Control Card.
B. INU A7 Chopper
Control Card
malfunctioning
B. Replace INU A7 Chopper Control Card
CHOP UNDERVOLT
(CP5)
(140 kVA and larger)
FL02 (CP1)
CHOP OVERVOLT
(CP5)
C9 Capacitor circuit
voltage too high.
Troubleshooting Guide Cont.
Diagnostic Display
Symptom
Probable Cause
Recommended Solutions/Comments
FL03 (CP1)
AUX
UNDERVOLTAGE
(CP5)
Voltage Supply to the
Circuit Boards is
insufficient
A. Voltage Supply to the
Drive is too low.
A. Check incoming supply voltage. Voltage
must be within ± 10% of nameplate rating
and each phase within 5% of each other.
B. Check condition of DC bus.
B. DC Bus voltage (UC) is
low or DC Bus is not
charged .
C. Auxiliary 215V AC
supply to INU is low or
missing.
D Power Supply INU - A3
or Auxiliary Power Card
INU A9 is
malfunctioning
FL04 (CP1)
OVERTEMPERATURE
(CP5)
INU Heatsink
temperature is too high.
A. Obstructed cooling air
flow.
B. Room air temperature
too high.
C. INU cooling fan is
malfunctioning or is
stalled.
D. Heatsink thermal switch
has malfunctioned or
has open connection.
E. Overtemperature
circuitry has
malfunctioned.
F. Unbalanced phase
voltage.
FL05(CP1)
OVERCURRENT
(CP5)
The Instantaneous Peak
Current has exceeded
230% of Drive rating
C. Measure 215V AC supply to INU at
Terminals. Replace Auxiliary power card if
necessary.
Verify INU cooling fan breaker F2 or F11 is
closed .
D. Check fuses on INU-A3 Power Card (INU-A9
on units 140 kVA and larger).
Check status of LED on Power Supply Card
INU A3. Replace card if necessary.
Check status of LED on Auxiliary Power
Supply Card INU A9. Replace card if
necessary.
A. Remove any obstructions from louvers or
heatsinks.
B. Cool air temperature to below 104°F (40°C).
C. Check Cooling fan circuit breaker. Check
that the fan rotates and remove any
obstructions. Replace fan if necessary.
D. Check that the thermal switch located at the
top of the INU is not open, replace if
required. Check continuity to A-3 power
supply or A-7 Chopper Control.
E. Replace the INU- A3 power supply (115 kVA
and smaller drives).
Replace the INU - A7 Chopper Control
(140 kVA and larger Drives).
F. Correct cause of unbalanced phase voltages
to within 5%.
A. A sudden increase in
motor load occurred
A. Check the process for unusual load or jam.
B. A mechanical bind has
caused high currents
C. Problem exists in motor
circuit.
B. Check for bearing, belt or gear failure.
D. IR Compensation
setting incorrect
E. Problem with
accel/decel rates
F. Attempted to start
before motor EMF
decayed
C. A motor winding has shorted or grounded.
A motor winding or connection has an open
circuit.
Check motor circuit with appropriate meter.
D. Check and reset IR Compensation
Check and reset current limit.
E. Check and reset accel/decel rates. Try to
adjust so that the Drive does not go into
current limit, but follows the ramp instead.
F. Increase Parameter 75 Restart Delay
(1000 = 1 Sec.).
Troubleshooting Guide Cont.
Diagnostic Display
Symptom
Probable Cause
Recommended Solutions/Comments
FL06 (CP1 )
DC OVERVOLT
(CP5)
The DC Bus (UC)
Capacitor Voltage has
exceeded 130% of rated.
A. Supply voltage to the
drive is too high.
A. Maximum permissible supply voltage is
110% of rated.
Transformer taps must be changed to reduce
AC voltage.
B. The decel ramp is too rapid. Extend the decel
ramp by increasing Parameter 66 value.
C. Reduce value of the Regen Torque Limit
Parameter 80 for Scalar Drives and
Parameter 58, 59, 60, 61 for Vector Drives.
Controlled braking may be required.
