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Parker 590+ series Frame 1, 2, 3, 4, 5, 6 & H. Product Manual (2012) - page 13

Trips and Fault Finding

7-3

Calibration Checks

The drive leaves the factory with the following calibration switches correctly set. Inappropriate settings will prevent the drive from operating correctly.

For your reference, the correct settings are given below.

IMPORTANT If you change the settings for any of these switches you MUST re-calibrate the Control Board. Refer to Chapter 4:

"Operating the Drive" - Calibrating the Control Board.

Control Board Calibration

The control board calibration scaling switch of previous DC590+ products (shown opposite) has been replaced by a software-controlled

1

scaling function. There are no user settings required.

OFF

Power Board Current Calibration Switches (Frame 2)

NO POWER IS CONNECTED AT THIS STAGE

View the switches with the drive door open:

SW1 - Product Identity Switch

HI

This switch is always set to HI.

SW2

LO

SW2 - Burden Switch

Burden Switch

This switch is always set to HI.

Power Board

HI

SW1

LO

Product Indentity

7-4 Trips and Fault Finding

Adaptor Board Current Calibration Switch (Frame 3)

NO POWER IS CONNECTED AT THIS STAGE

View the switch with the terminal cover removed:

IA CAL - Armature Current Calibration Switch

1

This switch should be set to "1" (ON) for armature current scaling greater than 128A.

Set to OFF for other values.

OFF

NOTE This switch must only be operated with the drive powered-down.

Power Board Current Calibration Switches (Frames 4 & 5)

NO POWER IS CONNECTED AT THIS STAGE

View the switches with the drive door open:

Power Board

IA CAL - Armature Current Calibration Switch (SW1)

This switch is always set to LO on Frame 4 & 5 drives of 500A or less, and HI for drives greater than 500A.

IF CAL - Field Current Calibration Switch (SW2)

This switch is always set to HI for Frame 4 & 5 drives. The maximum field current calibration is 30A.

IF CAL

HI

SW2

LO

IA CAL

HI

SW1

LO

Trips and Fault Finding

7-5

Power Board Current Calibration Switches (Frames 6 & H)

NO POWER IS CONNECTED AT THIS STAGE

To access the power board remove the terminal cover, unscrew the two fixings on the right hand side of the control door. Open the door to reveal the

power board.

ON

Armature Current Calibration

SW1 - 6

500A stages (factory setting = 2000A)

OFF

thus switches 1 to 4 = ON

1 2 3 4 5 6 7 8 910

SW7

Reserved (factory setting = ON)

Calibration Switches

SW8 - 9

Field Current Calibration

8

9

Field Current Range

0 = OFF

0

0

up to 20A (factory setting)

1 = ON

0

1

up to 40A

1

0

up to 60A

1

1

up to 80A

(not used on standard build)

SW10

Armature Voltage Calibration

Power Board

OFF = VA / 100 (for VA up to 875V) (factory setting)

Figure 7-1 Calibration Switches

IA CAL - Armature Current

Calibration switches 1 to 4 are always set to “ON”, and 5 to 6 are always set to “OFF”.

Armature Voltage

Calibration switch SW10 is always set to "OFF".

IF CAL - Field Current

For field currents greater than 20A, set the Field Current calibration switches 8 and 9 to give the required Field Current range. The drive’s Product

Code includes the value for Field Current. If you change the Field Current from the 20A factory setting to another value, you must now select the

correct Product Code rating:

7-6 Trips and Fault Finding

AUXILIARY POWER ONLY IS CONNECTED AT THIS STAGE

Apply auxiliary power. Note the current Product Code which is displayed on the MMI’s Welcome screen at the top of the menu, e.g. DC 4Q 1700A 20

D (20 = 20A Field Current range)

Set the following parameters, but first select CONFIGURE ENABLE to be ENABLED.

Now, for instance, to set the Field Current range for 40A, you must select the appropriate Product Code for a Field Current range of 40A, e.g. DC 4Q

1700A 40 D

MMI Menu Map

To do this, refer to Chapter 6: “The Keypad” - Changing the Stack Size (3-button reset).

1

CONFIGURE DRIVE

Note the nominal field current from the motor rating plate and set this value in the FIELD CURRENT parameter.

FIELD CURRENT

Now select CONFIGURE ENABLE to be DISABLED and perform a PARAMETER SAVE.

You MUST re-calibrate the Control Board.

Refer to Chapter 4: "Operating the Drive" - Calibrating the Control Board.

Adaptor Board Current Calibration Switch (Frames 6 & H)

NO POWER IS CONNECTED AT THIS STAGE

View the switch with the terminal cover removed:

IA CAL - Armature Current Calibration Switch

This switch is always set to "1" (ON).

1

OFF

Trips and Fault Finding

7-7

Alarm Messages

MMI Menu Map

When a trip occurs an alarm message is displayed on the MMI, and information about the trip is stored in the ALARM

1

ALARM STATUS

STATUS menu.

LAST ALARM

The alarm message and the LAST ALARM parameter are displayed in the selected language when viewed on the MMI.

HEALTH WORD

The HEALTH STORE, HEALTH WORD and ALARM HISTORY parameters display information as hexadecimal values,

HEALTH STORE

or the sum of the hexadecimal values when more than one alarm is active. Thus the unique value can represent one or more alarms.

NOTE

Hexadecimal refers to the common practice of counting to the base of 16 in computing rather than the base of 10. The sixteen `numbers’ used

being 0 to 9, A to F. Thus an 8 bit byte is represented by two characters in the range 00 to FF, while a 16 bit word is represented by four

characters in the range 0000 to FFFF.

