1340 TROUBLESHOOTING GUIDE SYMTOM STEP DIAGNOSTIC PROCEDURE A. Unit does not turn on when the ON pushbutton is depressed 1 Measure line-to-line input voltage at the disconnect switch with an AC voltmeter on the 500V AC scale. CONT. 2 DISC. SWITCH OFF Turn off input power at the disconnect switch. Check the continuity of installed controls and contacts per connection diagrams. 3 DISC SWITCH OFF Check for open, (N.C.), Thermal Overloads OTS-1 & OTS-2. If the drive has a Motor Overload Relay, (Option T), it's N.C. contact should be closed. 4 DISC. SWITCH OFF Check for open fuses F3, F4, & F5. PROBABLE FAILURE OR INDICATION Input line-to-line voltage below 207V AC or above 253V AC. Missing wires, poor connections, or improper controls, (e.g. momentary contacts used where maintained contacts are required). Open OTS-l contacts indicate 1st Bus not fully charging - Possible transistor damage to Chopper or Brake Modules. Go to steps B2 & B3. Open OTS-2 may indicate a brake problem. Heavy Duty Braking may be required. Contact your AllenBradley CSS Area Service Center. One or more fuses blown. REPAIR PROCEDURE Correct external line voltage to 230V AC, ±10%. NOTE: If necessary, refer to factory for information about 30 Input Isolation Transformers. Verify that connections and controls are as shown in the connection diagrams. It may be necessary to wait approximately (5) minutes for thermal protection devices to cool down. NOTE: If manual reset type, verify that the manual reset lever has been depressed. Replace blown fuses. Go to step A5. 5 DISC . SWITCH OFF For 10 & 15 HP drives, if F3, F4, or F5 are blown, check Rectifier Assemblies CR1 and CR4 as follows: < 50 Ohms indicates a leaky or shorted rectifier diode. Replace Rectifier Assembly CR1 and/or CR4. Go to step A6. < 50 Ohms indicates a leaky or shorted rectifier diode. Replace Rectifier Assembly CR4. Go to step A6. F6 blown. NOTE: If any faulty diodes were found on Rectifier Assembly CRl. F6 will be likely to fail. a) K2 relay not energized. Replace F6. VOM (Rx1 SCALE) (+) (-) Reading CR1 (+) CR1 (+) CR1 (+) CR4 (A) CR4 (B) CR4 (C) CR1 (A) CR1 (B) CR1 (C) CR4 (-) CR4 (-) CR4 (-) >50 Ohms >50 Ohms >50 Ohms >50 Ohms >50 Ohms >50 Ohms For 20-40 HP drives, if F3, F4, or F5 are blown, check Rectifier Assembly CR1 as follows: VOM (Rx1 SCALE) (+) (-) 6 DISC SWITCH OFF 7 CONT. 8 DISC SWITCH OFF CR1 (+) CR1 (A) CR1 (+) CR1 (B) CR1 (+) CR1 (C) CR1 (A) CR1 (-) CR1 (B) CR1 (-) CR1 (C) CR1 (-) Check Fuse F6 Reading >50 Ohms >50 Ohms >50 Ohms >50 Ohms >50 Ohms >50 Ohms With the enclosure door open and the hinged panel door closed, turn on power at the disconnect switch. Press the ON pushbutton and observe the relay state of Contactor K2 Turn off power at the disconnect switch. Check fuses Fl & F7. b) K2 relay energized. c) K2 relay energizes only momentarily when ON pushbutton is depressed a) Fl blown. b) F7 blown. a) Go to step A8. b) Go to step B1 to check Bus voltage. c) Go back to step A2 and carefully recheck ON/OFF pushbutton controls. a) Replace F1 and go to step A9. b) Replace F7 and go to step A10. SYMPTOM STEP DIAGNOSTIC PROCEDURE A. Unit does not turn on when the ON pushbutton is depressed. 9 Turn on power at the disconnect switch DO NOT press the ON pushbutton - and measure the primary and secondary voltages of Transformer T1 as follows: Voltmeter on 250V AC SCALE Terminal No.'s Reading 1 &2 230V AC, ± 10% 3&4 120V AC ± 15% REPAIR PROCEDURE Replace Transformer T1. 