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Power Distribution Unit

1. 2 GND SMC Chassis ground 3 return on any COM v1 Proportional frequency 5V squarewave 10 mV to DC voltage load side Hz OV 100Hz 0Hz of F4 100Hz 48V 4 9KHz 100 Hz 100V 10 1 KHz 100Hz 4 COM SMC common 5 return on any COM 114 Proportional frequency 5V squarewave 15 mA to DC current through Hz 0A 100Hz 0Hz F4 200Hz 130A 8 77 KHz 200Hz 150 A 10 1 KHz 200Hz 6 COM SMC common 7 return on any COM 12 Proportional frequency 5V squarewave 15 mA to DC current through F5 Hz 0A 100Hz 0Hz 200Hz 130A 8 77 KHz 200Hz 150 A 10 1 KHz 200Hz Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 5 of 54 gt Specification Pin Number Signal Description g p input output 8 return on any COM Vac Proportional frequency 5V squarewave 25 mV to AC output voltage Hz OV 100Hz 0Hz phase A to C 100Hz 208V 8 42 KHz 100Hz 250V 10 1 KHz 100Hz 9 COM SMC common 10 return on any COM MAINT Pattern
2. Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 28 of 54 ested Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Poor Check continuity OFF D 2 D 3 D 4 Phase Reseat or repair connection D 5 D 6 Controller cables as necessary from Phase Assembly J31 Controller to Gate Drive Assembly to Assembly J5 Gate Drive RC5 Phase Assembly Controller Assembly J32 to Gate Drive Assembly J9 RC7 Loose or Visually inspect connector ON D 3 D 4 D 5 Check J4 on Repair connection poor D 6 Phase connection to Controller AC input for Assembly for Phase solid Controller connections Assembly Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide
3. voltage Test Point Signal Description Scale Expected Range Input AC Voltage Proportional AC voltage to input 100 1 0 to 5 3 Vrms AC voltage Output AC Voltage Proportional AC voltage to output 100 1 0 to 2 3 Vrms AC voltage Output DC Voltage Proportional DC voltage to output 10 1 0 to 10 0 VDC DC voltage Control AC Voltage Wired directly to AC control 1 1 0 to 28 Vrms voltage Control DC Voltage Wired directly to DC control 1 1 0 to 28 VDC Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 30f54 Maintenance Signals An amber maintenance light on the PDU indicates that the PDU controller watchdog timer has timed out and flashes various two digit trouble codes for troubleshooting purposes when overtemperature or fan failure events have occurred Fan failure various fans are distributed throughout the system overtemperature of various locations and processor malfunction on the controller module are the three implemented maintenance signals The timing duration of each pulse defined as a flash of the LED or presence of the MAINT outp
4. Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 17 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Control Check voltages at input ON D 3 D 5 T2inputvoltage Replace control transformer and output of control should be transformer T2 PN failure transformer 10 to 15 541 242 00 of expected input voltage between wire s 94 amp 95 Output should be 20 28 VAC between wire s 96 amp 97 DC output AC Input Measure AC input voltage ON D 2 V 1 Input voltage at Correct source or voltage too voltage out of test points select other PDU tap high or too range should be low or 10 to 15 erratic of expected voltage divided by 100 Feedback Check continuity OFF D 3 D 4 D 5 Phase Correct wire voltage D 6 Controller connection problem connection Assembly J1 to J1 of Phase problem wire s 177 Controller Assembly between 178 180 181 to Phase DC output Controller Assembly and DC output Rev 0406 FLE Cables Cali
5. Power Distribution Unit PDU Troubleshooting Page 1 of 54 f im i PDU Troubleshooting The PDU Troubleshooting topic contains the following items e Test Points e Maintenance Signals e Connector Pinouts Cables e Troubleshooting Table Calibration e PDU Interlock Switch Troubleshooting samputar e PDU Electrical Schematic Cooling DIB Interface Note Field Replaceable Units For additional information about the PDU refer to the Troubleshooting Guide Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 2 of 54 Test Points Test points for various voltages are available on the exterior of the PDU The test points are current limited and scaled to a low level voltage All test points are accurate to 2 percent of actual See the Test Point Signals table Test Point Signals
6. D HOME HELP Power Distribution Unit PDU Troubleshooting Page 14 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Externally Measure 15Khz control ON D 2 D 6 Must be 15Khz Repair signal source supplied signal at J9 Pins 24 25 of square wave External to PDU 15Khz signal Phase Controller 2 50 duty not within Assembly cycle 2 specifications TTL level J66 Contactorcoil 24VDC control voltage ON D 3 D 5 Check for Replace contactor defective present at coil but 24VDC at input CON1 PN 361 076 contactor not pulled in to CON1 wire 00 s 72 amp 73 Control Visual Inspection of CB s ON D 2 D 5 CB2 CB3 Reset circuit breaker power not CB2 CB3 present due to tripped control circuit breakers Control Perform visual operational ON D 2 D 5 Check for Reset or replace Circuit inspection and or voltage normal circuit breaker CB2 breaker check at input output of operation of PN 522 995 02 or failure control circuit breakers circuit breakers CB3 PN 523 354 04 by measuring input and output from breaker CB2 and CB3 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Tr
7. D HOME HELP Power Distribution Unit PDU Troubleshooting Page 29 of 54 Input P Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Phase Check for proper gate ON D 3 D 4 D 5 Sync channel 1 Replace Phase Controller control signals Using D 6 of scope toa Controller Assembly Assembly oscilloscope that has iso See Theory of power refer PN 361 157 00 malfunction lated inputs to channels Operation ence sine wave Ensure Tester SMC connector is connected figure 4 and 5 for a depiction of a normal gate voltage square waves such as the out put of the con trol transformer T2 Observe on channel 2 Phase Controller Assembly J31 pins 1 3 5 7 9 11 for gates 1 6 respectively amp J32 pins 1 3 5 7 9 11 for gates 7 12 respectively pin 2 is common in any case you should see a low level square wave 3 5Vpk that is locked in phase to the power line Gates 1 6 See Figure 4 Gates 7 12 See Figure 5 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distri
8. No signal at output to light ON D 2 D 3 D 5 Test Point PC Replace Test Point Board Board PC Board Assembly Assembly Assembly J102 PN 361 158 00 malfunction output to LED should measure at least 17VDC Feedback Check continuity OFF D 3 D 4 D 5 Phase Correct wire voltage D 6 Controller connection problem connection Assembly J1 to J1 of Phase problem wire s 177 Controller Assembly between 178 180 181 to Phase DC output Controller Assembly and DC output Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 49 of 54 Mpa Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Main Bad indicator Replace light recheck OFF D 2 D 5 LED2 Replace light LED2 Power On light PN 702 393 00 LED not properly illuminated Bad Check continuity check OFF D 2 D 3 D 5 Test Point PC Repair connection connection that light is plugged in Board from Test Assembly J102 Point PC to LED2 Board Assembly to light Bad Check con
9. SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 24 of 54 i Kap Reference Reference Possible TAER Power i Symptom Determination Schematic Designator Solution cauas Bunny Drawin Value Check g Poor Check continuity OFF D 3 D 4 D 5 Phase Reseat or repair connection D 6 Controller cables as necessary from Phase Assembly J31 Controller to Gate Drive Assembly to Assembly J5 Gate Drive RC5 Phase Assembly Controller Assembly J32 to Gate Drive Assembly J9 RC7 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 25 of 54 Input P Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Phase Check for proper gate ON D 3 D 4 D 5 Sync channel 1 Replace Phase Controller control signals Using D 6 of scope toa Controller Assembly Assembly oscilloscope that has
10. Symptom Determination Schematic Designator Solution Lause During Drawin Value Check g F1 F2 F3 or Check fuses and inspect OFF D 3 D 5 Perform Replace fuse F1 F6 fuses are for possible causes of continuitycheck F2 F3 or F6 any blown or bad blown fuses Check on fuses one or all PN 471 connection to power to J4 of Phase There should 596 01 Repair Phase Controller Assembly and be 120VAC loose or broken Controller to Gate Drive Assembly 10 15 at connections to Assembly J3 Phase Phase Controller connector J4 Controller Assembly or Gate or Gate Drive Assembly J4 Drive Assembly Assembly J3 between pins 1 4 2 4 3 4 and at Gate Drive Assembly J3 Bad Check cable connection OFF D 2 D 3 D 4 Check Phase Repair or replace connection from SMC PDU connector D 5 D 6 Controller RC3 PN 4990372 from Phase to Phase Controller Assembly J9 Controller Assembly ribbon cable for Assembly J9 proper to SMC connection connector RC3 J66 DC Fuse s Continuity check OFF D 3 D 5 Perform Check load for blown Voltages VO V1 and V2 to continuitycheck possible cause of SMC will not be equal VO on fuses F4 overload and is main DC bus and V1 and or F5 replace fuse F4 and and V2 are protected by or F5 PN 471 688 branch fuses within PDU 00 Poor Check continuity OFF D 3 D 4 D 5 Gate Drive Reseat or repair connection D 6 Assembly J2 cables as necessary from Gate J11 J12 see Drive schematic for Assembly to wire s SCR modules
11. amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 34 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Failed Reset signals measured ON D 2 D 3 D 4 Use Replace indicator magnetic at Test Point PC Board D 5 oscilloscope to IND1 IND2 or indicator Assembly but magnetic check reset IND3 any or all indicator does not reset signal at Test magnetic PN 501 Point PC Board 325 02 Assembly J11 pins 5 to pin 12 should be 24VDC pulse of at least 100ms F1 F2 F3 Check fuses and inspect OFF D 3 D 5 Perform Replace blown fuse fuses are for possible causes of continuitycheck F1 F2 or F3 any blown or bad blown fuses Check on fuses one or all PN 471 connection to power to J4 of Phase There should 596 01 Repair Phase Controller Assembly be 120VAC loose or broken Controller 10 15 at connections Phase Assembly Phase Controller Assembly connector J4 Controller Assembly J4 Loose or Visual continuity check OFF D 2 D 3 D 5 J104 J106 on Repair or reseat in poor Test Point PC connection connection Board between Test Assembly Point PC Board Assembly and magnetic indicator Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive M
12. Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 10 of 54 Note The seven digit part numbers with no hyphens are Teal part numbers Input Reference Reference Possible ae Power l Symptom Determination Schematic Designator Solution sause Puring Drawin Value Check g AC output AC input Measure input voltage ON Tap change Check input Re tap distribution voltage too voltage board and or voltage at test transformer or re high or low provided to sheet V 1 points should configure tap PDU is too be 10 to change board to high or too 15 of match source low expected voltage voltage divided by 100 Main Measure input voltage ON Tap change Check input Re configure tap transformer and compare to the tap board and or voltage at test change board to incorrectly configuration sheet V 1 points should match source tapped be 10 to voltage See tap 15 of change diagram on expected tap cover board voltage divided by 100 Loose Inspect connections for OFF D 3 D 5 V 1 CB1 Input lug Tighten connection connection at proper torque torque 50 in at effected locations
13. Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 33 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Phase Check for proper bleeder ON D 3 D 4 D 5 Attach scope Replace Phase Controller power switching signal D 6 common to pin Controller Assembly Assembly with oscilloscope Ensure 12 or J10 and PN 361 157 00 malfunction Tester SMC connector is scope tip to pin connected 5 of J10 Expect approxi mately 48V when DC out put is on Test 1 Starting with DC power on and no load trip input CB pin 5 should go low 2V or less for 10 seconds Test 2 Starting with DC power on and no load turn off 15Khz DC control signal pin 5 should go low 2V or less for 10 seconds Magnetic Connection Check continuity OFF D 3 D 4 D 5 Phase Replace RC4 PN indicators between D 6 Controller 4990373 do not reset Phase Assembly J11 upon Controller to Test Point PC power up Assembly Board and Test Assembly J11 Point PC RC4 Board Assembly bad Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install
14. Current Visual inspection or OFF D 3 D 5 D 6 Check 11 12 Repair or replace Support Cabinet signal transducer continuity check current connections as Test Head frequency wiring transducers for necessary does not problem proper Troubleshooting correspond connection to Training to Phase measured Controller Product Integration Manuals DC current Assembly JA2 Site Prep Guide JB2 pin1 on Install amp Checkout Guide FnaSg Controller Assembly J2 corresponds to pin 1 on transducer connector Rev 0406 HOME HELP FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 40 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Bad Check cable connection OFF D 2 D 3 D 4 Check Phase Repair or replace connection from SMC PDU connector D 5 D 6 Controller RC3 PN 4990372 from Phase to Phase Controller Assembly J9 Controller Assembly ribbon cable for Assembly J9 proper to SMC connection connector RC3 J66 Current DC voltage from current ON D 3 D 4 D 5 Measure DC Replace curr
15. Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 19 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution Lause During Drawin Value Check g F1 F2 F3 or Check fuses and inspect OFF D 2 D 5 Perform Replace fuse F1 F6 fuses are for possible causes of continuitycheck F2 F3 or F6 any blown or bad blown fuses Check on fuses one or all PN 471 connection to power to J4 of Phase There should 596 01 Repair Phase Controller Assembly and be 120VAC loose or broken Controller to Gate Drive Assembly 10 15 at connections to Assembly J3 Phase Phase Controller connector J4 Controller Assembly or Gate or Gate Drive Assembly J4 Drive Assembly Assembly J3 between pins 1 4 2 4 3 4 and at Gate Drive Assembly J3 Failed power Measure input current to ON D 4 D 5 D 6 Current wave Replace Heat Sink SCR each SCR using current Figure 1 shape should Assembly PN 361 probe oscilloscope Theory of be similar to 156 00 Access to wires can be operation Figure 1 had at glastic terminal Amplitude will board vary with applied load Loose or Visually inspect OFF D 3 D 4 D 5 Check for Tighten or repair poor connections D 6 tightness from connections as connection Bar3 to L1 to necessary from SCR to Bard to F4 F5 Inductor to to CONN3 Capacitor CONN4 and bank to Bar2 to Ba
16. Replace light LED3 On LED light PN 702 393 00 not properly illuminated Bad Check continuity check OFF D 2 D 3 D 5 Test Point PC Repair connection connection that light is plugged in Board from Test Assembly J102 Point PC to LED3 Board Assembly to light Bad Check continuity OFF D 2 D 3 D 5 Phase Repair or replace connection Controller RC4 PN 4990373 from Test Assembly J11 Point PC to Test Point PC Board Board Assembly to Assembly J11 Phase RC4 Controller Assembly Test Point PC No signal at output to light ON D 2 D 3 D 5 Test Point PC Replace Test Point Board Board PC Board Assembly Assembly Assembly J102 PN 361 158 00 malfunction output to LED should measure at least 17VDC Rev 0406 Power Distribution Unit PDU Troubleshooting Page 51 of 54 FLE Mpa Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Bad AUX2 Check continuity of AUX OFF D 3 D 5 AUX2 contacts Replace contactor switch on switch on CON1 actuate switch should PN 361 076 00 Cables CON1 CON1 by hand be closed with Calibration CON1 actuated and open with Computer CON released Cooling Bad Visually inspect OFF D 3 D 4 D 5 Phase Repair connection DIB Interface connection connections D 6 Controller Field Replaceable Units from Phase Assembly J3 Controller pin 6 Instruments Assembly to Maintenance Sof
17. Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page90f54 Troubleshooting Table Use the troubleshooting table and refer to the PDU Electrical Schematic Also refer to the drawings and schematics in the Teal PDU Manual Test equipment properly calibrated required e DMM with RMS features Fluke 87 or equivalent e Clamp on general purpose ammeter able to measure up to 350A e Temperature measuring device able to measure up to 150 degrees C e Digital storage oscilloscope with isolated channel inputs Tektronix THS720A or equivalent e Current probe suitable for connection to oscilloscope 10A range or higher 10 MHz BW for measuring gate signals e Current probe suitable for connection to oscilloscope 200A range or higher capable of measuring 47 63 Hz currents that are DC biased for measuring current into SCRs For all AC voltages input to unit is specified to 10 15 of nominal rating All other AC voltages within the PDU will vary proportionally with the input voltage that is present Unless otherwise indicated below you should see AC voltages 2 of the expected value after correcting for any non nominal input voltage Note The seven digit part numbers with no hyphens are Teal part numbers Rev 0406 FLE Cables
18. Unit PDU Troubleshooting Page 23 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution Lause During Drawin Value Check g F1 F2 F3 or Check fuses and inspect OFF D 3 D 5 Perform Replace fuse F1 F6 fuses are for possible causes of continuitycheck F2 F3 or F6 any blown or bad blown fuses Check on fuses one or all PN 471 connection to power to J4 of Phase There should 596 01 Repair Phase Controller Assembly and be 120VAC loose or broken Controller to Gate Drive Assembly 10 15 at connections to Assembly J3 Phase Phase Controller connector J4 Controller Assembly or Gate or Gate Drive Assembly J4 Drive Assembly Assembly J3 between pins 1 4 2 4 3 4 and at Gate Drive Assembly J3 Failed Power Measure input current to ON D 3 D 6 Current Replace Heat Sink SCR each SCR using current waveshape Assembly PN 361 probe Access to wires should be 156 00 can be had at glastic similar to Figure terminal board 1 Amplitude will vary with applied load Poor Check continuity OFF D 3 D 4 D 6 Gate Drive Reseat or repair connection Assembly J2 cables as necessary from Gate J11 J12 see Drive schematic for Assembly to wire s SCR modules Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety
19. each sensor Output should be 500mvV 10mV per C 5 Temperature signals for three sensors are pins 2 6 10 of Phase Controller Assembly J5 with respect to pin 4 of J5 Sensors derive power from Phase Controller Assembly and must be plugged in during the measurement Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 46 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Maintenan Phase Check maintenance ON D 2 D 3 D 4 Apply power to Replace Phase ce amp LED Controller signal after controller D 5 D 6 the PDU Controller Assembly signal Assembly reset Observe PN 361 157 00 present malfunction maintenance Watch Dog indicator If Timer maintenance indicator transitions from off to on after 1 3 seconds of power application or controller reset this indicates a watchdog timer time out condition Power Bad indicator Replace light recheck OFF D 2 D 5 LED1 Replace light LED1 Available light PN 702 393 00 LED not p
20. gate cathode wire and measure gate pulse current ON D 3 D 4 D 5 D 6 See Theory of Operation figure 2 and 3 for a depiction of a normal gate pulses Sync channel 1 of scope toa power refer ence sine wave such as the out put of the con trol transformer T2 Check Gate Drive Assembly J2 wire s 298 300 302 304 306 308 J11 wire s 310 312 314 amp J12 wire s 316 318 320 for current pulses Current pulses should be like those in Figure 2 and 3 and locked in phase to the power line reference Replace Gate Drive Assembly PN 361 155 00 It could also be a bad connection to a gate pin or an open gate within the Bad D7 diode Continuity check OFF D 3 D 5 Disconnect one lead of D7 and check for open short using an ohmmeter Replace diode D7 PN 4990367 DC output ripple excessive Failed ripple capacitor Visual inspection for venting OFF D 3 D 5 Check C1 C6 for fluid leaking Replace capacitor C1 C6 any or all PN 131 428 00 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution
21. input breaker or tap change board Ibs output lug torque 120 in lbs Tap change board lug torque 50 in Ibs to specified torque Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 11 of 54 Mpa Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution cae During Drawin Value Check g No voltage No input Measure input voltage at ON D 2 Check input Check and repair present on voltage test points voltage at test AC service Un present points should switched be 10 to AC output 15 of expected voltage divided by 100 Input CB1 Visual inspection ON D 2 D 5 CB1 Turn on input CB1 tripped or off Branch Visual inspection ON D 2 D 5 CB4 CB9 Check for overload breaker problem reset tripped or off tripped branch breaker Loose Visual inspection and or OFF D 2 D 5 Wire s 6 8 Tighten connections connection continuity check on CB4 CB9 between main trans between effected circuit former secondary 1 transformer and CB secondary 1 Check bus bar and output connections at C
22. of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Maintenan DC current Check load currents and N A N A N A Repair problem with ce LED amp overload determine if load currents load equipment signal are below 260A DC total present Overtemper ature Ambient Check that vents are not ON D 2 D 3 D 6 Check for Repair problem If temperature blocked that fans are rotation of any fan is not rotat too high working and that external FAN1 FAN10 ing replace fan ambient is less than 30 C FAN1 FAN8 PN 361 175 00 FAN9 FAN10 PN 361 176 00 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 45 of 54 Input P Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Failed Check for proper output ON D 2 D 3 D 4 At room tem Temperature voltage of sensors D 5 D 6 perature mea Temperature Sensor Sensor sure output Assembly PN voltage of
23. 155 00 It could also source put a current 060_SCB See ence sine wave be a bad connection probe onto each gate Theory of such as the out to a gate pin or an cathode wire and Operation put of the con open gate within the measure gate pulse figure 2 and 3 trol transformer SCR current for a depiction T2 of a normal Check Gate gate pulses Drive Assembly J2 wire s 298 300 302 304 306 308 J11 wire s 310 312 314 amp J12 wire s 316 318 320 for current pulses Current pulses should be like those in Figure 2 and 3 and locked in phase to the power line reference DC output Signalsource 15Khz DC ON signal not ON D 2 D 3 D 4 Check 15Khz Repair source of sig voltage not not within shown on controller LED D 5 D 6 source from nal External to present specification SMC at 25 Pin PDU or missing D sub connec tor J9 Must be 15Khz square wave 2 50 duty cycle 2 TTL level Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 27 of 54 Input Reference Reference Possible TT Power
24. 9KHz 100 Hz 100V 10 1 KHz 100Hz 19 return on any COM Vab Proportional frequency 5V squarewave 25 mV to AC output voltage Hz OV 100Hz 0Hz phase A to B 100Hz 208V 8 42 KHz 100Hz 250V 10 1 KHz 100Hz 20 COM SMC common 21 return on any COM Vbc Proportional frequency 5V squarewave 25 mV to AC output voltage Hz OV 100Hz 0Hz phase B to C 100Hz 208V 8 42 KHz 100Hz 250V 10 1 KHz 100Hz 22 return on any COM FREQ Squarewave signal 5V squarewave indicating AC line frequency 50 Hz 3Hz 50Hz 1 60 Hz 3Hz 60Hz 1 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 7 of 54 Specification Power AC outputs turn on signal Pin Number Signal Description g p input output 23 5VRTN Return for signal voltage power supply 24 GND SMC Chassis ground 25 ON_RTN_K1 Return for the Test Refer to schematic drawing D 5 and D 6 and layout drawing number D 2 D 3 and D 4 for location of these components Rev 0406 FLE Cables Ca
25. B4 CB9 inputs to breakers Loose Visual inspection and or OFF D 2 D 5 CB4 CB9 J54 Tighten connections connection continuity check on J62 see on effected between effected circuit distribution receptacle or CB output CB schematic for and wire s receptacles Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 12 of 54 Symptom Possible Cause Determination Input Power During Check Reference Schematic Drawing Reference Designator Value Solution 24V power supply failure Check power supply input output voltage at test points ON D 2 D 3 D 5 Input voltage between test points 24VAC and N should be 20 28 VAC Output voltage between 24VDC test point and N test point should be 22 28 VDC Replace power supply REG1 PN 361 154 00 Failed output circuit breaker Perform visual operational inspection and or voltage check at output circuit breakers ON D 2 D 5 CB4 CB9 input voltage should be 120VAC from any terminal to case ground Output voltage should match input whe
26. Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 36 of 54 Input P Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution Lae During Drawin Value Check g Control Check control voltages at ON D 3 D 5 Check voltage Re tap control transformer test points Check that at 24VAC test transformer T2 to improperly control transformer tap points should match input voltage tapped selected matches input be 20 28 VAC resulting in a voltage low control circuit voltage Internal Check that all covers are OFF D 3 D 5 LS1 LS3 Tighten down loose interlock in place and that all normally closed cover Or replace open bad interlock switches are switches interlock switch LS1 interlock closed LS2 or LS3 any or switch all PN 801 646 01 External Check continuity of OFF N A N A Correct external interlock external EMO loops EMO loop problem open Thermal Check continuity across OFF D 5 Check TH1 for Replace thermal cutout switch failure thermal switch This switch is normally closed normal operation at wire s 80 amp 81 Should be closed below 160 C cutout TH1 PN 4990378 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Main
27. F D 3 D 5 Perform Replace fuse F1 fuses are for possible causes continuitycheck F2 or F3 any one blown on fuses or all PN 471 596 01 Feedback Loose or Visually inspect connector ON D 3 D 4 D 5 Check J4 on Repair connection signal poor D 6 Phase frequency connection to Controller does not AC input for Assembly for correspond Phase solid to Controller connections measured Assembly AC phase rms voltage F1 F2 or F3 Check fuses and inspect OFF D 3 D 5 Perform Replace fuse F1 fuses are for possible causes continuitycheck F2 or F3 any one blown on fuses or all PN 471 596 01 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 42 of 54 Mpa Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Phase Check for proper signal ON D 3 D 4 D 5 Feedback sig Replace Phase Controller with Oscilloscope D 6 nals are 50 Controller Assembly Assembly Ensure Tester SMC duty cycle PN 361 157 00 malfunction connector is connected square wave Teste
