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I/R Module Troubleshooting

Warning! Dangerous voltages are present! It must be assured that power is removed and the DC Bus has drained to a safe level before any connections are removed or checked! Wait at least 5 minutes for the DC Bus to discharge to a safe level after power off.
When the I/R Module is enabled and functioning properly, there should be 600 VDC across the DC Bus terminals P600, M600 and only the yellow LED(middle on the right) should be lit. The incoming voltage at terminal U1, V1 and W1(drive side of 3-Phase inductor) will increase significantly when the I/R Module is enabled. This is a result of the PWM switching through the 3Phase inductor and should be considered normal. The line voltage should be 3-Phase 400 V +/- 10% at the line side of the 3-Phase inductor. Possible Cause Check that the incoming line voltage at terminals U1,V1,W1 are 3-Phase 400 V +/- 10%. For the 80 and 120 KW, Check that line voltage across L1 and L2 is 1-Phase 400V +/- 10%. L1 must be in phase with U1 and L2 must be in phase with V1. Check that terminal block X181 is plugged in and the jumpers between 1U1, 2U1, etc. are connected correctly. If problem found - Repair and re check If input voltage and X181 are OK - ReplaceI/R module See Module Dead. Check that terminal block X171 is installed and that jumpers between NS1 and NS2 are installed. Check that terminal 48 is +24V with reference to terminal 19. Power down and wait for DC Bus to drain to a safe level. Disconnect Ribbon cable(X151) and terminal blocks X121, X141, X161, X171. Power up. If Fault is gone - There is a short in the interface. Plug in one terminal block at a time to determine where the short is. If in the interface, trace & repair. If in the ribbon cable circuit, plug the ribbon cable into one module at a time to find which module is dragging down the voltage. When that module is found, pull the controller PCB out of the backplane, if problem is gone, Power section is bad, if problem still exists, controller PCB is bad. Caution! Power down before plugging or unplugging the ribbon cable or controller PCBs. Faults still present - ReplaceI/R Module.

I/R Faults Module Dead No LEDs or Aux. Voltages

Unit Enable LED not Lit

15 V, 5V fault LED

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Supply Fault LED

Determine if the fault appears on power up or enable. If on power up - One phase missing from terminals U1, V1, W1, X181 or bad power connection. Check power connections and line voltage level (see dead module). If problem found - Repair and re-check If input voltage and X181 are OK - ReplaceI/R module If on enable(48 and 63) - Bad power connection, short in DC Bus, line voltage too low, line matching transformer KVA too low or impedance too high. Power down and wait for DC Bus to drain to a safe level. Disconnect bus bars from P600 and M600 and re-check. If problem found - Repair and re-check If OK with DC Bus Bars open - There is a short in the DC Bus of one of the modules. If all OK - ReplaceI/R module

DC Bus Overvolts Determine if the fault appears on power up or motor deceleration. LED If on power up - Line volts too high. (360 to 440 VAC) If on motor decel - Check setting of Dip Switch bit 3, line regeneration mode. For line regeneration, bit 3 = off. If line voltage is above 424 VAC, set Dip Switch Bit 1 (on = DC Bus 625 VDC). Re-check. If problem still exists - Replace I/R. Ext. Enable LED Lit Check terminals 63, 64, 48 with reference to terminal 19. If all are not +24 Volts, check ground connection to terminal 19, and/or interface. If all OK but fault still exists - Check tightness of screw terminals. If all OK but fault still exists - Replace I/R Module.

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