eseries service manual b section 4 faults f4 f5 f6
Contents
1. Gate Emitter i Hold Gate SIGNAL On i To Turn On The IGBT The IGBT Will Turn Off i ue When the Gate Signalisi Gel k i Removed i Flyback AUS Diode Collector 12 Volt Battery 4508 298A Figure 4 12 Individual IGBT Testing Elite Series Service Manual 4201 230 Rev B57 80 Frame 5 687 4 4 6 TESTING THE DCCT AND DCCT SUPPLY The DCCTs measure motor current and are located on the output of the Elite DCCT failure may be indicated by Fault 21 Ground fault or Fault 58 Current imbalance even with the motor disconnected If fault 21 is apparent and the motor and motor cable have been checked and are OK check the DCCT terminations as shown in figure 3 9 and the Inverter as shown in figure 4 7 The 6 pin connector is located at the very top of the Control Board ia a Check plugs P1 P2 and P3 connecting the DCCTs to the Power tray Ensure they are correctly inserted jex ia How to test the DCCTs 1 Power up the Elite but do not start refer to figure 4 13 This drawing shows two options for testing the DCCTs either test between ground and terminal 1 then between ground and terminal 4 and 6 to confirm the DCCT has a 14V supply or test at the plug If the 14 supply is not present unplug the DCCT s and recheck the 14 supply If the supply has returned one or more of the DCCTs are faulty If the supply has not returned the Con2. ULTRAJEME ROMOTOR CONTRERAS zni G T i EARTH LINK BRAID Hinge Plate FF M6 x 16 CW SCREWS 2 OFF M6 x 12 CW SCREWS DISPLAY LOOM P NG AND SERIAL 082814 4201 230 Rev B57 Frame 5 6 8 7 69 4 2 PRINTED CIRCUIT BOARD DESCRIPTION Display The Display has three buttons and a 2 by16 character display It is the user interface for all parameter settings and is gt common to the Elite Series for a fault finding guide see section 4 3 3 Ta Control Board The Control board is common to the Elite Series For a description and a fault finding guide see section 4 3 4 The Control board accepts all external control inputs and generates output signals The inputs and outputs include digital analogue fibre optic and Modbus serial communications A shaft encoder interface and 5V power supply is standard The Display plugs into the control board The Control board also has a bidirectional 24Vdc user power supply rated at 500mA Power Tray The Power tray Power Electronics Assembly is made up of a metal support tray Control board mounting tray and Power board The Power tray receives power from the DC bus via the DC Supply board Circuitry included on the Power Tray The main switch mode power supply provides various isolated DC supplies required by the Elite these are 1 6 off 17V OV 14V
3. Check fuses for correct rating 5 Disconnect supply cables and test for phase to phase or phase to earth fault 6 Mark and disconnect the output cables test the cables and motor for phase to phase and phase to earth fault 7 Test the Elite for rectifier inverter or DC Bus faults as per section 4 5 1 8 If no faults are found the best option is to Soft Power the Elite as per section 4 5 If you consider the fuses failed because of an external issue such as short term overload or cyclic stress reconnect the Elite replace the fuses and attempt to run the Elite Control Board Fuse Located on the Control board This fuse is in series with the user 24Vdc 500mA power supply accessed via T36 and T37 The user power supply is short circuit protected and will shut down if a short is present in the field control wiring or other device connected to T36 and T37 Elite Series Service Manual 4201 230 Rev B57 72 Frame 5 687 2A 440V Power Tray DC Supply Fuses Fitted on Elite Power Supply Board _ Possible reason for failure Fault in main switch mode power supply on Power tray Inspect the Power tray for visibly damaged or blackened components If damaged components exist replace the Power tray If there is no visible damage replace the fuse and repower the Elite If the fuse blows again replace the Power tray WARNING These fuses must not be replaced with glass fuses glass fuses will rupture an
