Diagnostics / Troubleshooting 8510 Drive Chapter Objectives The purpose of this chapter is to assist you in determining the cause of a drive fault or improper drive operation and to define possible corrective actions. Possible corrective actions include: • • • • Correcting programming or wiring errors Replacing blown fuses Replacing subassembly modules that have malfunctioned Replacing the complete drive Introduction The drive performs a number of diagnostic tests at different times during system operation. The different classes of tests include the following: • • • Power On Tests - when AC power is applied, all logic level functionality is checked and the data tables are tested to verify data integrity. Drive Enable Tests - when the Drive Enable input is applied, the DC bus is energized and the power section is checked for correct operation. Normal Operation Tests - various data integrity, control system functionality, and power section tests are performed on a continuous or periodic basis during normal drive operation. ATTENTION: Power must be applied to the system to perform many of the checks specified in this chapter. Some voltages present are at incoming line potential. To avoid injury to personnel and/or damage to equipment, only qualified service personnel should perform the troubleshooting procedures provided. Thoroughly read and understand any procedure before beginning. The drive provides two discrete digital outputs to indicate fault conditions; Soft Fault and Hard Fault. The Soft Fault output will be turned Off as a result of motor/drive overtemperature, or improper command sequences that can not be acted upon by the drive. During a soft fault condition, the drive will continue to operate normally. The Hard Fault output will be turned Off whenever a drive fault condition occurs that will prevent the drive from properly controlling the motor. In either case, the 8510 display will show a short text message that describes the fault. In addition, the drive can display the last eight faults that have occurred. Circuit Board Descriptions The functionality associated with each circuit board in the 8510 AC Spindle Drive is described below. Refer to Figure 1.1 for board locations. I/O Board Includes all analog and discrete digital user interface functions along with the integral drive programming system. The EEPROM for user programmed parameter storage is located on this board. Main Control Board Used on 85l0A-A11-x2 and 85l0A-A22-x2 drives only. This board contains all of the basic drive control circuitry including the digital control system for position, velocity and commutation control, motor current loops, IGBT gate drive circuits with fuses, logic power supplies with fuse, resolver feedback interface, spindle position feedback interface, dual winding motor contactor control interface, and fault diagnostics system. CPU Board Used on 8510A-A04-xl and 8510A-A06-xl drives only. This board contains the digital control system for position, velocity and commutation control, motor current loops, spindle position feedback interface, and fault diagnostics system. Gate Drive Board Used on 8510A-A04-xl and 8510A-A06-xl drives only. This board contains the IGBT gate drive circuits with fuses, logic power supplies with fuse, resolver feedback interface and dual winding motor contactor control interface. Power Board Interconnects all items in the power structure to minimize power wiring. The board includes the snubber networks, power filtering, control relays, and AC control fuses. The following assemblies are mentioned in the sections that follow. Locations are not shown in Figure 1.1, but will be described in text as appropriate. Interconnect Boards These are three small circuit boards used to interconnect signals from the Power Board to the Main Control or Gate Drive Board . Power Unit The Power Unit is the complete drive structure less the I/O and Main Control Board or CPU and Gate Drive Boards . Figure 1.1 Circuit Board Locations Bottom View of 8510A-A04, A06 Drive Power Distribution and Control The initial power-up sequence is described below. Refer to Figure 1.2 for the associated power distribution and control circuitry. 1. When AC power is applied to the drive, the cooling fans and all internal control logic is immediately energized through AC control power fuse sets F1, F2, and F3. 2. The external Coast to stop input must be closed to allow any of the following power-up sequence to be executed. Closing this contact will close the coast to stop control relay (K10) and allow the main contactor (KM) to close. 