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1. MAINTENANCE AND TROUBLESHOOTING In This Chapter Maintenance and Inspection 0 000 c eee es 6 2 Monthly Inspection axes nasiener esau E EERE cee Ux 6 2 Annual Inspection EST 6 2 Recharge Capacitors for unused drives 0000 eee 6 2 Troubleshooting o aia acci re led Redes dene eek eee 6 3 Fault MESSIS uasa eR VERS Sean ee ce weer ware ee daa d 6 3 Warning Messages Serial Communication and Keypad Errors 6 7 Chapter 6 Maintenance and Troubleshooting Maintenance and Inspection Modern AC drives are based on solid state electronics technology Preventive maintenance is required to operate the AC drive in its optimal condition and to ensure a long life We recommend that a qualified technician perform a regular inspection of the AC drive Some items should be checked once a month and some items should be checked yearly If the drive is stored or is otherwise unused for more than a year the drive s internal DC link capacitors should be recharged before use Otherwise the capacitors may be damaged when the drive starts to operate We recommend recharging the capacitors of any unused drive at least once per year discharged before inspecting the AC drive 1 WARNING Disconnect AC power and ensure that the internal capacitors have fully Wait at least two minutes after all display lamps have turned off Monthly Inspection Check the following items at least once a month 1 Make sure the moto2. Copy Error COMMS 1 Check connection between the keypad and drive and make sure itis not loose Communications error during Copy Keypad 2 Check communications protocol for correct settings function Copy Error Data 1 Check connection between the keypad and drive and make sure it is not loose 2 Check communications protocol for correct settings Data error during Copy Keypad function 6 8 DURAputse AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 6 Maintenance and Troubleshooting eee Warning Messages Error Name Description 1 Ensure that the ambient temperature falls within the specified temperature range 2 Make sure that the ventilation holes are not obstructed The AC drive temperature has exceeded 3 Remove any foreign objects on the heat sinks and check for 85 of the O ver temperature condition possible dirty heat sink fins 4 Provide enough spacing for adequate ventilation Overheat Warning Write Failure When the copy function is enabled P 9 40 W rite to EEPROM fails Parameter Locked Parameters have been locked read only cannot be set cannot write Error The configuration is not accepted or the parameter is locked Value Accepted Value Accepted Error Duplicate This occurs when attempting to set two mutually exclusive parameters to the same value This is most commonly seen when P4
3. External Fault AUTO RAMP FAULT Auto accel decel failure Refer to O ver current or O ver voltage error GROUND FAULT 1 Possible unbalanced load 2 Possible current leakage Check the motor for possible insulation damage Check for possible poor insulation at the output line EXT BASE BLOCK AC drive output is turned off When the external input terminal base block is active the AC drive output will be turned off Disable this connection and the AC drive will begin to work again INPUT POWER LOSS ase of the input power is lost Check for possible poor connection on the input power line Check for possible loss of phase on input power line OUTPUT SHORTED IGBT Short Circuit Contact ADC Support for assistance PID FBACK LOSS 1 If P 7 27 0 warn and AC drive stop PID feedback loss recorded 2 If P 7 27 1 warn and continue operation PID feedback loss not recorded 1st Ed Rev D 05 2013 PID Warning PID Feedback Loss The 4 20mA PID signal has been lost The corrective action can be set with the PID Feedback Loss parameter P 7 27 The available settings are 00 Warn and AC Drive Stop 01 Warn and Continue The default setting is 00 DURAPuLsE AC Drive User Manual 6 5 Chapter 6 Maintenance and Troubleshooting ET Fault Messages Fault Name Description Corrective Actions E