5&6 10 B. Main Contactor K1 does not energize. CONT. 1 42 V AC ± 15% With the AC voltmeter still on the 250V AC scale, press the ON pushbutton and measure the voltage across terminals 9 & 10 on Contactor K2. Turn off power at the disconnect switch. Set the manual speed pot fully CCW to minimum speed. With a voltmeter set on the 500V DC scale, connect the (+) lead to the (+) side of the 1st Bus Bar and the ( - ) lead to the common ( -) Bus Bar. Turn on power at the disconnect switch and press the ON pushbutton. Wait approximately (3) seconds for the 1st Bus to "precharge" before taking a reading. PROBABLE FAILURE OR INDICATION Secondary voltages not present or not within limits. NOTE: If primary reads 230V AC, +10%, and F1 fails repeatedly Transformer T1 must be removed and "bench" tested. Voltage reads 120V AC +15% but K2 does not energize. Replace Contactor K2. a) DC voltage <5V DC. a) Go to step B2. b) DC voltage approximately 40V DC. b) Go to step B3. c) DC voltage is ≥275V DC. NOTE: When DC voltage is ≥275V DC, LED CR15 on Power Supply board PS-1 will be lit. c) If LED CR15 on Power Supply board PS-1 IS NOT lit, replace PS-1. If LED CR15 IS lit, go to step B4 2 DISC. SWITCH OFF CONT. Turn off power at the disconnect switch. Remove the black plastic covers from Chopper SW Modules SM-1 & 2 - (10 & 15 HP), or SM-1, 2, & 3 - (20-40 HP). Remove the large, BLACK, 10 AWG wires from their terminal posts. With a VOM set on the Rx1 SCALE, connect the ( + ) VOM lead to the disconnected BLACK wire. Connect the (-) VOM lead to the large, WHITE, 10 AWG wire at it's terminal post. Check each chopper module individually. Repeat the procedure with the VOM set on the Rx10K scale. a) On the Rx1 scale the Ohms reading should be infinity. A low reading, (<10 Ohms), indicates a shorted transistor. a) Replace faulty module(s) and reconnect the black wires to their terminal posts. Go to step B5. b) On the Rx10K scale the Ohms reading should be ≥500K Ohms. A reading below 500K Ohms indicates a leaky transistor. b) Replace faulty module(s) and reconnect the black wires to their terminal posts. Go to step B5. NOTE: All transistors on the Chopper SW Modules are individually fused. A blown fuse will indicate a failed transistor. HOWEVER, for purposes of verifying drive performance and for troubleshooting under LIGHT LOAD, (≤50% of drive's rated KVA), or NO LOAD conditions, fuses may be removed from faulty transistors. IN NO CASE should a module be installed with less than (6) functional transistors. SYMPTOM STEP DIAGNOSTIC PROCEDURE B. Main Contactor K1 does not energize. 3 DISC. SWITCH OFF At Brake SW Module SM-5 (10 & 15 HP), or SM-7 (20-40 HP), remove the large, BLACK, 10 AWG wire from it's terminal post. With the VOM set on the Rx1 scale, connect the ( + ) VOM lead to the disconnected BLACK wire. Connect the (-) VOM lead to the large, WHITE, 10 AWG wire at it's terminal post. Repeat the procedure with the VOM set on the Rx10K scale. 4 5 CONT. PROBABLE FAILURE OR INDICATION a) On the Rx1 scale the Ohms reading should be infinity. A low reading, (<10 Ohms), indicates a shorted transistor. b) On the Rx10K scale the Ohms reading should be ≥500K Ohms. A reading below 500K Ohms indicates a leaky transistor. With the disconnect switch OFF, connect a voltmeter to Contactor K1, terminals 1 & 4, (coil terminals). With the voltmeter set on the 250V AC scale, turn on power at the disconnect switch and press the ON pushbutton. After approximately (6) seconds the voltage should be 120V AC, ±15%. a) Voltage not present or insufficient. Turn off power at the disconnect switch. Set the manual speed pot fully CCW - minimum speed. With the voltmeter set on the 500V DC scale, connect the (+) lead to the (+) side of the 1st Bus Bar and the ( - ) lead to the common ( - ) Bus Bar. Turn on power at the disconnect switch and