BULLETIN 1318 TROUBLESHOOTING GUIDE Page 1 of 10 CHART 1A. MOTOR WILL NOT START OR STOPS AND WILL NOT RESTART. Check continuity of Fault/Safety interlocks and machine limit switches. OK Check AC input to Drive section. Look for "Drive Healthy" LED illumination. OK Check motor armature voltage. There should be more than 5 Volts at the armature terminals. OK Check motor armature current. Is voltage less than 100V? No No No Reset Fault/Safety interlock or limit switch and try again. If Fault tripping persists, investigate cause and correct. Check branch disconnect and associated fuses. Check for low Trip input or field loss. Close disconnect or replace fuses after correcting Fault. Correct cause of low Trip input or field loss. Problem is in Drive Controller or interconnecting wiring. Proceed to Chart 1B or contact the nearest Area Service Center. Motor armature circuit is open. Repair or replace motor. Replace contact in DC loop contactor. Drive is "in current limit." Is current limit pot set correctly? Check motor shaft for free rotation. Investigate and rectify machine mechanical problem. No YES Is LED 2 illuminated? Yes OK BULLETIN 1318 TROUBLESHOOTING GUIDE Page 2 of 10 CHART 1B. MOTOR WILL NOT START OR STOPS AND WILL NOT RESTART. Check that the DC loop or AC line contactor is energized. Turn to Chart 1BB. No OK Check AC power input to controller.. No OK Check that the RUN input, terminal (36) is more than 20V. No OK Check external SPEED reference input circuits. No OK Check Speed reference input from operator's controls (run mode only). No Check for blown fuses F1, F2 and external branch circuit fusing. Replace blown fuses after correcting Fault condition. Check associated relays supplying the START and STOP functions. Replace as necessary. Refer to schematic diagrams and trace problem or call Field Service. Check associated relays and circuits in motor control logic. Replace relay(s) as necessary. Refer to schematic diagrams and trace problem or call Field Service. Refer to schematic diagrams and check for continuity in external and operator's SPEED reference circuits. Repair or replace circuitry as necessary. (CONTINUED ON NEXT PAGE....) OK 1318 TROUBLESHOOTING GUIDE Page 3 of 10 CHART 1B (CONT.) MOTOR WILL NOT START OR STOPS AND WILL NOT RESTART. OK Check external SPEED reference input circuits. No OK Check for firing pulses at power converter (pulse transformer inputs (R36). OK Check associated relays and circuits in motor control logic. Refer to schematic diagrams and trace problem. OK No pulses. Problem is in electronic control. Proceed to Chart 1C . Pulses present. Problem is in power converter. Proceed to Chart !C. BULLETIN 1318 TROUBLESHOOTING GUIDE Page 4 of 10 CHART 1BB. MOTOR WILL NOT START OR STOPS AND WILL NOT RESTART. Check for AC and +24V DC supply voltage to control logic relays. OK Check for operation of AC and DC contactors. Check coil circuit continuity. Contactor coil circuit is open. Replace contactor. Check operator's pushbuttons and interconnection wiring. Repair or replace components, correct wiring errors, or repair broken wires. Improper relay logic sequence. Dirty, broken, or wrong relay contacts. Correct logic sequence, correct wiring erros, repair or replace components. No No OK Proceed to Chart 1C or call for service. Replace blown fuses after correcting the Fault condition. No OK Check for START/STOP logic inputs. OK Refer to schematic diagrams. Trace and check relay START sequence and contact operation. Check for blown fuses F5, F6, F8 and F9. BULLETIN 1318 TROUBLESHOOTING GUIDE Page 5 of 10 CHART 1C. MOTOR WILL NOT START OR STOPS AND WILL NOT RESTART. Check +15V (8) and -15V (9) regulated power supply outputs. OK Check SPEED reference input to speed amplifier (26) or ram generator (19). 10V = Max. Speed. OK Check SPEED reference output (38) of ramp generator (if used). OK Check current demand output of speed amplifier (23). +/- 5V = full load current. No No No No OK Replace control board. Problem is in regulated DC power supply. If (5) is > 20V and (7) more negative than -20V, then problem is in DC power supply. Replace Control Board or repair interconnections. Refer to schematic diagrams and check SPEED reference circuits for continuity or correct voltage. Replace malfunctioning component(s) or repair wiring external to the Drive. Ramp generator or assoc iated potentiometer(s) has malfunctioned. Replace control board. Is LED 2 illuminated? If so, drive is in current limit. Checkf or correct current