Rockwell Automation FlexPak Plus NRG DC Drive - Manual (Page 22)

21
TABLE 5.A - TROUBLESHOOTING SUGGESTIONS FOR THE COMPLETE CONTROLLER (Continued)
Symptom Probable Cause Recommended Procedures
4. In reversing conĆ
trollers only . . .
Controller's M
contactor not
picking up when
FORWARD/REVERSE
switch malfunction,
V Examine Remote Operator Adapter on Regulator Module for firm seating and proper
wiring and pin connections.
V Test FORWARD/REVERSE switch. Use basic technique outlined above for the
START/STOP switch.
picking up when
START switch is
pressed (closed).
M contactor malfuncĆ
tioning.
V On the Auxiliary M pins located on the Regulator Module, connect an ohmmeter.
Place it on the pin 39 and pin 67.
V Place the FORWARD/REVERSE switch in the FORWARD position. The reading should
be approximately 150 to 1000 ohms if it is operating properly.
V Without changing test points, place the switch in the REVERSE position. The reading
should be between 150 to 1000 ohms. if it is operating properly. If a short is observed,
remove jumper J9 and repeat the test.
V If a 150 Ć1000 ohm resistance reading cannot be obtained when the switches are
open, the M contactor is malfunctioning and must be replaced.
5. M contactor picks
up but remains in
only when START
RUN/JOG switch is in
JOG position.
V Place the RUN/JOG switch in the RUN position.
only when START
pushbutton is
pressed and held
in.
CR relay not picking
up.
V Connect a voltĆohmmeter on the Remote Operator Adapter. Place it on terminal 35.
V Connect the second probe to connection 139 connected to the FlexPak Plus M
contactor.
V The reading should be +24 VDC for normal operation.
V Next, shift the probe from terminal 35 to terminal 38 on the same terminal board.
However, leave the second probe where it is.
V Press the START switch, The reading should be approximately 24 VDC for normal
operation.
V Press the START/STOP switch to STOP, and then START. A 24 VDC (approximately)
reading should continue to appear. If it does not, the CR relay is not picking up. In this
case, replace the Regulator Module.
6. Drive motor does
not run, but M
contactor and CR
pull up.
(Use this proceĆ
dure only if conĆ
troller does not
have optional Test
Meter Adapter
Kit.)
No input signal from
SPEED potentiometer
on Control Station.
V If the controller does not have an optional AUTO/MANUAL switch, inspect the
Regulator Module to determine that jumper J4 is In place. (The jumper is removed
when the AUTO/ MANUAL switch is installed.)
V Check the SPEED potentiometer on the Control Station. First, open the power
disconnect switch.
V Connect a voltĆohmmeter to the Regulator Module Remote Operator Adapter inputs,
Connect one lead to terminal 28. Connect the other to terminal 20. (Refer to Figure
3.4 for a Remote Station,)
V For proper operation, the reading should be 5K ohms,
V Disconnect the VOM lead from terminal 20. Connect it to terminal 426.
V Turn the SPEED potentiometer from 10 to 0. The resistance should vary from 5K to 0
ohms. If it does not, replace the potentiometer.
7. Drive motor does
not run, but M
contactor and CR
Pull up.
(Use this proceĆ
dure only if conĆ
troller has optionĆ
al Test Meter
Adapter Kit. )
No input signal from
SPEED pot.
V First check the main power supplies. This must be done with power applied to the
FlexPak Plus controller,
V Connect one lead of voltĆohmmeter to test pin 357 on the Test Meter Adapter Module.
V Connect the second lead to test pin 356 on the Module.
V The reading should be within the range of 10.8 to 11.5 VDC for normal operation.
N t th l d f i 356 Pl it i 456
V The reading should be within the range of 10.8 to 11.5 VDC for normal operation.
V Next, remove the lead from pin 356. Place it on pin 456.
V The reading should be within the range of +16 to +28 VDC for normal operation.
V Next, remove the lead from pin 456. Place it on pin 471.
V The reading should be within the range of Ć16 to Ć28 VDC for normal operation.
V If the proper readings are obtained, the power supplies may be assumed to be
operating correctly,
V If incorrect reading are obtained, replace the Regulator Module.
V Next, check the reference voltage input signal. (This changes in direct proportion to
an increase of SPEED potentiometer voltage caused by a turning of the dial.)
V Connect one lead of a voltĆohmmeter to pin 357 on the Test Meter Adapter Module.
V Connect the other lead to pin 826. Readings vary from 0 to +8.2 VDC, depending on
the set point of the SPEED potentiometer dial.
V If no voltage is noted between pins 357 and 826, check to see if jumper J4 on the
Regulator Module is properly placed/removed for the specific controller. (It is to be in
place, as factoryĆshipped, if there is no AUTO/MANUAL switch. It is to be removed if
there is an AUTO/MANUAL switch.)
V If the SPEED potentiometer is functioning normally, and if the J4 jumper is
placed/removed, as necessary, replace the Regulator Module.
DANGER
THE PROCEDURE DESCRIBED HERE IS PERFORMED WITH
LIVE AĆC VOLTAGE APPLIED TO THE CONTROLLER. USE ONLY
ONE HAND TO APPLY VOM LEADS/PROBES. KEEP YOUR
OTHER HAND BEHIND YOU AT ALL TIMES. DO NOT HOLD ONTO
THE CONTROLLER FOR SUPPORT. PERSONAL INJURY MAY
RESULT IF THESE PRECAUTIONS ARE NOT TAKEN.