press the ON pushbutton. Wait approximately (3) seconds for the 1st Bus to precharge before taking a reading a) 1st Bus does not charge to 275V DC after Chopper and Brake SW Modules verified ''normal" in steps B2 & B3. b) Proper voltage present, BUT Contactor K1 is not energized. b) 1st Bus charges to 275V DC and K1 energizes. REPAIR PROCEDURE a) Replace the Brake SW Module and reconnect the black wire to it's terminal post. Go to step B5. b) Replace the Brake SW Module and reconnect the black wire to it's terminal post. Go to . step B5. NOTE: All transistors on the Brake SW Module are individually fused. A blown fuse will indicate a failed transistor. HOWEVER, for purposes of verifying drive performance and for troubleshooting under LIGHT LOAD (≤50% of drive's rated KVA), or NO LOAD conditions, fuses may be removed from faulty transistors. IN NO CASE should a module be installed with less than (6) functional transistors. a) Replace Power Supply board PS-1 b) Replace Contactor K1. NOTE: Contactor K2 is a pneumatic adjustable timer and must pull-in prior to Contactor K1 energizing. Delay time for K2 contacts may be set by the thumbwheel adjust on the timer. Contacts on K2 SHOULD NOT change from their normal de-energized state until 2-3 seconds after LED CR15 on Power Supply Board PS-1 is lit. LED CR15 should light approximately 3-6 seconds after the ON pushbutton is pressed. a) Go to step B6. NOTE: If 1st Bus does not charge at all - (0V DC measured) - Go to step B10. b) Go to step C1. SYMPTOM STEP DIAGNOSTIC PROCEDURE B. Main Contactor K1 does not energize. 6 DISC. SWITCH OFF Turn off power at the disconnect switch. Remove the black plastic guard from the Bus Bank capacitors. Connect the ( +) VOM lead to the (+) 1st Bus Bank bar and the (-) VOM lead to the (-) 1st Bus Bank bar. Push in and hold the RESET on Contactor K2. The VOM should read between 5 and 25 Ohms and slowly rise to above 30 Ohms. 7 DISC. SWITCH OFF 8 DISC. SWITCH OFF 9 DISC. SWITCH OFF Leave the (-) VOM lead connected to the (-) 1st Bus Bank bar and the VOM on Rx1. Disconnect all wires to the ( + ) 1st Bus Bank bar. Verify that the disconnected wires are not touching. Connect the (+) VOM lead to the (+) 1st Bus Bank bar Leave the ( - ) VOM lead connected to the (-) 1st Bus Bank bar and the VOM on Rx1. Connect the ( + ) VOM lead to C8(+) - (10 & 15 HP), or C15(+) (20-40 HP), and check indication. Repeat for C9 (10 & 15 HP), or C16 (20-40 HP) With the VOM on the Rx1 scale, check Rectifier Assembly CR2 as follows: VOM (+) CONT. CR2 (+) CR2 (+) (AC) (AC) (-) (AC) (AC) CR2(-) CR2(-) PROBABLE FAILURE OR INDICATION A sustained low reading, (<25 Ohms), indicates a short on the 1st Bus. REPAIR PROCEDURE Go to step B7. - EITHER•· Shorted Bus Bank capacitor C1, C2, or C3 (10 & 15 HP), or C1-C6 (20-40 HP). •· Shorted Rectifier Assembly CR2. •· Shorted Steering Diode Assembly DD-1 or DD-2. •· Pinched wires to the Bus Bank capacitors. a) A low reading, (≤100 Ohms), indicates a shorted or leaky Bus capacitor. b) A high reading, ( >100 Ohms), indicates the fault is elsewhere. a) A low reading, (≤100 Ohms), indicates a shorted or leaky Bus capacitor. b) A high reading, (>100 Ohms), indicates the fault is elsewhere. a) A low ohmmeter reading, (< 50 Ohms), indicates a shorted or leaky Rectifier Assembly CR2. a) Remove the brass bar(s) from the (+) 1st Bus Bank. Isolate and replace faulty Bus capacitor(s). Replace brass bar(s) b) Go to step B8. NOTE: When checking capacitors, always wait for the ohmmeter reading to stabilize. a) Replace faulty capacitor(s) b) Go to step B9 a) Replace CR2. Reading >50 Ohms >50 Ohms >50 Ohms >50 Ohms b) A high reading indicates the fault is elsewhere. b) Carefully reconnect all wires to the (+) 1st Bus Bank bar. Replace the black plastic Bus Bank guard. Go to step B10. SYMPTOM B. Main Contactor K1 does not energize. STEP DIAGNOSTIC PROCEDURE 10 DISC. SWITCH OFF With the VOM on the Rx1 scale, check precharge current limiting resistors R1 and R4 on Resistor Assembly 41103 - (10 & 15 HP), or R1 and R2 on Resistor Assembly 41101 (20-40 HP). 