4. Unplug the other end of the corresponding gatedrive cable from the Power tray Turn on the power supply and set the output voltage to 24Vdc approx Apply a trigger pulse to the SCR under test with 24Vdc via a resistor of between 18 Jand 100 ohms via the plug on the unplugged end of the gate drive cable Trigger the SCR as per figure 4 9 below H jex J Note the SCR will not be damaged if the red lead makes contact with the trigger lead from the power supply When the gate has been triggered the SCR should latch into conduction and the supply go to current limit or the lamp glow for the alternative testing arrangement Since the supply is DC the SCR will not turn off until the supply is removed If the SCR will not stay latched on check the current limit is not set too low or the lamp is too low a wattage to allow sufficient current for the SCR to maintain a latched state If the SCR fails to conduct suspect a failed input fuse SCR Gate Trigger PCB or interconnecting loom Rectifier 4VE DC Bus ee x 24V Current limited Power SOR SOR SCR PCB supply Alternative Test Apparatus PCB o PCB v FSR A A A Power fone ote DI 18 to 100 Ohm Tray Lamp to Limit Current Resistor and Protect Battery L1 i f z 18 to 100 i YY a Touch Ohm Resi
5. field control wiring for faults or disconnect it Is 28VDC present on the fan terminals see note 1 Replace the Power Tray Yes high voltage applied Is 24VDC present on terminals 20 amp 21 Replace the Control Board Check the field wiring again and replace the 500mA fuse on the Control Board 24VDC present on terminals 37 amp 36 Replace the Control Board 4508 327A Note 1 The fan terminals are located between the fibre optic connections at the bottom of the Control Board These are not used in these frame sizes but still indicate that the Power Tray switch mode power supply is producing the 28Vdc required by the Control Board Figure 4 3 Control Board Fault Finding Elite Series Service Manual 4201 230 Rev B57 74 Frame 5 687 4 3 5 INPUT RECTIFIER The Rectifier is a half controlled bridge that combines DC conversion and the Soft Charge section of the Elite into one stage The SCR s on Line 1 are phase controlled to limit the inrush current due to the DC Bus capacitors when the Elite is powered up this is termed Soft Charge The phase control is continued until the capacitors are fully charged then all SCRs are turned on i a _Rectifier Soft Charge failure can be indicated by Ss I Input fuses blowing on power application or display of SUPPLY FAULT especially
6. meter The meter readings below are a guide and may vary with differing meter brands It is best to compare the suspect IGBT s with a known good IGBT Note the gate and emitter are shorted together for one test as shown below The IGBTs should be stored and handled in this state SHORT GATE TO EMITTERFOR STORAGE AND HANDLING SHORT GATE TO EMITTER FOR THIS TEST p k i Emitter 4 Diode conduction H 0 3 0 45V Flyback gt 10K IGBT Diode Collector 4508 261A Figure 4 11 Individual IGBT Testing The final tests are done as shown in figure 4 12 This test is very important as it is possiblefor the multi meter tests to I u show the IGBTs are OK but the IGBT may not actually work the IGBT does not respond to a Gatedrive signal If this is not detected and the Elite is reassembled with a non functioning IGBT in parallel with good IGBTs the current will be shared between the good IGBT s When the Elite is supplying full load current the IGBT s in the half phase with the faulty one will be overloaded and will fail prematurely Important note the 1K resistor must be between the gate and emitter at all times during the tests CONDUCTION TEST ALTERNATIVE TEST APPARATUS 1K Ohm Resistor 1K Ohm Resistor 1 K Ohm Resistor 1 K Ohm Resistor 12V Current limited Power supply Lamp to Limit Current and Protect Battery
7. to the Gatedrive board 2 28V for the internal fans and Control board 3 24V 500mA user power supply via the Control board SCR switch mode power supply provides various isolated DC supplies required by the Elite these are 1 8V OV for SCR Gatedrive circuitry and DC Bus discharge control 2 15 OV for switch mode regulation circuitry The Gatedrive control for the SCR s and DC Bus discharge circuit are also located here The drive select module plugs into this board Note the locations are different for the 400V and 500V models The Power tray is also used as an interface board for the DCCT s and Gatedrive Board to the Control Board Light emitting diodes LEDS located on the Power tray LED Green One for each half phase 6 Actual indication IGBT Gatedrive circuit active Implication The Elite is running LED RED One for DC Bus indication Actual indication DC BUS is LIVE Implication The Elite has power connected When ordering a replacement Power Tray it will come with the metal support tray and Control Board mounting plate Elite Series Service Manual 4201 230 Rev B57 70 Frame 5 687 Gatedrive Board Gatedrive Circuits responds to a fibre optic signal from the control board via the Power tray and controls the inverter JIGBTs F Desat Circuits monitors the voltage across the IGBTs and turn off the IGBTs in a controlled manner if they become overloaded On this condition the Desat circuitry al