D. Check that Parameter 207 is between 900
and 1100. If the value is beyond these limits,
replace INU- A3.
Measure the actual DC Bus voltage with a
meter. It should be 621V DC (460V). Verify
values with Parameter 207. If the DC Bus
voltage is OK, see Section 5 to adjust or,
replace INU- A-13.
*Note: At no load, DC voltage may be as
high as 716 volts with 460V input + 10% .
B. The load has
overhauled the motor.
C. Regen torque limit too
high.
D. INU A3 Power Supply
UC voltage
measurement
erroneous.
FL07 (CP1 )
DC UNDERVOLT
FL09, V11 - U1 FAULT
FL10, V14 - U2 FAULT
FL11, V12 - V1 FAULT
FL12, V15 - V2 FAULT
FL13, V13 - W1 FAULT
FL14, V16 - W2 FAULT
(GTO Only)
(140 to 870 kVA only)
DC Bus Voltage (UC)
Capacitor Voltage is less
than 70% of rated.
A. DC Bus not charged.
A. Check if main contactor is closed.
B. DC Bus fuse blown.
B. Replace fuse.
C. INU- A3 Power Supply
UC voltage
measurement
erroneous.
C. Measure the actual DC Bus Voltage with a
meter and verify the value with Parameter
207. If the D.C. Bus voltage is within + 10%
of 621V DC, see Section 5 to adjust or
replace INU-A3.
A. Power semiconductor
device or pulse
amplifier malfunction.
For example: V12-V1
FAULT refers to the
power semiconductor
of positive branch of
"V" phase or its pulse
amplifier.
A. Reset the fault. Drive will check for shorted
cells, motor leads or ground faults. Fault 15
will be the acknowledgment if they are
present.
If the fault repeats check that pulse
amplifier (cards A4,A5 and A6) LED's are lit.
If not, check power supply connector X3 and
condition of Fuses F1 and F2.
Check fuses on Power Supply Card A3 and
Aux Power Supply A9.
If the fault cannot be located, it may actually
be a FL 05 Fault.
If it is not possible to reset the fault, check
that the flat cables of control and pulse
amplifier cards are firmly connected. Check
the fuses F2 through F5 on the Power Supply
Card. If a fuse is blown, check the power
semiconductor device. If the fault isn't
found, replace the pulse amplifier card or
control card as required.
Check Snubber diodes.
Troubleshooting Guide Cont.
Diagnostic Display
Symptom
FL09, V1 FAULT
FL10, V4 FAULT
FL11, V2 FAULT
FL12, V5 FAULT
FL13, V3 FAULT
FL14, V6 FAULT
(GTR Only)
(30 to 115 kVA only)
FL15(CP1)
SHORT CIRCUIT /
GROUND FAULT
(CP5)
(140 kVA and Larger)
FL17 (CP1)
COMMUNICATION
FAULT
(CP5)
FL18 (CP1)
TACH LOSS
(CP5)
A Low resistance Phaseto-Phase or Phase-toGround is detected.
Serial Data
Communication has
been interrupted or lost
Tach pulses faulty or
nonexistent, or motor
has stalled.
Probable Cause
Recommended Solutions/Comments
A. Power semi-conductor
device or pulse
amplifier malfunction.
For example: V5 FAULT
refers to the power
semi-conductor of
positive branch of "V"
phase or its pulse
amplifier.
A. Reset the fault. Start-up the inverter. If the
fault occurs again, there is a short circuit in
the output connector or phase power semiconductor device of the phase indicated by
the fault code or pulse amplifier
malfunction. In the case of no short circuit
in the output connector, check the condition
of the power semi-conductor device.
If it is not possible to reset the fault, check
that the flat cables of control and pulse amplifier
cards are firmly connected. Check the fuses F2
through F5 on the Power Supply Card. If a fuse is
blown, check the power semiconductor device.
If the fault isn't found, replace the pulse
amplifier card or control card as required.
A. Moisture in wire or
motor insulation .
A. Dry out or replace.
B. Cracked or stripped
wire insulation or
termination tape.