11 Set the VOM on the 500V DC scale. Set the manual speed pot fully CCW - minimum speed. Connect the ( + ) VOM lead to the (+) side of the 1st Bus Bar and the (-) VOM lead to the common (-) Bus Bar. Apply power at the disconnect switch and press the ON pushbutton. After approximately (3) seconds bus voltage should be 275V DC and LED CR15 on Power Supply board PS-1 should be lit. After approximately (6) seconds, Contactor K1 should energize. 12 DISC. SWITCH OFF a) Turn off power at the disconnect switch and check fuse F2. b) Set the VOM on the Rx1 scale and check Rectifier Assembiy CR3 as follows: PROBABLE FAILURE OR INDICATION Each resistor should read 10 Ohms. An open resistor will disable precharge. a) Bus not charging or voltage to low. REPAIR PROCEDURE Replace Resistor Assembly 41103 or 41101. NOTE: An open resistor will cause overheating. Check wire insulation near the Resistor Assembly for damage. Replace Thermal Overload OTS-1 and wires if damaqe has occurred. a) Contact your Allen-Bradley Area Service Center. b) Voltage is ≥275V DC, LED CR15 is lit, but K1 is not energized. b) Replace Control Logic board CL1 . c) K1 is energized, and LED 1 on Brake Board BB-1 is lit or flickering c) Turn potentiometer R2 on BB-1 CCW until LED 1 turns off, then turn an additional 1/2 turn CCW. NOTE: If LED 1 does not turn off, replace Brake Board BB-1. d) Bus voltage is ≥275V DC, but CR15 is not lit. a) F2 blown. d) Go to step B12a) a) Replace F2 and go to step b). bl) <50 Ohms indicates a shorted or leaky diode on CR3. b1 ) Replace CR3. b2) VOM reads > 50 Ohms. b2) Go to step B13. VOM (+) CONT. (-) CR3 (+) (AC) CR3 (+) (AC') (AC) CR3 (-) (AC') CR3 (-) Readings >50 Ohms >50 Ohms >50 Ohms >50 Ohms 13 DISC. SWITCH OFF a) Disconnect twist-lock connector J4 at Converter Board CO-1. With the VOM on the Rx1 scale, connect the (+) VOM lead to C7(+) (10 & 15 HP), or C14(+) (20-40 HP). Connect the (-) VOM lead to the ( - ) terminal of the capacitor. The VOM should read low and rise to a high reading, (>100 Ohms). al) >100 Ohms indicates the fault is elsewhere. a1) Go to step b). a2) A low ohmmeter reading, (≤100 Ohms, indicates a shorted or leaky converter capacitor. a2) Replace faulty capacitor b) With the VOM on the Rx10 scale, check CR3 and CR4 on Converter Board CO-1 as follows: bl) ≥lM Ohm indicates no fault. bl) Go to step B14. b2) < 1M Ohm indicates faulty diodes or transistors on Converter Board CO-1 b2) Replaces CO-1. a) Voltage not present or insufficient. a) Replace Power Supply board PS-1 and recheck CO-1. If voltage is still not present or insufficient contact your Allen-Bradley Area Service Center VOM 14 (+) (-) CR4 (Cathode) CR4 (Anode) Readings ≥1M Ohm CR3 CR3 ≥1M (Cathode) (Anode) Ohm Reconnect twist-lock connector J4 to Converter Board CO-1. Insure that ALL connections previously removed have been replaced. Set the VOM on the 50V DC scale. Reapply power at the disconnect switch and press the ON pushbutton. Check Power Supply board PS-1 as follows: (+) VOM (-) C4 (+) C6 (-) C6 (-) C5 (-) C6 (+) C6 (-) Reading +5.3V DC + 10% +15V DC + 10% +15V DC + 10% b) Voltage present and sufficient. b) Go to step C1. SYMPTOM STEP DIAGNOSTIC PROCEDURE C. Motor starts but trips off drive. 