limit setting. Replace control board. Replace power board or call field service. No Yes BULLETIN 1318 TROUBLESHOOTING GUIDE Page 6 of 10 CHART 2A. MOTOR RUNS AT HIGH SPEED WITH NO SPEED CONTROL. Run motor momentarily with low SPEED reference. Check for voltage at tach terminals. OK Check for presence of speed feedback at terminal (28). See Note Below. OK Check the SPEED reference at speed amplifier (26) and ramp generator (19). No No No Tach is not generating voltage or coupling to the motor has loosened or broken. Repair coupling or repair/replace tach. Open or short circuit between tach and motor controller. Trace cable for open or short circuit and repair or replace the cable. Refer to schematic diagrams and check external SPEED reference circuits for voltage and continuity. Repair or replace parts or wiring. YES Problem is in controller. Replace control board or contact field service. NOTE: POLARITIES ARE DEPENDENT UPON REFERENCE POLARITY AND DIRECTION OF MOTOR ROTATION. BULLETIN 1318 TROUBLESHOOTING GUIDE CHART 3A. MOTOR RUNS AT LOW SPEED WITH NO SPEED CONTROL. With maximum speed demand, check for presence of 10V DC at terminals (26) or (19). No YES Check if motor is in current limit. (LED 2 is lit). Refer to schematic diagrams and check external SPEED reference circuits for correct voltage. Repair or replace parts and wiring. Problem is in the motor controller. Proceed to Chart 3C or call field service. Problem is in the motor, controller, or interconnections. Proceed to Chart 3B or refer problem to field service. Motor shunt field winding or circuit is open. Repair or replace motor. Problem is in the motor controller. Proceed to Chart 3C or refer problem to field service. No YES Check for motor shunt field voltage at motor terminals. Should be more than 180V. OK Check that the motor shund field current is within 25% of nameplate.. OK Uncouple the motor. Check if motor now runs normally. YES Mechanical problem on the machine. No No No Page 7 of 10 BULLETIN 1318 TROUBLESHOOTING GUIDE Page 8 of 10 CHART 3B. MOTOR RUNS AT LOW SPEED WITH NO SPEED CONTROL. Check for motor shunt field voltage at termininal block (Field + and Field -). See Note 2. No Check for AC input supply to the field supply circuit at L1 (FLD) and L2 (FLD). Check for blown F3 and F4 fuses. Correct fault, replace blown fuses or broken wiring. If fuses are OK replace power board. YES Problem is in controller. Refer to field service. NOTE 1: REFER TO SCHEMATIC DIAGRAMS FOR APPLICATION CIRCUITRY IN RESPECT TO SPEED REFERENCE. NOTE 2: LOSS OF SHUNT FIELD CURRENT WILL TRIP MOTOR FIELD LOSS PROTECTION IF PROTECTION IS SELECTED (SW1-2 IS OPEN). NOTE 3: LOSS OF CURRENT FEEDBACK WILL CAUSE SYSTEM INSTABILITY. CHART 3C. MOTOR RUNS AT LOW SPEED WITH NO CONTROL. Replace control board. Doesmotor continue to run at low speed. YES Refer problem to field service. Problem corrected. No BULLETIN 1318 TROUBLESHOOTING GUIDE Page 9 of 10 CHART 4A. PERFISTANT FUSE ''BLOWING''. Check for motor shunt field voltage at motor terminals (more than 180V). Check for motor shunt field current (must be within 25% of motor nameplate). Check motr armature, commutator, and brushgear for damage or short circuits. NO Check that motor shaft is free to rotate. Check that overload and fuse ratings are correct. No Problem is in motor controller or interconnections. Proceed to Chart 4B or refer problem to field service. Open circuit shunt field winding. Repair or replace motor. No Repair or replace motor. Yes Correct the situation. No YES Problem is in controller. Proceed to Chart 4B or refer to field service. NOTE: LOSS OF SHUNT FIELD CURRENT WILL TRIP MOTOR FIELD PROTECTION IF FIELD FAILURE PROTECTION IS SELECTED (SW1-2 IS OPEN). BULLETIN 1318 TROUBLESHOOTING GUIDE Page 10 of 10 CHART 4B. PERSISTANT FUSE ''BLOWING''. With motor running at full load, check current feedback at controller terminal (41). +/1mA = 200% rated controller current YES Check for motor shunt field voltage at terminal block (should be more than 180V). See note 2. No No Controller or interconnection problem. Call field service. See note 1. Check for AC input supply the field supply. Check for blown fuses F3 and F4. After correcting fault, replace blown fuses or repair/replace field supply bridge. YES Replace control board or call field service. NOTE 1: LOSS OF CURRENT FEEDBACK WILL CAUSE THE SYSTEM TO BE UNSTABLE. NOTE 2: LOSS OF SHUNT FIELD CURRENT WILL TRIP MOTOR FIELD PROTECTION IF FIELD FAILURE PROTECTION IS SELECTED (SW1-2 OPEN).