B. Replace wire or tape.
C. Motor circuit incorrectly
wired or terminated.
C. Verify, inspect, correct and test with
megohmeter.
D. Motor winding shorted.
D. Replace Motor.
E. ES Limit incorrect.
E. Parameter 275 should be set to 100.
A. Drive improperly
grounded.
A. See Section 2 for proper grounding
procedures.
B. A1 Supply Card LED not
illuminated.
B. Check that the cables connecting A9
auxiliary power supply and control card are
firmly connected.
C. A1 Supply Card LED is
illuminated.
C. Baud rate values are set incorrectly or A1
IOC Card is malfunctioning. Replace IOC
Card if necessary.
D. Fiber optic cables
damaged or
disconnected .
D. Check connections, and replace cables if
damaged or broken.
A. Tach cables faulty or
disconnected.
B. Process overload has
caused motor to stall.
A. Check condition of cables and that they are
installed correctly.
B. Check the motor and load for jamming and
correct.
Troubleshooting Guide Cont.
Diagnostic Display
Symptom
Probable Cause
Recommended Solutions/Comments
FL19 (CP1 )
CURRENT MEASURING
FAULT or CURRENT
FEEDBACK ERROR
(CP5)
A current signal is sensed
when the inverter is
stopped.
A. Current is being
backfed from the
motor.
B. A Hall Effect transducer
is giving an erroneous
signal.
C. The signal conversion to
digital data is incorrect.
A. A bypass or alternate supply voltage is
present. Isolate the Drive output from the
motor circuit.
B. A ribbon cable connection to the Hall Effect
Transducers is bad, or the transducer itself is
malfunctioning and must be replaced.
C. Check Parameters 219 and 220 for excessive
value, they should be less than 1000.
(Parameter 219 monitors U-Phase Current,
and Parameter 220 monitors V Phase
Current.)
Recheck calibration of the current
measurement in Startup Section 5-7.
Replace control card if necessary.
D. Check Parameter 190. Value should be 50.
D. Current Offset limit
incorrect.
FL20 (CP1 )
MOTOR STALLED
(CP5)
(SCALAR ONLY)
Drive has been in current
limit and below stall
frequency too long.
FL21 (CP1)
MATCHING CARD FAULT
(CP5)
A. Stall protection feature
improperly adjusted.
B. Load is too great for
motor
C. Stall Time setting is too
low
D. IR Comp level is too
low.
A. Matching Card INU
A-2.2 Connection is
loose or missing.
B. Matching Card is
malfunctioning
EPROM's D17 and D18
faulty or Control Card
INU-A2 malfunctioning.
S-5 and S-6 set for wrong
size EPROM.
A. Refer to Section 5 for adjustment procedure.
B. Reduce load.
C. Correct Stall Time setting at Parameter 83
("0" = Infinity).
D. Readjust IR Comp. (Section 3)
A. Check that the matching card is firmly
connected and that the matching card type
corresponds to the inverter type.
B. Replace Matching Card.
FL22 (CP1 )
PROCESSOR FAULT
(CP5)
Processor information is
erroneous.
FL25 (CP1 )
INTERLOCK or
CUSTOMER FAULT
(CP5)
An Interlock at a Digital
Input is missing .
A. Custom Programmable
Fault Signal.
A. Check Custom software drawing for
application.
FL26 (CP1 )
INTERLOCK or
CUSTOMER FAULT
(CP5)
Same as FLT 25.
(Normally used for
motor overload, RTD
Monitor, Motor
Thermostat, etc.
A. Motor running hot.
A. Check for proper cooling air flow through
motor. If motor is operating at below base
speed, it may require a separate cooling fan.
B. Blocks run before 10C
card ready.
B. Reset faults.
SA50 (CP1)
NO BACKUP /
NEW EPROM (CP5)
There is no information in
the EEPROM Memory.
SA51 (CP1)
STORED TO BACKUP
Writing to EEPROM
Memory.
Turn power on and off and wait two minutes.
Try operation again. Replace EPROM's D17 and
D18 on Control Card if malfunction remains.