8. 1 TESTING FRAMES 5 TO 7 RECTIFIER AND INVERTER Refer figure 4 7 and using a Fluke 75 or similar check the rectifier as the drawing indicates Note each test is carried out 3 times once per phase which is a total of twelve tests Diode blocking gt 100k 4 4 2 ve DC Bus e SCR reverse blocking Diode A 0 3 0 45y conduction 0 3 0 5V Figure 4 7 FURTHER TESTING DETAILS Diode conduction 4504 030B Rectifier and Inverter Testing Frames 5 to 7 conduction IGBT gt 10k IGBT Forward blocking gt 10k Forward blocking The components and the numbers per half phase are shown below to assist in understanding what you are testing 1 To test the rectifier components individually remove the input fuses and test on the load side of the fuses 2 To test the IGBTs individually requires disassembly of the Elite FRAME 5 POWER ELECTRONICS SUMMARY Figure 4 8 Rectifier and Inverter Power Electronics Summary 4508 293A Elite Series Service Manual 4201 230 Rev B57 78 Frame 5 687 4 4 3 TESTING FOR CORRECT SCR CONDUCTION Using a 24Vdc current limited power supply or battery arrangement as shown in figure 4 9 Connect the supply positive to the respective input fuse choke terminal and the supply negative to the positive DC Bus terminal F
9. 67 ULTRADRIVE ELITE FRAMES 5 6 AND 7 FAULT FINDING AND TESTING This section covers 400V models UE 170 to UE 660 and 500V models UE 170D to UE 700D Frame 5 UE 170 to UE 250 UE 170D to UE 250D Frame 6 UE 305 to UE 480 UE 305D to UE 540D Frame 7 UE 575 to UE 660 UE 620D to UE 700D These will be referred to Frames 5 6 or 7 The voltage range will not be mentioned unless there are specific differences between the 400V and 500V models a a US TRABIRIVI o UETRADRIME ahs A o TN Mas HE ig Lo 4 CE mem um Contents 4 1 BEFORE STARTING TESTING OR SERVICE WORK 68 4 2 PRINTED CIRCUIT BOARD DESCRIPTION 69 4 3 FAULT FINDING GUIDE 71 4 4 TESTING 77 4 5 SOFT POWERING AFTER REPAIR 81 Elite Series Service Manual 4201 230 Rev B57 68 Frame 5 687 4 1 BEFORE STARTING TESTING OR SERVICE WORK 4 1 1 SITE PREPARATION i 1 The work area in front of the Elite be cleaned ii 2 Some flat surfaces are arranged for placement of parts 3 Provide containers for small items like screws and bolts Tool Requirements 1 x No 2 Phillips Screw Drivers 1 x No 3 Phillips Screw Drivers 1 x Flat blade 3 5 mm for terminals 2 x 10 mm Ring spanners 2 x 13mm Ring spanners 1 x 3 8 inch ratchet driver 1 x 3 8 inch small extension 1 x 10mm socket 1 x 13mm socket 1 x Category 3 multimeter with rang
10. circuit REPLACEMENT SCR S Replacement SCRs do not require batch matching 4 3 6 INVERTER DESCRIPTION The inverter consists of insulated gate bipolar transistors IGBTs in parallel to achieve the required current rating Frame size 5 has two IGBTs per half phase Frame 6 has four and Frame 7 has six These are in parallel and share evenly the current supplied to the motor SYMPTOMS OF INVERTER FAILURE 1 Input fuses blowing on power application 2 DC bus fuses blowing on power application 3 DESAT fault 08 to 13 constantly on the same phase and polarity 4 Current limit fault 07 this is a hardware trip to indicate that 220 of rated output current has been reached For all of the above faults test the IGBTs as per section 4 4 1 Check the motor and motor cables If no faults are found attempt to reset the Elite If the fault is repetitive on the same phase and polarity check the IGBTs again If the fault is a DESAT fault and not always on the same phase the problem is most likely in the Gatedrive board There is a small possibility that the Power tray may be at fault and since it is the easiest it is worth replacing it first U HALF PHASE FRAME 5 INVERTOR LAYOUT _ i 4 k be 4 Ta 4 x 4 K z v SEE e e a 8 U HALF 4508 292A PHASE Figure 4 5 IGBT Half Phase Layout Elite Series Service Manual 4201 230 Rev B57 Frame 5 6 8 7 75 Replacing