4. has occurred to 4 Reduce the current level so that the AC drive output current does a CL or motor not exceed the value set by the M otor Rated Current P 0 01 OVER TORQUE If P 6 07 is set to 2 to enable detection during accel decel 1 Reduce the motor overload Parameter settings P 6 07 to P 6 09 i i i i Am seem condidon has oteumed 2 Adjust the over torque detection setting to an appropriate level cause an over torque fault OVER CURRENT ACC Check for possible poor insulation at the output line O ver current during acceleration Decrease the torque boost setting in P 2 02 1 Short circuit at motor output Increase the acceleration time P 1 01 and P 1 05 2 Torque boost too high Replace the AC drive with one that has a higher output capacity 3 Acceleration time too short 4 AC drive output capacity is too small OVER CURRENT DEC Check for possible poor insulation at the output line O ver current during deceleration Increase the deceleration time P 1 02 and P 1 06 1 Short circuit at motor output Replace the AC drive with one that has a higher output capacity 2 Deceleration time too short 3 AC drive output capacity is too small OVER CURRENT STD Check for possible poor insulation at the output line O ver current during steady state operation 2 Check for possible motor stall l 1 Short circuit at motor outpu
5. 00 and P4 13 are both set to the same value Firmware version 1 04 or higher only Function 1st Ed Rev D 05 2013 DURAPuLsE AC Drive User Manual 6 9 Chapter 6 Maintenance and Troubleshooting ET 6 10 BM OURApuse AC Drive User Manual Ist Ed Rev D 05 2013
6. NCODER LOSS _ 1 Verify that the encoder board has power IfP 10 05 1 A 2 S and AC n 2 Check to be sure it is not mis wired stop Encoder feedback loss would be 3 Check for incorrect voltage or encoder set up recorded S qus M P 30 05 O am and eshtinde 4 nd the mechanical and electrical integrity of the operation Encoder feedback loss would not be recorded ENC SIGNAL ERROR 1 Verify power to the encoder feedback card 2 Verify encoder and feedback card wiring 3 Check encoder feedback card dip switch settings and encoder voltage requirements Encoder A B phase signal is in error when the control mode is from the encoder 6 6 DURAputse AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 6 Maintenance and Troubleshooting ee Warning Messages Serial Communication and Keypad Errors There are several Warning Messages that a DU RAPuLse AC Drive may give The DU RApuLse AC Drive allows you to decide its response to these messages The descriptions of the Warning Messages are listed below Warning Messages Error Name Description 1 The Keypad LCD display has failed 2 Check input power 3 Make sure the keypad is tightly connected to the drive No display shown on the keypad Invalid Cmd Code Invalid Command Code when communicating Invalid Address Invalid Address when communicating Invalid Data Invalid Data when communi
7. cating Slave Comm Fault Slave Comm Fault device failure Comm Time Out Communication Time O ut Drive Error Drive model doesn t match keypad EEPROM Fault When the copy function is enabled P 9 40 there is a Read Write EEPROM Fault Ist Ed Rev D 05 2013 DURAPULsE AC Drive User Manual 6 7 Chapter 6 Maintenance and Troubleshooting ET Warning Messages Error Name Description Rating Mismatch Data range doesn t match Group Overflow When the copy function is enabled P 9 40 keypad s group number data is more than the drive s No Space When the copy function is enabled P 9 40 EEPROM data block in the keypad is full Delete Failure When the copy function is enabled P 9 40 delete EEPROM block fails No Data When the copy function is enabled P 9 40 EEPROM data block is null R1 Detect Error 1 Check to make sure the motor is connected to the drive correctly 2 Check line power to drive Failure to detect motor resistance during 3 STO P key was pressed during Auto Tune procedure Auto tune procedure No Load Error 1 Check to make sure the motor is connected to the drive correctly 2 Check line power to drive 3 STO P key was pressed during Auto Tune procedure Failure to detect any motor load during Auto tune procedure
8. ges The AC drive has a comprehensive fault diagnostic system that includes several different alarms and fault messages Once a fault is detected the corresponding protective functions will be activated The fault messages are then displayed on the digital keypad LCD display The six most recent faults can be read on the digital keypad display by viewing parameters P06 31 to P06 36 NOTE Faults can be cleared by a reset from the keypad or input terminal Fault Name Description Fault Messages Corrective Actions OVER CURRENT The AC drive detects an abnormal increase in current 1 Check whether the motor s horsepower is equal to or less than the AC drive output power 2 Check the wiring connections between the AC drive and motor for possible short circuits Increase the Acceleration time P 1 01 or P 1 05 Check for possible excessive loading conditions at the motor If there are any abnormal conditions when operating the AC drive after short circuit is removed or fault does not clear call ADC Support for assistance OVER VOLTAGE The AC drive detects that the DC bus voltage has exceeded its maximum allowable value Check whether the input voltage falls within the rated AC drive input voltage Check for possible voltage transients Bus over voltage may also be caused by motor regeneration Either increase the decel time or add an optional braking resistor Check whether the