1 Turn off power at the disconnect switch and disconnect the motor from the drive at TB1, terminals 1, 2, & 3. Set the manual speed pot fully CCW minimum speed. Turn on power at the disconnect switch and press the ON pushbutton. If the drive has RUN/STOP pushbuttons, press RUN. Slowly turn the speed pot CW. PROBABLE FAILURE OR INDICATION a) Drive trips off with motor disconnected Possible faulty Chopper SW Module(s). b) Drive trips off with motor disconnected Chopper SW Module(s) are correct per step B2. REPAIR PROCEDURE a) Go to step B2. b) Go to step B3 to check Brake SW Module. c) Go to step C7. 2 DISC. SWITCH OFF CONT. Turn off power at the disconnect switch. Remove the black plastic covers from Pull Down SW Modules SM-3 & 4 - (10 & 15HP), or SM-4, 5. & 6 - (20 & 40HP). Remove the large, BLACK, 10 AWG wires from their terminal posts. With a VOM set on the Rx1 scale, connect the (+) VOM lead to the disconnect BLACK wire. Connect the (-) VOM lead to the large , WHITE, 10 AWG wire at it's terminal post. Check individually. Repeat the procedure with the VOM set on the Rx10K scale. c) Drive does not trip off with motor disconnected. a) On Rx1 scale the Ohms reading should be infinity. A low reading, (<10 Ohms), indicates a shorted transistor. b) On Rx10K scale the Ohms reading should be ≥500K Ohms. A reading below 500K Ohms indicates a leaky transistor. a) Replace faulty module(s) and reconnect the black wires to their terminal posts. Go to step C5. b) Replace faulty module(s) and reconnect the black wires to their terminal posts. Go to step C5. NOTE: All transistors on the Pull Down SW Modules are individually fused. A blown fuse will indicate a failed transistor. HOWEVER, for purposes of verifying drive performance and for troubleshooting under LIGHT LOAD (≤50% of drive's rated KVA), or NO LOAD conditions, fuses may be removed from faulty transistors. IN NO CASE should a module be installed with less than (6) functional transistors. SYMPTOM STEP DIAGNOSTIC PROCEDURE C. Motor starts but trips off drive. 3 a) With the motor still disconnected, turn on power at the disconnect switch. Set the manual speed pot fully CCW- minimum speed. If the drive has RUN/STOP pushbuttons, DO NOT press RUN. Place the toggle switch located on the bottom of Chopper Driver Board DB-1 in the OFF position. Press the ON pushbutton. LED CR7, (Pull Down LED), on Chopper Driver Board DB-1 should light. After approximately (3) seconds, LED CR15, (Bus Sense LED), on Power Supply Board PS-1 should light. After approximately (6) seconds, one LED on each of the Power Driver Boards, DB-2, 3, & 4 should light. NOTE: The above sequence will occur ONLY if the drive is equipped with RUN/STOP AND/OR the drive has a minimum speed pot setting of (0) Hz. b) If the drive has RUN/STOP pushbuttons, press RUN, slowly turn the speed pot CW. Observe LEDs CR7 & CR4 on Chopper Driver Board DB-1. CR7 should dim while CR4 should remain off. LEDs on Power Driver Boards DB-2, 3, & 4 will alternately start to flash. As the speed is increased above 10 Hz, all LEDs on the Power Driver Boards will appear to be lit constantly. 