11. ctronics Sub Assembly Connect the Soft Power supply to the mains preferably via an isolating transformer Do not switch on Remove the Power tray DC supply plug P204 and connect the output plug from the soft power supply to plug P204 P204 is on the lower left hand side of the Power tray Energise the Soft Power supply The Display should come up as per normal and the red BUS LIVE LED should energise on the Power tray Set the Elite to local start stop and speed reference control see Technical manual part number 4201 180 for details The Elite should respond to Display key pad start stop commands and speed reference changes Bring the output to zero speed and stop Power down the Soft Power supply Energising the DC Bus Now connect a 24Vdc Power Supply current limited to the DC Bus and DC Bus terminals observing correct polarity Turn on this power supply and slowly bring up the output voltage to 24Vdc The supply should not draw noticeable current except the bus capacitor charging current when increasing the output voltage Once the DC bus voltage is at 24Vdc energise the Soft Power Supply again Start the Elite from the keyboard and increase the output frequency or speed to100 Now use a multimeter set to AC VOLTS to measure the output voltage between terminals U V V W W U These voltages should all be balanced at approximately 17 5Vac If there is any sign of imbalance measure between each output and earth If any output
12. current before tripping again 2 Excessive mains distortion harmonics can also cause excessive ripple on the DC Bus The cause of excessive supply distortion in an industrial situation may be SCR controlled heating eguipment DC drives current source inverters and other high current non linear loads This can occur where backup generators are used which have not been sized correctly relative to the total variable speed drive load VSD The total loading of VSDs on a backup generator should be about 60 and the remaining 40 made up of linear loads 4 3 2 FUSE FAILURE Frames 5 to 7 Elite have a number of fuses for SAFETY backup Fuse failure is not a normal event and it usually indicates a more serious fault Thus the reason for fuse failure should be investigated A list of fuses with their locations possible reasons for failure and suggested corrective actions follows Input and DC Bus Fuses The input fuses are located in the lower cabinet and the DC bus fuses are located in the electronics cabinet Possible reason for failure Supply surge age or cyclic stress failure wrong fuses fault in supply cable to the Elite rectifier or inverter fault motor or motor cable fault Action 1 See section 4 1 before starting 2 Perform a visual inspection for mechanical damage water entry or any other possible damage to the system 3 For new or modified installations check the wiring is correct as per the Technical Manual 4201 180 4
13. d cause catastrophic as damage Use only the specified ceramic fuse Action Replace fuses If failure persists replace Power tray 10A 440V heatsink fan supply fuses Fitted on SCR boards Possible reason for failure Supply surge 400V models external cooling fan fault or for 500V models a fault in the external cooling fan power supply Action Check cooling fans or cooling fan power supply Check varistor on SCR boards for signs of damage a small dentist s style mirror is suitable for this Elite Series Service Manual 4201 230 Rev B57 Frame 5 6 8 7 4 3 3 DISPLAY Display Unit Fault Finding Is the screen Put the Elite in appearance normal Yes commission mode see note 2 No Are there lines of pixels missing Yes Replace the Display Unit Re connect correctly No Note The Display Unit may be permanently damaged No Are the screen terminations correct see note 1 Yes Is 24VDC present between T10 amp T12 No See Control Board fault finding Yes Is the Display Unit mounted gt 3 metres from the Elite Reduce to 3 metres Replace Display Unit 4508 249A Note 1 Terminal 10 red Terminal 11 white Terminal 12 black screen Note 2 See Elite Series Technical Manual 4201 180 Screens Z to Z1 Figure 4 2 Display Fault Finding 73 CONTROL BOARD 4 3 4 Control board fault finding Check
14. es to 1000V AC and DC maximum 1 x PDL Soft Power Supply 1 x Isolating Transformer 1kVA These frame sizes are the most likely to be serviced in place due to their physical size and weight Many locations where they are mounted will not be ideal for servicing and therefore it is recommended that 1 x 24Vdc volt power supply a current limited supply is preferred but a simple plug pack or batteries can be used if it is not available with a lamp in series to limit the current flow to about 2 amps SAFETY 1 Static safe procedures must be observed A grounding strap must be worn and earthed 2 Isolate and lock out the mains supply to the Elite and any low voltage supply that may be in parallel with the control power supply 3 Allow approximately 5 minutes for the DC bus capacitors to discharge 4 Open the cabinet door and check the red LED DC bus live indicator is not showing This is located on the lower right hand side of the control board This indicates the DC bus is discharged Note this is only an indicator TESTING BEFORE STARTING REPAIRS USING FRAME 5 AS AN EXAMPLE 1 Remove the 2 off M5x12 CW screws and remove the bottom front panel 2 Test between input terminals L1 L2 L3 and L1 L2 L3 to earth to ensure the supply has been disconnected 3 Finally test between the VE and VE DC bus terminals to ensure the DC bus has fully discharged Figure 4 1 Frame 5 Cabinet View Elite Series Service Manual S