9. required braking power is within the specified limits Check braking resistor on drives under 20H P and dynamic brake unit amp braking resistor on drives 20HP and above OVER TEMPERATURE The AC drive temperature sensor detects excessive heat Ensure that the ambient temperature falls within the specified temperature range Make sure that the ventilation holes are not obstructed Remove any foreign objects on the heat sinks and check for possible dirty heat sink fins Provide enough spacing for adequate ventilation UNDER VOLTAGE The AC drive detects that the DC bus voltage has fallen below its minimum allowable value Check whether the input voltage falls within the rated AC drive input voltage OVERLOAD The AC drive detects excessive drive output current 1st Ed Rev D 05 2013 1 Check whether the motor is overloaded 2 Reduce torque compensation setting as set in P 2 03 3 Increase the AC drive s output capacity Note The AC drive can withstand up to 150 of the rated current for a maximum of 60 seconds DURAPuLsE AC Drive User Manual 6 3 Chapter 6 Maintenance and Troubleshooting ET Fault Messages Fault Name Description Corrective Actions THERMAL OVERLOAD If P 6 07 is setto 1 to enable during steady state 1 Check for possible motor overload 2 Check electronic thermal overload relay setting P 6 00 An external condition
10. rs are operating as expected Make sure the installation environment is normal Make sure the cooling system is operating as expected Check for irregular vibrations or sounds during operation Make sure the motors are not overheating during operation Check the input voltage of the AC drive and make sure the voltage is within the operating range Check the voltage with a voltmeter OU BW NN Annual Inspection Check the following items once annually 1 Tighten and reinforce the screws of the AC drive if necessary They may loosen due to vibration or changing temperatures Make sure the conductors and insulators are not corroded or damaged Check the resistance of the insulation with a megohmmeter Check the capacitors and relays and replace if necessary Clean off any dust and dirt with a vacuum cleaner Pay special attention to cleaning the ventilation ports and PCBs Always keep these areas clean Accumulation of dust and dirt in these areas can cause unforeseen failures 6 Recharge the capacitors of any drive that is in storage or is otherwise unused U AeA WwW N Recharge Capacitors for unused drives Recharge the DC link before using any drive that has not been operated within a year 1 Disconnect the motor from the drive 2 Apply input power to the drive for 2 hours DURAPuLsE AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 6 Maintenance and Troubleshooting Troubleshooting Fault Messa
11. t 3 Replace the AC drive with one that has a higher output capacity 2 Sudden increase in motor loading 3 AC drive output capacity is too small Switch off power supply CPU FAILURE 1 Check whether the input voltage falls within the AC drive s rated input voltage memory IC cannot be programmed Switch the AC drive back on If fault does not Clear contact ADC Support for assistance CPU FAILURE 2 Reset drive to factory defaults P 9 08 to 99 Switch off power supply Switch the AC drive back on If fault does not clear contact ADC memory IC cannot be read Support for assistance CPU FAILURE 3 1 Check all connections at L1 L2 and L3 2 Verify correct voltage at L1 L2 L3 3 Contact ADC Support for assistance Intemal memory IC failed to receive outputstatus 6 4 DURApuse AC Drive User Manual Ist Ed Rev D 05 2013 Chapter 6 Maintenance and Troubleshooting ee Fault Name Description Fault Messages Corrective Actions HARDWARE FAILURE Hardware protection failure 1 Check all connections at L1 L2 and L3 2 Verify correct voltage at L1 L2 L3 3 Contact ADC Support for assistance MOM POWER LOSS Input power has been lost Check line power to drive EXTERNAL FAULT The external terminal EF CM goes from OFF to ON W hen external terminal EF CM is closed the output will be turned off under Normally Open
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