3. When the Drive Enable input is closed, the DC bus discharge control relay (KM3) is energized. This disconnects the DC bus discharge resistor and allows the main contactor (KM) to be closed. 4. After KM3 energizes, the DC bus precharge control relay (KM1) is energized to allow the DC bus to charge through the precharge resistors. 5. When the DC bus voltage exceeds the under voltage trip level (250V DC), the pilot relay for the main contactor (KM2) will energize, which closes the main AC contactor (KM). The precharge relay (KM1) will also open at this time. 6. After the main contactor is closed, the IGBT output inverter is turned on and the motor is ready to operate. 7. If the Drive Enable or Coast to Stop inputs are opened, the main contactor (KM) will be opened (either after the motor has stopped or immediately, depending on which input is opened). If the Coast to Stop input is opened, the DC bus discharge relay (KM3) will be de-energized which connects the bus discharge resistor across the DC bus. A time delay guards against the relay being energized again until the bus discharge current has decreased to a level that will not damage the relay contacts . ATTENTION: If an oscilloscope is used during troubleshooting, it must be properly grounded. The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded. Always connect the oscilloscope chassis to earth ground. When using an oscilloscope it is recommended that the test probe ground be connected to the test point labeled “GND.” Fuse Locations and Types Fuse location and specific fuse information is provided in the paragraphs that follow. AC Control Power Fuses The electrical location of the AC control power fuses is shown in Figure 1.2. Refer to Figures 1.10, 1.13 and 1.14 for fuse locations. Table 1.A provides information on fuse types. Table 1.A AC Control Power Fuses - Power Board Designator FU1R, FU1S FU2R, FU2S, FU2T On A11 & A22 only FU3R, FU3S, FU3T On A04 & A06 only FU3R, FU3S, FU3T Rating 5A, 250V 5A, 250V 0.5A, 250V Vendor Name & Number Fuji-FGBO 5A 250V 1 Fuji-FGBO 5A 250V 1 Fuji-FGBO 0.5A 250V 1 A-B P/N 145863 145863 151287 0.5A, 250V Daito Tsushin - HM05 151465 1 Any substitute fuse for the Fuji-FGBO type fuses must be a metric style measuring 6.35 mm diameter by 30 mm long. Gate Drive and +5V DC Fuses Fuses for each of the IGBT gate drive circuit outputs and for the +5V DC logic power supply are located on the Gate Drive or the Main Control Board, depending on the drive rating. The following tables show the fuse types used. Refer to Figures 1.9 and 1.12 for fuse locations. Table 1.B 8510A-A04-x1 and 8510A-A06-x1 - Gate Drive Board Designator Gate Drive Fuses F1 to F12 5V DC Power Supply Fuse F13 0.3A, 250V Rating Vendor Name & Number Daito Tsushin-HM03 A-B P/N 148133 5A, 250V Daito Tsushin-MP50 148134 Table 1.C 8510A-A11-x2 and 8510A-A22-x2 - Main Control Board Designator Gate Drive Fuses F1 to F6, F8 to F13 5V DC Power Supply Fuse Rating 0.3A, 250V Vendor Name & Number Daito Tsushin-HM03 A-B P/N 148133 5A, 250V Daito Tsushin-MP50 148134 If the +5V DC power supply fuse has opened, a white indicator will show in the window on the front of the fuse. The +5V DC test point is before the fuse, so measuring the test point voltage will not verify that the fuse is OK. The gate drive fuses can not be visually checked to determine if they have malfunctioned. The fuse element is too small to allow a reliable visual check. Use an ohmmeter to test these fuses (with power off & out of circuit). ATTENTION: Do not apply power to the drive if any of the IGBT gate drive fuses have opened or been removed. The IGBT power module will be damaged if power is applied without the module gate leads connected to the control circuitry. Fault Diagnostics System The integral display and programming system is used to display drive diagnostic messages. When a fault occurs, the display will automatically change (within about 2 seconds) to the Current Fault display. If any key is pressed, the display will return to its previous state. Through the DIAGNOSTICS menu, the current fault and a fault history showing the eight (8) most recent faults can be accessed. The fault history does not contain date/time information and can not be reset. The tables found later in this chapter group the fault conditions or the fault display messages by general classification, describe the specific fault, and show probable causes and possible solutions. The general groupings are: • • • • • • • Problems that occur when AC power is applied Problems that occur when Drive Enable is applied Problems that occur while the drive is operating