15. f full voltage Elite Series Service Manual 4201 230 Rev B57 76 Symptoms of DC Bus Capacitor Failure Open Circuited Capacitor H 4 current jex Short Circuited DC Bus Capacitor Frame 5 687 If a single DC Bus capacitor goes open circuit the symptoms may not be noticeable However the remaining capacitors will have an increased ripple current and will run hotter If more capacitors consequently go open circuit the DC bus ripple will increase and may cause a SUPPLY FLT trip especially when the Elite is running at or near full output A shorted capacitor should cause two input fuses to fail during or soon after the soft charge interval Because they are connected in series to share the DC bus voltage if one capacitor has shorted it will have exposed all the capacitors opposite it to above rated voltage This is shown in figure 4 6 In the right hand drawing the top set of capacitors have been exposed to full DC bus voltage which will be approximately twice their rating In this event it is recommended to replace all the DC Bus capacitors or at a minimum all the opposing capacitors as well as the faulty one Normal Conditions One Capacitor Failed Short Y_4 44 T Figure 4 6 Elite Series Service Manual vi2 vi2 4508 323A DC Bus Capacitor Short Circuit 4201 230 Rev B57 Frame 5 6 8 7 77 4 4 TESTING 4 4
16. on application of load See section l 4 4 1 for supply problems ia Some Causes of Rectifier Failure Bus Capacitor Failure Excess current drawn by a shorted capacitors may damage the rectifier See section 4 3 3 Internal fault in Elite Failure to a short circuit will cause two input phase fuses to blow See section 4 3 Fault in supply cable motor cable or motor Input supply imbalance If Line 1 L1 is low with respect to yellow and blue the Elite will soft charge the capacitors to 1 414 x the L1 RMS voltage level When the soft charge is finished the SCRs on L2 and L3 will be turned on fully applying a higher DC level to the DC bus than is currently there This can generate sufficient inrush current to damage the input rectifier Supply voltage exceeding the Elite s rating The Elite has VDR s to protect against voltage transients these will not cope with a supply that is constantly above the maximum level the Elite was designed for The VDR s will fail and the Elite may be damaged also Soft Charge Failure Failure of the Soft Charge function Some or all of the SCR s may not respond to a gate signal or the Power tray may not be producing an SCR gatedrive signal Look for a dislodged cable and test the SCR s as per section 4 4 2 Diode or SCR Failure If part of the rectifier stage has failed open circuit the Elite may not soft charge and no voltage will appear on the DC bus Note it is uncommon for semiconductors to fail open
17. rther details To achieve the reguired voltage rating two capacitors are connected in series The capacitors are rated at 400V and 450V for the 400V and 500V models respectively Possible Causes of Failure The definition of capacitor failure is for the capacitance of the capacitor to drop or exceed the manufacturers tolerance or to suffer a catastrophic failure which is an open or short circuit While this section is guite detailed the capacitors seldom cause any problems 400V capacitors rating 2200 MFD 20 at 20 C and 120Hz 500V capacitors rating 1800 MFD 20 at 20 C and 120Hz Factors Affecting The Life of The DC Bus Capacitors Stress related issues these are vibration excessive ripple above rated voltage and or temperature Over heating is the most likely cause of premature failure and can be brought about by reduction in cooling air flow to the drive Check the heatsink for blockage and fans excessive ambient temperature or excess ripple due to some of the capacitors going open circuit Shelf life the recommended storage period without use should not exceed 3 years If there is concern regarding the time an Elite has been stored a DC supply can be connected to the DC Bus terminals and starting at about 50Vdc and over 8 hours the voltage is gradually increased to about 560 to 600Vdc for 400V models and 660 to 700Vdc for 500V models Failure to do this can cause failure of the DC Bus capacitors on initial application o