4 DISC. SWITCH OFF CONT. Incorrect LED indication on a Power Driver Board indicates a faulty (+) or (-) SW Module connected to that Power Driver Board. Turn off input power at the disconnect switch and remove the black plastic covers from the (+) and (-) SW Modules associated with the faulty Power Driver Board. Remove both the large, (10 AWG) and small, (18 AWG) . BLACK wires from their terminal posts. With the VOM set on the Rx10K scale, connect the (+) VOM lead to the large disconnected BLACK wire. Connect the (-) VOM lead to the large, WHITE, 10 AWG wire at it's terminal post. The VOM should read low and slowly rise to approximately 500K Ohms after 10-15 seconds Repeat for each SW Module PROBABLE FAILURE OR INDICATION a) None or both LEDs on Power Driver Boards DB-2, 3, or 4 are lit. b1) LEDs on Power Driver Boards DB-2, 3, or 4 not indicating as explained. b2) LEDs on Chopper Driver Board DB-1 not indicating as explained. b3) All LEDs indicating normally. A sustained low reading indicates a shorted or leaky SW Module. REPAIR PROCEDURE a) Replace faulty Power Driver Board(s). NOTE: DB-2, 3, & 4 may be interchanged to determine if the problem stays with the board or whether wiring to the board is at fault. b1) Go to step C4. b2) Go to step C5. b3) Go to step C7. Replace faulty SW Module(s). Reconnect all SW Module wires. Go to step C7. SYMPTO M C. Motor starts but trips off drive. STEP DIAGNOSTIC PROCEDURE 5 With the motor still disconnected and the disconnect switch off, set the manual speed pot fully CCW minimum speed. Switch the toggle switch on Chopper Driver Board DB-1 to ON. With the VOM set on the 500V DC scale, connect the ( + ) VOM lead to the ( +) side of the 2nd Bus Bar and the (-) VOM lead to the common ( -) Bus Bar. Turn on power at the disconnect switch and press the ON pushbutton. Wait approximately (6) seconds for Contactor K1 for energize. If the drive has RUN/STOP pushbuttons. press RUN and slowly turn the speed pot CW. Observe the vo!tage and note the action of LEDs CR4, (Chopper LED), and CR7, (Pull Down LED), on Chopper Driver Board DB-1. The voltage should slowly increase from O to 280V DC while CR7 dims and CR4 lights. 6 DISC. SWITCH OFF CONT. a) Turn off power at the disconnect switch. Remove the black plastic guard from the Bus Bank capacitors. Connect the (+) VOM lead to the (+) 2nd Bus Bank bar. Connect the (-) VOM lead to the (-) 2nd Bus Bank bar. The VOM should read low and slowly rise to above 25 Ohms. PROBABLE FAILURE OR INDICATION a) Voltage and LEDs indicating correctly. b) Voltage not present. CR7 remains lit and CR4 remains off as speed pot is turned CW. NOTE: Insure that the drive is processing the speed signal by checking the LEDs on Power Driver Boards DB-2, 3, and 4. LEDs should alternately start to flash as the speed pot is turned CW. Above 10 Hz, they will appear to be lit constantly. c) Voltage not present. CR7 goes off but CR4 remains off when speed pot is turned CW. d) Voltage not present or very low, (<10V DC). CR7 begins to dim, CR4 begins to light then drive trips off. a) A sustained low reading indicates a short on the 2nd Bus. b) Leave the (-) VOM lead connected to the (-) 2nd Bus Bank bar and the VOM on Rx1. Disconnect all wires to the (+) 2nd Bus Bank bar. Insure that the disconnected wires are not touching. Connect the (+) VOM lead to the (+) 2nd Bus Bank bar. b1) A high reading, (>100 Ohms), indicates the fault is elsewhere. b2) A low reading, (≤100 Ohms), indicates a shorted or leaky Bus capacitor. c) Leave the (-) VOM lead connected to the (-) 2nd Bus Bank bar and the VOM on Rx1. Connect the (+) VOM lead to C10 (+) (10 & 15 HP), or C17 (+) (20-40 HP), on the drive back panel. c1) A high reading, (>100 Ohms), indicates the fault is elsewhere. c2) A low reading indicates a shorted capacitor. REPAIR PROCEDURE a) Go to step C7. b) Replace Control Logic board CL-1. Go to step C7. c) Replace Chopper Driver Board DB-1. Go to step C7. d) Go to step C6. a) Go to step b). b1) Go to step c). b2) Remove the brass bar from the (+) 2nd Bus bank. Isolate and replace faulty Bus capacitor(s). Replace brass bar. Go to step C7. c1) Carefully reconnect all wires to the ( +) 2nd Bus Bank bar AND ALL OTHER WIRES previously removed. Go back to step C3. c2) Replace faulty capacitor. Go to step C7. SYMPTOM STEP C. Motor starts but trips off drive. 