Problems that occur during spindle orient Other faults that indicate a control hardware malfunction Problems specifically related to the l/O Board Problems caused by programming errors Table 1.D Table 1.E Table 1.F Table 1.G Table 1 .H Table 1.L Table 1.J document #1407 document #1407 document #1407 document #1407 document #1407 document #1407 document #1407 For each fault condition or operating problem, the causes and solutions are listed in order of decreasing probability of occurrence or increasing complexity of required tests. To aid in locating a specific fault, an alphabetized list of all fault display messages and a Problem Number is provided. This listing can be used to quickly locate an explanation of the fault in the tables that follow . Display Text Line 1 Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Display Text Line 2 Abs Overspeed AC Phase Loss Bad Comb M & D Bad PG Count Bad PG Marker Bad PG Output Bus Overvoltge Bus Undervolt Convrtr Short Data Conflict Drive Overtemp Hi Accel Rate Hi Positn Cmd Hi Positn Err Hi Speed Cmd Inv/Mtr Short I/O Comm Err Main A/D Conv Main Comm Err Main CPU Loss Main CPU Ovfl Main CPU1 Err Main CPU2 Err Main RAM Err Main RAM Init Main Watchdog Max Spd None Motor Overtemp Problem Number 16 4, 19 52 27 26 28 17 18 9 14 21 40 41 42 43 11 30 34 32 31 38 35 36 29 37 33 53 20 Continued...... Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault Current Fault !Fault I/O Board 45 !Fault I/O Board !Fault I/O Board !Fault I/O Board !Fault I/O Board !Fault I/O Board !Fault I/O Board Warning I/O Brd Motor Short Mtr Windg Chg Need Parametr No Precharge Op Dig Set Er Optical Intpt Orient Prm Er Parameter Err Power Supply Resolver Loss Spd Error HI Sp Mtr 1 P Er Sp Mtr 2 P Er Bad EEPROM Bad Optional A/D EEPROM Sumchk H8 CPU RAM I/O DURM LCD Timeout Misc. Messages EEPROM No Data 10 23 12 8 54 39 55 13 5 6 22 56 57 46 47 48 49 50 51 44 The basic approach to hardware maintenance is to replace the I/O Board, Control Board, or complete power section. Component level repair of any board or the power section is not a recommended field repair procedure. ATTENTION: High voltage that presents an electrical shock hazard is present on the Main Control Board of the 8510A-A11-x2 and 8510A-A22-x2 drives. The upper right half of the board contains the IGBT gate drive circuits, while the upper left quarter contains the power supply. DC bus voltage (approximately 325V DC) is present in both of these areas. These areas contain the voltage warning symbol and are outlined with a heavy white line. To avoid injury, only qualified personnel should perform start-up or maintenance procedures on this drive. ATTENTION: This product contains stored energy devices. To avoid hazard of electrical shock, verify that all voltage on the capacitors has been discharged before attempting to service, repair or remove this unit . A relay connects a resistor across the DC bus to discharge the capacitors. Normally the capacitors will discharge within 30 seconds. An LED on the upper right side of the Main Control Board on 8510A-A11-x2 and 8510A-A22-x2 drives will be illuminated when the bus voltage is above 50V DC. IGBT Test Procedure The following procedure provides the steps needed to properly test the IGBT modules to determine if replacement is necessary. 1. Remove all power to the drive. Remove the front cover from the drive. 2. Label and remove the three motor wires from the drive terminals U, V and W. 3. Access to the IGBT modules must be gained by removing the following boards: On 8510A-A04 and A06 drives remove the CPU, Gate Drive and I/O Boards. On 8510A-A11 and A22 drives remove the Main Control (and I/O) Board. 4. The 8510A-A04 and A06 drives have two modules, while the 8510A-A11 and A22 drives have six. For proper testing, each module must be checked four different ways. The procedure for 8510A-A04 and A06 drives is shown in Figure 1.5. The procedure for 8510A-A1 1 and A22 drives is shown in Figure 1.6. On 8510A-A11 and A22 drives the IGBT module will have 4 spade lugs for the gate connection. Use these as a reference point for orientation. Measurements must be taken with a Digital Voltmeter (DVM) equipped with a “Diode” setting. The connection polarity for the meter is shown in each figure. A reasonable ohm reading would be 1 meg to infinity. A reasonable voltage drop would be 450 - 700mV. If a measurement differs appreciably from these values, the module is bad and the Power Unit must be replaced. 5. When testing/replacement is complete, replace board(s), cover and check for proper operation . Figure 1.5 continued...