28. Replace Phase Controller control signals Using D 6 of scope toa Controller Assembly Assembly oscilloscope that has iso See Theory of power refer PN 361 157 00 malfunction lated inputs to channels Operation ence sine wave Ensure Tester SMC connector is connected Figure 4 and 5 such as the out put of the con trol transformer T2 Observe on channel 2 Phase Controller Assembly J31 pins 1 3 5 7 9 11 for gates 1 6 respectively amp J32 pins 1 3 5 7 9 11 for gates 7 12 respectively pin 2 is common in any case you should see a low level square wave 3 5Vpk that is locked in phase to the power line reference Gates 1 6 See Figure 4 Gates 7 12 See Figure 5 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 22 of 54 Symptom Possible Cause Determination Input Power During Check Reference Schematic Drawing Reference Designator Value Solution Gate Drive Assembly malfunction Once Phase Controller Assembly has been eliminated as a problem source put a current probe onto each
29. Tighten down loose interlock in place and that all normally closed cover Or replace open bad interlock switches are switches interlock switch LS1 interlock closed LS2 or LS3 any or switch all PN 801 646 01 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 38 of 54 Input Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g External Check continuity of OFF N A N A Correct external interlock external EMO loops EMO loop problem open Thermal Check continuity across OFF D 5 Check TH1 for Replace thermal cutout switch thermal switch This normal cutout TH1 PN failure switch is normally closed operation at 4990378 wire s 80 amp 81 Should be closed below 160 C 24V power Check power supply ON D 3 D 5 Input voltage Replace power supply failure input output voltage at between test supply REG1 PN test points points 24VAC 361 154 00 and N should be 20 28 VAC Output voltage between 24VDC test point and N test point should b
30. aining Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 15 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Loose or Visual continuity OFF D 3 D 4 D 5 Phase Repair loose poor control inspection D 6 Controller connection in control circuit Assembly J3 to path connection contactor SMC connector to Phase Controller Assembly J9 RC3 power source to Phase Controller Assembly J4 Loose or Visual inspection and or OFF D 3 D 5 T1 to CON1 Tighten effected poor power continuity check on CON1 CB10 connections circuit effected circuit CB12 CB10 between transformer connection CB12 to J50 secondary and J53 see output receptacles distribution schematic for wire s 24V power Check power supply ON D 2 D 3 D 5 Input voltage Replace power supply failure input output voltage at test points between test points 24VAC and N should be 20 28 VAC Output voltage between 24VDC test point and N test point should be 22 28 VDC supply REG1 PN 361 154 00 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabin
31. aintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 35 of 54 Symptom Possible Cause Determination Input Power During Check Reference Schematic Drawing Reference Designator Value Solution Phase Controller Assembly malfunction Check for proper signal with Oscilloscope ON D 3 D 4 D 5 D 6 Connect scope common to J11 Pin 6 24Vdc common Connect scope tip to J11 Pin 12 Apply power to PDU and turn on input breaker Pin 12 should transition low for at least 100mS Toggle reset switch for Phase Controller Assembly Pin 12 should transition low for at least 100mS Replace Phase Controller Assembly PN 361 157 00 Can t turn on input circuit breaker No input power Measure AC input voltage Input breaker will not turn on without a source of input power ON D 2 D 3 D 5 V 1 Check input voltage at test points should be 10 to 15 of expected voltage divided by 100 Provide correct 3 phase power to PDU Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support
32. bration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 18 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Poor Check continuity and OFF D 4 D 5 D 6 Gate Drive Reseat or repair connection visually inspect connector Assembly J2 cables as necessary from Gate pins J11 J12 see Drive schematic for Assembly to wire s SCR modules Poor Check continuity and OFF D 3 D 4 D 5 Phase Reseat or repair connection visually inspect connector D 6 Controller cables as necessary from Phase pins Assembly J10 Controller to Gate Drive Assembly to AssemblyJ1 Gate Drive Phase Assembly Controller Assembly J31 to Gate Drive AssemblyJ5 Phase Controller Assembly J32 to Gate Drive AssemblyJ9 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site
33. bution Unit PDU Troubleshooting Page 30 of 54 Symptom Possible Cause Determination Input Power During Check Reference Schematic Drawing Reference Designator Value Solution Gate Drive Assembly malfunction Once Phase Controller Assembly has been eliminated as a problem source put a current probe onto each gate cathode wire and measure gate pulse current ON D 3 D 4 D 5 D 6 See Theory of Operation figure 2 and 3 for a depiction of a normal gate pulses Sync channel 1 of scope toa power refer ence sine wave such as the out put of the con trol transformer T2 Check Gate Drive Assembly J2 wire s 298 300 302 304 306 308 J11 wire s 310 312 314 amp J12 wire s 316 318 320 for current pulses Current pulses should be like those in Figure 2 and 3 and locked in phase to the power line reference Replace Gate Drive Assembly PN 361 155 00 It could also be a bad connection to a gate pin or an open gate within the SCR Loose or poor connection from SCR to Inductor to Capacitor bank to output Visually inspect connections OFF D 3 D 4 D 5 D 6 Check for tightness from Bar3 to L1 to Bar5 to F4 F5 to CONN3 CONN4 and Bar2 to Bar6 to CONN3 amp CONN4 Tighten or repair connections as necessary Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceabl
34. e 22 28 VDC Input CB Short in Locate short by checking OFF D 3 D 5 See schematic Repair control loop does not control loop various points for for potential short trip on EMO continuity wire s and or interlock switches operation Rev 0406 Power Distribution Unit PDU Troubleshooting Page 39 of 54 FLE Input P Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g External Locate faulty switch or OFF D 3 D 5 Use ohmmeter Replace external EMO button push button to check LS1 push button or Cables or PDU LS3 for proper replace interlock Calibration interlock operation switch LS1 LS2 or switch stuck Should be LS3 any or all PN Computer in the closed closed when 801 646 01 Cooling position depressed or defeated open DIB Interface P when released Field Replaceable Units Inst t Faulty U V Voltage at U V input coil ON D 2 D 3 D 5 Measure Replace circuit PSWUMeEntS Coil on input properly goes to OV but voltage at TB4 breaker CB1 PN Maintenance Software breaker CB1 breaker does not trip position 3 amp 4 523 353 00 Manipulator Should be OVDC to trip Power breaker Preventive Maintenance Failed EMO Visually inspect connector OFF D 2 D 5 Check J63 Repair or replace Safety connector J64 for proper connector J63 and SMC connection or J64 PN 4990377 Support Board Feedback