7 DISC. SWITCH OFF 8 9 CONT. DIAGNOSTIC PROCEDURE Check Fuse F6. Carefully reconnect all wires to the (+) 2nd Bus bar AND ALL OTHER WIRES previously removed. With the motor still disconnected and the disconnect switch off, set the manual speed pot fully CW maximum speed. With the VOM set on the 500V AC scale, connect the ( + ) VOM lead to TB1, terminal 1, and the (-) VOM lead to TB1, terminal 2. Turn on power at the disconnect switch and press the ON pushbutton. If the drive has RUN/STOP pushbuttons, press RUN. Wait approximately (6) seconds and measure the voltage. a) Test the motor and leads for "grounds" or "opens" and repair as required. Turn off power at the disconnect switch and reconnect the motor at TB1, terminals 1, 2, & 3. If the drive has manual reset motor overload relays, insure that they have been RESET. Set the manual speed fully CCW - minimum speed. Turn on power at the disconnect switch and press the ON pushbutton. If the drive has RUN/STOP pushbuttons, press RUN. Wait approximately (6) seconds, then SLOWLY turn the speed pot fully CW to maximum speed. SLOWLY turn the speed pot back to minimum speed. PROBABLE FAILURE OR INDICATION F6 blown a) Voltage between 200 to 250V AC Repeat procedure with (+) VOM lead connected to TB1, terminal 3. REPAIR PROCEDURE Replace F6. Go to step C8. a) Voltage still between 200 to 250V AC - Go to step C9. b) Contact your Allen-Bradley Area Service Center. b) Voltage not present. a1) Motor follows speed pot signal and runs smoothly. a1) Go to step b). a2) Motor starts but runs unstable or stalls at certain speeds. a2) It may be necessary to change capacitor C29 on Control Logic board CL-1. Contact your Allen-Bradley Area Service Center. a3) Drive trips as soon as speed pot is turned CW. a3) Improper motor rating for the drive. Contact your Allen-Bradley Area Service Center. SYMPTOM STEP C. Motor starts but trips off drive. 9 DIAGNOSTIC PROCEDURE b) With the motor still connected, press the OFF pushbutton and set the speed pot fully CCW minimum speed. Press the ON pushbutton. If the drive has RUN/STOP pushbuttons, press RUN. Wait approximately (6) seconds, then QUICKLY turn the speed pot CW to maximum speed. Once the motor has reached full speed, QUICKLY turn the speed pot back to minimum speed. PROBABLE FAILURE OR INDICATION bl ) Motor follows speed pot signal and runs smoothly. b2) Drive trips upon acceleration as speed pot is quickly turned CW. REPAIR PROCEDURE b1) Contact your Allen-Bradley Service Center. b2) Acceleration Rate set too High, (potentiometer R86 on Control Logic Board CL-1). CAUTION: Do not adjust RED sealed potentiometers. Breaking of these seals will void any drive warranties. Incorrect adjustment may cause damage to the motor and/or drive. b3) Drive trips upon deceleration as speed pot is quickly turned CCW. b3) Deceleration Rate set to High. (potentiometer R87 on Control Logic Board CL-1) CAUTION: Do not adjust RED sealed potentiometers. Breaking of these seals will void any drive warranties. Incorrect adjustment may cause damage to the motor and/or drive. NOTE: If LED 1 on Brake Board BB-1 remains on or flickers when the speed pot is fully CCW minimum speed, BB-1 may need readjustment. Go back to step B11c). b4) Drive trips upon deceleration - Braking Resistor Heater(s) R3 (10 & 15 HP), or R5 & R6 - (20-40 HP) overheated and/or Over temperature switch OTS-2 tripped. b4) Heavy Duty Dynamic Braking, (Option K2), may be required. Contact your Allen-Bradley Area Service Center.