18. so sends a trip signal to the Control board via the fibre optic link to the Power tray This signal will trip the Elite and the display will indicate which half phase was overloaded H i p s l Snubber Circuits 2 off protects the IGBTs from damage due to voltage spikes caused by inductance in the Elite the l motor circuit and the IGBTS rapid switching Power tray LED indicators are located by the fibre optic connections LED red One for each half phase Actual indication Transmit fibre OK Implication The Desat fibre optic driver has power this is not an indication of a fault it is a normal condition LED Green One for each half phase Actual indication IGBT Gatedrive circuit active Implication The Elite is running Power Supply Board Provides power to the power tray and has two LED s to indicate DC bus voltage is present Bus Sharing Boards This boards ensures that the DC bus voltage is divided evenly across the DC Bus capacitors SCR Boards These boards have voltage transient RFI protection for the Elite and snubbering for the SCR s They also have a connection to the SCR gate for the Gatedrive signal from the Power tray and a 10 Amp fuse for the external fans or fan power supply on the 500V models 500V External Fan Power Supply A 400Vac to 500Vac to 24Vdc linear power supply for the 500V model external fans Note there are connection points for voltage ranges from 400V to and incl
19. stor j Briefly to i IYYY 3 Trigger L I 4 O LI 7 oe a z as Nad 12 to 24 Volt A A m a d Battery e To L2 and L3 VE DC Bus SCR 4508 262 Figure 4 9 SCR Conduction Test 4 4 4 INDIVIDUAL SCR TESTING When the Elite is disassembled the SCR s can be tested individually as shown in figure 4 10 DIODE TESTS SCR TESTS SCR TESTS 6 gt gt 100K boj gt 100K conduction 0 3 0 45V ALTERNATIVE TEST APPARATUS O O O Lamp to Limit Current and Protect Battery 24V Current limited Power te SER supply O 18 to 100 Ohm Resistor ON aioe anti ww hey Touch Gate Briefly To 18to 100 i Trigger SCR H Ohm Resistor 12 to 24 Volt Ne rer SS pro Battery O O 4508 297A No do eet Figure 4 10 Individual SCR Conduction Test Elite Series Service Manual 4201 230 Rev B57 Frame 5 6 8 7 79 4 4 5 TESTING INDIVIDUAL IGBT You must wear a static grounding wrist strap and it must be earthed The IGBTs should be tested individually this can be done with or with out the Gatedrive board in place The preliminary tests are done with a multi
20. the IGBT The IGBTs are manufactured in batches and each batch has a unique batch number The IGBTs from a specific batch are made from the same silicon therefore their operating characteristics will be the same Therefore we require that IGBTs in each half phase be from the same batch When an Elite is repaired under warranty the complete half phase Tr must be replaced with the same batch or the warranty will be void Note the batch in a half phase does not have to match the batch in another half phase For example in a Frame 7 it may have transpired that 2 IGBTs are damaged and the other 4 in the half phase test OK with a multimeter In this po situation PDL or its agent would replace all six IGBTs Apart from the batch issue we have found that while the iz remaining IGBTs in the half phase may test OK they will have been stressed The effect on their life span due to the stress cannot be gauged For these reasons a repair without full half phase IGBT replacement can not be guaranteed BATCH NUMBER 4508 235A Figure 4 5 Batch Number 4 3 7 DC BUS FILTER The DC Bus filter is comprised of electrolytic capacitors and chokes The chokes are mounted in series with L1 L2 and L3 and are called line chokes The filter s function is to reduce the harmonic current drawn by the Elite and the ripple on the DC Bus Excess ripple gt 40Vac will be detected and displayed as a supply fault see section 4 3 1 for fu