35. e Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 31 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Bad CONN3 Visually inspect OFF D 3 D 5 Check CONN3 Replace connector CONN4 connectors amp CONN4 for CONN3 CONN4 PN power proper contact connector mating and or cracked housings When Bad Check continuity OFF D 3 D 4 D 5 Phase Repair or replace turned off connection D 6 Controller DC output from Phase Assembly J10 does not Controller to Gate Drive reach 2V in Assembly to Assembly J1 less than 10 Gate Drive Seconds Assembly F1 F2 F3 Check fuses and inspect OFF D 3 D 5 Perform Replace fuse F1 fuses are for possible causes of continuitycheck F2 or F3 any one blown or bad blown fuses Check on fuses or all PN 471 596 connection to power to J4 of Phase There should 01 Repair loose or Phase Controller Assembly be 120VAC broken connections Controller 10 15 at to Phase Controller Assembly Phase Assembly connector J4 Controller Assembly J4 between pins 1 4 2 4 3 4 Rev 0406 FLE Cables Calibration Com
36. ent transducer transducer does not D 6 voltage at transducer 11 and or malfunction correspond with current 12 PN 541 243 00 measured DC current transducer should be 0 05 volts amp Phase Check for proper signal ON D 3 D 4 D 5 Feedback sig Replace Phase Controller with Oscilloscope D 6 nals are 50 Controller Assembly Assembly Ensure Tester SMC duty cycle PN 361 157 00 malfunction connector is connected square wave Tester provides 5V power for open collector outputs proportional to DC current Frequency corresponds to 15mA per Hz with 100 Hz equal to 0 Amps 10100 Hz equal to 150 Amps 100 10100 Hz range Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 41 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g DC output Check actual load current OFF N A Low currents can current too not be accurately low detected with the hall effect based transducer This is normal operation F1 F2 or F3 Check fuses and inspect OF
37. et Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 16 of 54 Mpa Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Failed output Perform visual operational ON D 2 D 5 CB10 CB12 Replace circuit circuit inspection and or voltage input voltage breaker CB10 CB11 breaker check at output circuit should be PN 522 995 16 or breakers 120VAC from CB12 PN 523 355 any terminal to 16 case ground Output voltage should match input when breaker is on should be zero when breaker is tripped or off Phase Check for proper output ON D 3 D 4 D 5 With a proper Replace Phase Controller voltage to AC contactor D 6 15kHZ signal Controller Assembly Assembly coil applied Phase PN 361 157 00 defective Controller Assembly J3 pin 1 3 should be approximately 24V DC Failed output Visually inspect OFF D 2 D 5 J50 J53 Replace receptacle receptacle receptacle and or perform J52 J53 PN 351 continuity check on each 240 00 or J50 PN receptacle between 351 358 00 or J51 terminals and slots PN 4990334 Failed EMI Compare voltage at input ON D 3 D 5 Voltage at filter Replace EMI RFI RFI filter output of EMI RFI filter output should filter P N 521 353 match voltage at filter input 00
38. iso See Theory of power refer PN 361 157 00 malfunction lated inputs to channels Operation ence sine wave Ensure Tester SMC connector is connected figure 4 and 5 for a depiction of a normal gate voltage square waves such as the out put of the con trol transformer T2 Observe on channel 2 Phase Controller Assembly J31 pins 1 3 5 7 9 11 for gates 1 6 respectively amp J32 pins 1 3 5 7 9 11 for gates 7 12 respectively pin 2 is common in any case you should see a low level square wave 3 5Vpk that is locked in phase to the power line Gates 1 6 See Figure 4 Gates 7 12 See Figure 5 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 26 of 54 Input Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution cae During Drawin Value Check g Gate Drive Once Phase Controller ON D 3 D 4 D 5 Sync channel 1 Replace Gate Drive Assembly Assembly has been D 6 of scope toa Assembly PN 361 malfunction eliminated as a problem 4100019 020_ power refer
39. libration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 8 of 54 System Interface Panel LEDs connector J65 9 Pin D sub Pin Number Signal Description Specification PWR_AVAIL High when input power is 5V 5V On available to the PDU OV 5V Off TEST_PWR_ON High when the Test Power 5V 5V On contactor has pulled in OV 5V Off MAIN_PWR_ON High when the main input 5V 5V On breaker is on OV 5V Off 48V_ENERGIZED Voltage proportional to the 3 5V 5V 200 resistive 48VDC 48V buss OV 5V 200 resistive OVDC N C PWR_AVAIL_RTN Return for the signal indicating input power is available TEST_PWR_ON_RTN Return for the signal indicating the Test Power AC contactor has pulled in MAIN_PWR_ON_RTN Return for the signal indicating the main input breaker is on 48V_ENERGIZED_RTN Return for the voltage proportional the 48V buss Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance
40. lly inspect Board from Test connections Assembly J101 Point PC wire s 17 19 Board Assembly to CB1 Bad Check continuity and OFF D 2 D 3 D 5 Test Point PC Repair connection connection visually inspect Board from Test connections Assembly J103 Point PC wire s 1167 Board 168 amp J107 Assembly to wire s 77 333 24V power supply Bad Check continuity and OFF D 3 D 5 Test Point PC Repair connection connection visually inspect Board from Test connections Assembly J100 Point PC wire s 164 Board 166 Assembly to F1 F3 Phase Phase Controller ON D 3 D 4 D 5 Check signals Replace Phase Controller Assembly provides pass D 6 from J11 Pins Controller Assembly Assembly through connection of 2 3 4 with PN 361 157 00 malfunction 24V DC and current respect to J11 limiting resistors for Pin1 Voltage TP_VO V2 Possible but unlikely cause should be close to the voltages present at 48V DC power output Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 53 of 54 PDU Interlock Switch Troubleshooting The PDU interlock system c
41. n breaker is on should be zero when breaker is tripped or off Replace circuit breaker CB4 CB6 PN 523 354 16 or CB7 CB9 PN 522 995 16 Control Circuit breaker failure Perform visual operational inspection and or voltage check at input output of control circuit breakers ON D 2 D 5 Check for normal operation of circuit breakers by measuring input and output from breaker CB2 and CB3 Reset or replace circuit breaker CB2 PN 522 995 02 or CB3 PN 523 354 04 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 13 of 54 gt Input Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution Lae During Drawin Value Check g Control Check voltages at input ON D 3 D 5 T2inputvoltage Replace control transformer and output of control should be transformer T2 PN failure transformer 10 to 15 541 242 00 CB2 may trip if T2 has an of expected internal short If CB3 is input voltage off when this happens T2 between wire fail