Replace Control Card INU-A2. S-5 and S-6 = A-C.
Troubleshooting Guide Cont.
Diagnostic Display
Symptom
SA52 (CP1)
Writing to EEPROM
NO WRITE TO EEPROM Memory is inhibited.
SA53 (CP1)
PARAMETER OUT of
LIMITS (CP5)
Probable Cause
Recommended Solutions/Comments
A. Position of S4 switch
must be A-B to write.
A. Check switch position.
B. EEPROM D16 is faulty.
B. Replace D16 EEPROM with known good
EEPROM.
Drive will set parameter
value to min/max
allowable.
Re-Check value being entered for validity.
SA55 (CP1)
Parameter remains at
ILLEGAL PARAMETER - original value.
CHANGE NOT PERMITTED
(CP5)
SA56 (CP1)
NO BATTERY BACKUP
Insufficient voltage from
NiCad battery.
A. Switch S-3 is in A-C
(battery OFF position).
A. Change switch position
B. Battery has
malfunctioned or
discharged.
B. Allow 20 hours with power on for battery to
recharge. Cycle power on and off to clear
fault message. If message refuses to clear
replace battery or Control Card INU - A2.
SA57 (CP1)
LOW AC/DC Volt
Auxiliary Power is low.
Check Supply Voltage.
SA58(CP1)
START INHIBIT
(CP5)
Start is inhibited by the
processor.
A stop signal overrides a start signal. Check logic
sequencing external to drive. Check Start/Stop
buttons.
SA59 (CP1)
SYSTEM RESTART (CP5)
The processor is initializing
its operation. This normally
occurs when power is first
applied to a Control Card.
Troubleshooting Guide Cont.
Changing Printed Circuit
Boards
The Drive incorporates printed circuit boards that require no adjustments
as part of the normal troubleshooting and maintenance. This feature also helps simplify board replacement.
Circuit Board Replacement - The following steps should be adhered to when changing the printed circuit boards:
.
CAUTION: The CMOS circuits utilized on the control circuit cards can be destroyed by static
charges generated by friction of materials made of synthetic fibers. Use of damaged circuit cards
may also damage related components.
A. Remove power by opening the disconnect switch and verify with a meter that all circuits are voltage free.
B. Carefully detach all ribbon cables, noting their location and orientation and whether the connectors were
properly seated.
C. Remove small metric mounting hardware with a screwdriver, taking care not to drop associated washers into
other circuits of the Drive.
D. Lift out the circuit board in question, and check that the replacement board is correct before attempting
installation. Install the new circuit board by replacing the mounting hardware and reinserting the connectors
and switches in their correct location on the new board.
IMPORTANT: A grounded wrist strap should be used when replacing circuit boards to guard against static discharge
damage to the boards!
.
Steps A through D apply to replacement of all printed circuit boards in Drive. Control Card (3500 - 187 / 187 - CON)
Replacement - In addition to the previous steps, the Control Card of the Drive requires the additional transfer of the
following components when changing cards:
A. Transfer EPROM's D17 & D18 to the corresponding locations on new Control Card using an IC.
removal/insertion tool for CMOS Circuits.
B. In order to retain the application software values and program, it will be necessary to transfer the EEPROM
D16 to the new card.
CAUTION: EPROM's and EEPROM cannot be transferred from a 103 CON to a 187 CON.
NOTE: If the new EEPROM D16 is left in the replacement control card, it is important that you observe item "D"
when first reapplying power.
C. Transfer the matching card and its spacers from the suspect board to the new control board by removing the
four mounting screws from behind the card and reinstalling them in the proper location on the new card. Be
sure to attach the X-2 connector firmly into its socket and latch the connector tabs.
D. When reapplying power to the Drive after installing a new control card, You must wait at least 2 minutes after
the red LED in the control card lights before interrupting power .or adjusting parameters. If you choose to
use the new EEPROM (D16) which was supplied with the card,, it can take as long as 3 or 4 minutes after
the LED lights. If power is interrupted, process restarts.