21. trol board or Power tray s switch mode power supply may be faulty see section 3 3 4 to determine which is faulty 2 Test the DCCTs by measuring between ground and terminals 3 5 and 6 this should be OV if the three readings are not at 0 volts replace the faulty DCCT s DCCT PLUG GROUND GREY DCCT Output ovf YELLOW TT PURPLE ee BROWN 14Vde 6 Pin Connector 6 Pin HE Connector Control Board V DCCT Output U DCCT Output 14 Volts W DCCT Oputputs Ground 2 14 Volt 4508 259A Figure 4 13 DCCT and Supply Testing 4 4 7 DC BUS CAPACITOR TESTS First test the rectifier and inverter by following the procedure in section 4 4 1 Test the capacitors by using a meter set to OHMS between HVDC terminals and The resistance should start low then increase as the capacitors charge to the meter battery voltage ensure the DC bus capacitors are fully discharged first This charging period could take some time and it is best carried out by testing the suspect machine against a known good Elite of the same amperage rating or check the spare parts list and pick an Elite of the same frame size with the same number of DC Bus capacitors Time the rate of charge i e the increase in ohms on the meter and comparing this against the suspect Elite If this test indicates reasonable variation there may be a problem with the capacitors Further testing reguires disassembly of the Elite To test for individual open or short circ
22. uding 500V Elite Series Service Manual 4201 230 Rev B57 Frame 5 6 8 7 71 4 3 FAULT FINDING GUIDE 4 3 1 SUPPLY ISSUES Power supply problems can be misinterpreted as faults in the Elite some are listed below T Fault 01 LOW Vdc The supply to the Elite is dropping below the switch mode power supply operating level and it is shutting down This is usually caused by a weak supply or faults in the supply system Look for motors starting direct on line or other F machines drawing high current For further details see the fault list in section 8 of this manual Fault 02 HIGH Vdc The supply to the Elite is surging too high Rapid load changes in the supply system may be at fault For further details see the fault list in section 8 of this manual Fault 04 SUPPLY FLT Supply fault Fault 04 is an indication that the ripple on the DC Bus has exceeded 40Vac The Elite will trip if this condition is reached and display fault 04 SUPPLY FLT This can be caused by diode s in the rectifier going open circuit see section 1 4 But is more likely to be caused by 1 The loss of an input phase will increase the ripple on the DC Bus The Elite can run on two phases up to about half to two thirds of its current rating At which point the DC Bus filter will not be capable of maintaining the ripple below 40Vac and the Elite will trip The Display will stay live and the Elite can be reset and will run to about the same
23. uited capacitors Elite must also be dismantled and each capacitor individually checked with a multimeter Ensure all capacitors are fully discharged then connect the meter on OHMS range across each capacitor in turn with the meter positive to the capacitor positive On a good capacitor the resistance should start low then increase as the capacitor charges to the meter battery voltage Visual Inspection These capacitors are a sealed canister with a vent beside the terminal posts If the capacitor has overheated or suffered an internal fault and pressure build up internally the bung in the vent hole should be displaced Elite Series Service Manual 4201 230 Rev B57 Frame 5 6 8 7 81 4 5 SOFT POWERING AFTER REPAIR Once all faulty components and assemblies have been replaced and the Elite has been carefully reassembled it is recommended that the machine be tested as per section 4 4 1 then Soft Power mod 4 5 1 SOFT POWERING le This procedure uses a special Soft Power supply available from PDL Electronics or the circuit diagram to build one is in section 8 of this manual This power supply generates a 600Vdc power source which can be used to power up the power electronics PCB without powering up the DC bus Then the DC bus is energised with a separate DC power supply around 24Vdc with current limiting The procedure enables any remaining inverter fault to be found without causing further damage Energising of Power Ele
24. voltage is significantly different suspect that there is still an unrepaired fault on that particular phase or a loose termination If the test shows no faults and a good output voltage balance the test power supplies can be disconnected mains and motor reconnected and a full test done UE FRAME 5 6 and 7 SOFT POWERING Bridge rectifier DC bus Inverter switches 4508 260A S lt c Isolated Power Supply 230Vac Output 24Vde current limited 230Vac recommended Isolation Transformer 1kVA 14 Figure 4 14 Soft Power Supply Connections Elite Series Service Manual 4201 230 Rev B57 82 H 4 Elite Series Service Manual NOTES Frame 5 687 4201 230 Rev B57
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