42. of TTL signals 5V squarewave indicating what type of Digit 1 6S on 5S off maintenance is required 4 Fan Failure 2 Over temperature 1S off between digits Digit 2 6S on 5S off 1 10 Failed Item Number 2S between trouble codes 11 return on pin 23 5V Supply voltage for all 5VDC 5 signals on J66 12 GND SMC Chassis ground 13 return on pin 25 K1_ON 15 KHz signal that 5V squarewave commands the Test 15KHz 2 Power AC outputs to turn on 14 ON_RTN_48V Return for 48V buss turn on signal 15 GND SMC Chassis ground Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 6 of 54 gt Pin Number Signal Description Specification input output 16 return on any COM vo Proportional frequency 5V squarewave 10 mV to DC voltage line side Hz OV 100Hz 0Hz of F4 and F5 100Hz 48V 4 9KHz 100 Hz 100V 10 1 KHz 100Hz 17 COM SMC common 18 return on any COM v2 Proportional frequency 5V squarewave 10 mV to DC voltage load side Hz OV 100Hz 0Hz of F5 100Hz 48V 4
43. onsists of three interlock switches wired in series between the negative terminal of the 24 Volt PDU low voltage power supply and the PDU transformer thermal cutout TH1 To troubleshoot the PDU interlock system first remove lock out and tag out all AC power to the system Disabling CB1 is not sufficient all AC power must be disabled Remove the service access panels from the PDU and measure the resistance value across the terminals of each switch Each switch should have infinite resistance with the panel removed Manually depress each switch and the resistance across it should drop to near zero Replace any switch that fails this test Refer to the PDU Electrical Schematic for wiring information The switch designators are LS1 LS2 and LS3 PDU Interlock L Switch 1 of 3 PDU Interlock Switch 1 of 3 Rev 0406 Page 54 of 54 J p Power Distribution Unit FLEX NOTES 1 REFER TO V 1 FOR INPUT VOLTAGE CONFIGURATIONS 2 OB1 100A FRAME SEE TABLE A FOR CURRENT SETTINGS 3 SCHEMATIC SHOWN WIRED FOR HEX AND 120 208AVC WYE OUTPUT 4 MAXIMIM RECOMMENDED BRANCH PROTECTION FEEDING POWER CONDIMIONER REFER TO TABLE 6 INPUT EQUIPMENT TERMINAL LUG WIRE RANGE 6 AWG 2 0 AWG 6 GRONDING ELECTRODE TERMINAL LUG WIRE RANGE 6 AWG 2 0 AWG Cables Calibration Computer Cooling DIB Interface Field Replaceable Units PDU Electrical Schematic Instr
44. or all PN 471 596 connection to power to J4 of Phase There should 01 Repair loose or Phase Controller Assembly be 120VAC broken connections Controller 10 15 at to Phase Controller Assembly Phase Assembly connector J4 Controller Assembly J4 between pins 1 4 2 4 3 4 48 VDC Bad indicator Replace light recheck OFF D 2 D 5 LED4 Replace light LED4 Present light PN 702 393 00 LED not properly illuminated Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 48 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Bad Check continuity check OFF D 2 D 3 D 5 Test Point PC Repair connection connection that light is plugged in Board from Test Assembly J102 Point PC to LED4 Board Assembly to light Bad Check continuity OFF D 2 D 3 D 5 Phase Repair or replace connection Controller RC4 PN 4990373 from Test Assembly J11 Point PC to Test Point PC Board Board Assembly to Assembly J11 Phase RC4 Controller Assembly Test PointPC
45. puter Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 32 of 54 ested Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution cauas Bunny Drawin Value Check g Fast bleeder Resistance measurement OFF D 3 D 4 D 5 Disconnect Replace Gate Drive resistor s D 6 Gate Drive Assembly PN 361 open Assembly circuited on connector J1 Gate Drive Resistance of Assembly Gate Drive Assembly resistors R19 R20 R62 64 should read less than 4 5 ohms in parallel Failed Power Measure input current to ON D 3 D 4 D 5 Current Replace Heat Sink SCR each SCR using current D 6 waveshape Assembly PN 361 probe Access to wires should be can be had at glastic similar to Figure terminal board 1 Amplitude will vary with applied load Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp
46. r provides 5V power proportional to for open collector AC RMS volt outputs age Frequency corresponds to 25mV per Hz with 100 Hz equal to 0 Volts 10100 Hz equal to 250 Volts 100 10100 Hz range Bad Check cable connection OFF D 3 D 4 D 5 Check Phase Repair or replace connection from SMC PDU connector D 6 Controller RC3 PN 4990372 from Phase to Phase Controller Assembly J9 Controller Assembly ribbon cable for Assembly J9 proper to SMC connection connector RC3 J66 Feedback Loose or Visually inspect connector ON D 3 D 4 D 5 Check J4 on Repair connection signal poor D 6 Phase frequency connection to Controller does not AC input for Assembly for correspond Phase solid to Controller connections measured Assembly DC output voltage Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 43 of 54 Mpa Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Bad Check cable connection OFF D 2 D 3 D 4 Check Phase Repair or
47. r6 to output CONN3 amp CONNG4 Rev 0406 Power Distribution Unit PDU Troubleshooting Page 20 of 54 FLE Input P Reference Reference Possible fog Power Symptom Determination Schematic Designator Solution Cause During Drawing Value Check Bad power Visually inspect OFF D 3 D 5 Check CONN3 Replace connector connector connectors amp CONN4 for CONN3 and or Cables proper contact CONN4 PN Calibration mating and or cracked Computer housings Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 21 of 54 Input P Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Phase Check for proper gate ON D 3 D 4 D 5 Sync channel 1
48. replace connection from SMC PDU connector D 5 D 6 Controller RC3 PN 4990372 from Phase to Phase Controller Assembly J9 Controller Assembly ribbon cable for Assembly J9 proper to SMC connection connector RC3 J66 Phase Check for proper signal ON D 2 D 3 D 4 Feedback sig Replace Phase Controller with Oscilloscope D 5 D 6 nals are 50 Controller Assembly Assembly Ensure Tester SMC duty cycle PN 361 157 00 malfunction connector is connected square wave Tester provides 5V power proportional to for open collector DC voltage outputs Frequency corresponds to 10mV per Hz with 100 Hz equal to 0 Volts 10100 Hz equal to 100 Volts 100 10100 Hz range Maintenan Fan failure or Check fan and connection OFF ON D 2 D 3 D 4 Check Repair any connec ce LED amp bad corresponding to D 5 D 6 connection on tions signal connection maintenance signal code J1 J10 on Fan If any fan is not present PCB Check for rotating replace fan Fan fail rotation of FAN1 FAN8 PN FAN1 FAN10 361 175 00 FAN9 FAN10 PN 361 176 00 Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 44
49. roperly illuminated Bad Check continuity check OFF D 2 D 3 D 5 Test Point PC Repair connection connection that light is plugged in Board from Test Assembly J102 Point PC to LED1 Board Assembly to light Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 47 of 54 Mpa Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Bad Check continuity OFF D 2 D 3 D 5 Phase Repair or replace connection Controller RC4 PN 4990373 from Test Assembly J11 Point PC to Test Point PC Board Board Assembly to Assembly J11 Phase RC4 Controller Assembly Test Point PC No signal at output to light ON D 2 D 3 D 5 Test Point PC Replace Test Point Board Board PC Board Assembly Assembly Assembly J102 PN 361 158 00 malfunction output to LED should measure at least 17VDC F1 F2 F3 Check fuses and inspect OFF ON D 3 D 4 D 5 Perform Replace fuse F1 fuses are for possible causes of D 6 continuitycheck F2 or F3 any one blown or bad blown fuses Check on fuses
50. tenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 37 of 54 Mpa Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution Lae During Drawin Value Check g 24V power Check power supply ON D 2 D 3 D 5 Input voltage Replace power supply failure input output voltage at between test supply REG1 PN test points points 24VAC 361 154 00 and N should be 20 28 VAC Output voltage between 24VDC test point and N test point should be 22 28 VDC Voltages at No input Measure AC input ON D 2 D 3 D 5 Check input Provide correct 3 control power voltage Input breaker will V 1 voltage at test phase power to PDU voltage test not turn on without a points should points too source of input power be 10 to low or not 15 of present expected voltage divided by 100 Control Check control voltages at ON D 3 D 5 Check voltage Re tap control transformer test points Check that at 24VAC test transformer T2 to improperly control transformer tap points should match input voltage tapped selected matches input be 20 28 VAC resulting ina voltage low control circuit voltage Internal Check that all covers are OFF D 3 D 5 LS1 LS3
51. tinuity OFF D 2 D 3 D 5 Phase Repair or replace connection Controller RC4 PN 4990373 from Test Assembly J11 Point PC to Test Point PC Board Board Assembly to Assembly J11 Phase RC4 Controller Assembly Test PointPC No signal at output to light ON D 2 D 3 D 5 Test Point PC Replace Test Point Board Board PC Board Assembly Assembly Assembly J102 PN 361 158 00 malfunction output to LED should measure at least 17VDC Bad CB1 Check continuity of CB1 OFF D 2 D 3 D 5 AUX1 contacts Replace input circuit AUX1 contact AUX1 contacts should be breaker CB1 PN closed with 523 353 00 CB1 on and open with CB1 off Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 50 of 54 Mpa Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution bale During Drawin Value Check g Bad Visually inspect OFF D 2 D 3 D 5 Phase Repair connection connection connections Controller as necessary from Phase Assembly J3 Controller pin 5 Assembly to CB1 AUX1 Test Power Bad indicator Replace light recheck OFF D 2 D 5 LED3
52. tware contactor Manipulator Test points Bad Check continuity OFF D 3 D 4 D 5 Phase Repair or replace Power not connection D 6 Controller RC4 PN 4990373 Preventive Maintenance functioning from Test Assembly J11 Point PC to Test Point PC Safety Board Board SMC Assembly to Assembly J11 Support Board Phase RC4 Controller Support Cabinet Assembly Test Hosa Test PointPC Check continuity OFF D 3 D 5 Using Replace Test Point Troubleshooting Board ohmmeter PC Board Assembly Training Assembly check continuity PN 361 158 00 malfunction between Test Product Integration Manuals Point PC Board Site Prep Guide Assembly J100 Install amp Checkout Guide output N G J101 input J103 24VAC J107 24VDC J200 201 48VDC Rev 0406 HOME HELP FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide D HOME HELP Power Distribution Unit PDU Troubleshooting Page 52 of 54 ipin Reference Reference Possible TT Power Symptom Determination Schematic Designator Solution cae During Drawin Value Check g Bad Check continuity and OFF D 2 D 3 D 5 Test Point PC Repair connection connection visua
53. uments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board CONN 084 58 16A 1 P Co p sne 959 360 16A 1 P_ uW Spare Z 2e 161 362 16A 1 P PTS ZT 3087 954 16A 2 P SMC _PS la703 pull_down_meo Ax 6 __ o A ZT Sca8 155 164 2 P Comp Monit Convenience Strip Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide a Z Too 156 157 16A 2 P uW SC and Exp Cab hardware CONN2 T o810 452 383 16A 2 P 0G supples la703 Spare Z Ton 50 10a 2 P img x T Z zaz 951 16A 3 P DC Instrument Pulse Power 6 D HOME HELP AO 6 00 NEW RELEASE ever Ea ornon n R sermons on PANTHER iso 05 04 01 POWER CONDITIONER oan oy MAIN SCHEMATIC SUE SCALE CAD Use Onp PART NUMBER PEVBION ace D nts 1050176 AO FIDENTIAL PROPRIETARY INFORMATION AND IS NOT OR IN PART WITHOUT THE WRITTEN PERMISSION OF PA Manuals 100 105 1050176 1050176_005_T53_A0 D 5 Rev 0406
54. ure is the likely cause s 94 amp 95 Output should be 24VAC between wire s 96 amp 97 Failed output Visually inspect OFF D 2 D 5 J54 J62 Replace receptacle receptacle receptacle and or perform J58 J62 PN 358 continuity check on each 092 00 or J54 J57 receptacle between PN 351 240 01 terminals and slots Failed EMI Compare voltage at input ON D 3 D 5 Voltage at filter Replace EMI RFI RFI filter output of EMI RFI filter output should filter P N 521 353 match voltage 00 at filter input No voltage F1 F2 or F3 Check fuses and inspect OFF ON D 3 D 5 Perform Replace fuse s F1 present on fuses are for possible causes of continuitycheck F2 or F3 any one Switched blown or bad blown fuses Check on fuses or all PN 471 596 AC output connection to power to J4 of Phase There should 01 Repair loose or Phase Controller Assembly be 120VAC broken connections Controller 10 15 at J4 to Phase Controller Assembly between pins 1 Assembly connector J4 4 2 4 3 4 Branch Visual inspection ON D 2 D 5 CB10 CB12 Check for overload breaker problem reset tripped or off tripped branch breaker Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide
55. ut signal on J66 of the SMC in the two digit trouble code is as follows e Pulse duration is typically 600 ms e Pause between digits is typically 1000 ms e Pause between pulses within a digit is typically 500 ms e Pause between successive trouble codes is typically 2000 ms The specific trouble code indications are e A solid LED not flashing or constant HIGH output signal indicates that a PDU microprocessor reset is required e A single pulse for the first digit indicates a fan failure The number of pulses 1 10 for the second digit indicate the failed fan unit Two pulses for the first digit indicates and overtemperature condition The number of pulses 1 3 for the second digit indicate the overtemperature sensor number Rev 0406 FLE Cables Calibration Computer Cooling DIB Interface Field Replaceable Units Instruments Maintenance Software Manipulator Power Preventive Maintenance Safety SMC Support Board Support Cabinet Test Head Troubleshooting Training Product Integration Manuals Site Prep Guide Install amp Checkout Guide HOME HELP Power Distribution Unit PDU Troubleshooting Page 4 of 54 Connector Pinouts Tester System Monitor Controller SMC connector J66 25 Pin D sub Pin Number Signal Description Specification input output 1 return on pin 14 48 V_ON 15 KHz signal that commands the 48V buss to turn on 5V squarewave 15KHz 2

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