LAST ALARM

(Tag 528). This display shows the last alarm message to have been displayed. To reset the parameter simply press the t (DOWN) key to clear the

alarm. Alternatively, you can switch the auxiliary supply off and on, causing NO ACTIVE ALARMS to be displayed.

NOTE

The LAST ALARM value is presented in hexadecimal format when viewed in DSELite or when used in the Block Diagram.

HEALTH WORD

(Tag 115).This parameter is used to continuously monitor the status of the Drive. As alarms are added or removed, the display will immediately update

to show the hexadecimal sum of these alarms.

The value reverts to 0x0000 when the Start (C3) input is raised (+24V), and when no trip condition is present.

HEALTH STORE

(Tag 116).This displays the hexadecimal value of the first (or only) alarm to occur causing the trip condition.

The display reverts to 0x0000 when the Start (C3) input is raised (+24V).

ALARM HISTORY

The most recent 10 alarm events are stored in the ALARM HISTORY funtion block, with the oldest in parameter ALARM

10 (OLDEST), and most recent in ALARM 1 (NEWEST). As with the HEALTH STORE and HEALTH WORD

parameters, the alarm history is stored as four character hexadecimal numbers.

7-8 Trips and Fault Finding

Hexadecimal Representation of Trips

The LAST ALARM, HEALTH WORD, HEALTH STORE and ALARM HISTORY parameters use a four digit hexadecimal number to identify

individual trips. Each trip has a unique corresponding number as shown below.

LAST ALARM, HEALTH WORD and HEALTH STORE

Trip Codes : LAST ALARM only

Trip

Trip Code

14

AUTOTUNE ERROR

F

0

0

1

First Digit

Digit

Digit

Last Digit

14

AUTOTUNE ABORTED

F

0

0

2

NO ACTIVE ALARMS

14

SEQ PRE READY

F

0

0

3

0

OVERSPEED

1

14

CONTACTOR DELAY

F

0

0

4

1

MISSING PULSE

2

14

EXTERNAL TRIP

F

0

0

5

2

FIELD OVER I

4

14

REMOTE TRIP

F

0

0

6

3

HEATSINK TRIP *

8

14

ENABLE LOW

F

0

0

7

4

THERMISTOR

1

14

SEQUENCING

F

0

0

9

5

OVER VOLTS (VA)

2

14

COMMS TIMEOUT

F

0

1

0

6

SPD FEEDBACK

4

14

CONFIG ENABLED

F

2

0

0

7

ENCODER FAILED

8

14

CALIBRATION TRIP

F

3

0

0

8

FIELD FAILED

1

14

NO OP-STATION

F

4

0

0

9

3 PHASE FAILED *

2

14

AUX SUPPLY

F

F

0

3

10

PHASE LOCK

4

11

5703 RCV ERROR

8

12

STALL TRIP

1

13

OVER I TRIP

2

14

OTHER •

4

15

ACCTS FAILED *

8

* Refer to “Power Board LED Trip Information (Frame 4, 5, 6 & H)” below

• For the LAST ALARM parameter, replace OTHER with trip codes opposite.

Trips and Fault Finding

7-9

When more than one trip is to be represented at the same time then the trip codes are simply added together to form the value displayed. Within each

digit, values between 10 and 15 are displayed as letters A to F

For example, if the HEALTH WORD parameter is 01A8 then this represents a “1” in digit 3, an “8” and a “2” in

Decimal number

Display

digit 2, (8+2 = 10, displayed as A) and an 8 in digit 1. This in turn represents the active trips FIELD FAILED,

ENCODER FAILED, OVER VOLTS (VA) and HEATSINK TRIP (an unlikely situation).

10

A

11

B

12

C

13

D

14

E

15

F

Power Board LED Trip Information (Frame 4, 5, 6 & H)

The HEATSINK TRIP, 3 PHASE FAILED and ACCTS FAILED trips are associated with the following LED indications:

Frame 4

Check the LEDs on the power board for more HEATSINK TRIP information.

The LEDs light to indicate a problem.

Trips

field heatsink overtemperature

FLD HS OT

HEATSINK TRIP

armature heatsink overtemperature

ARM HS OT

3 PHASE FAILED

phase loss

PHASE LOSS

7-10 Trips and Fault Finding

Frame 5

The master power board (on the left hand side of the unit) is fitted with a Parallel Expansion Board. This board has four additional LEDs providing

information about the slave power board (on the right hand side of the unit), and about the general status of the unit.

The LEDs light to indicate a problem.

Trips

Master Power Board

Slave Power Board

(indicated by the

Parallel Expansion Board)

field heatsink overtemperature

FLD HS OT

HEATSINK TRIP

armature heatsink overtemperature

ARM HS OT

ARM HS OT

phase loss

PHASE LOSS

PHASE LOSS

3 PHASE FAILED

phase rotation fault

PH ROT FLT

ACCTS FAILED

current imbalance

CUR IMBALANCE

It is essential that the phase sequence applied

to the two stacks are identical otherwise the

converter will trip on 3 PHASE FAILED.

If there is a current imbalance between the

stacks which exceeds 10% the converter will

trip on ACCTS FAILED.

MASTER

SLAVE

Trips and Fault Finding

7-11

Frame 6

Eight diagnostic LEDs indicate further trip information, and general status of the unit. The LEDs go out to indicate a problem (note that LED1 may

also flash as the SMPS attempts to power-up repeatedly, indicating a fault).

Trips

Power Board

switched mode power supply on

SMPS OK

|

LED1

trigger board connection status

TRIGGER BOARD PRESENT

|

LED9

ACCTS FAILED

ac current transformer connection status

ACCTS PRESENT

|

LED10

3 PHASE FAILED

thyristor fuses status

THYRISTOR FUSES

|

LED11

field heatsink temperature normal

FIELD THERMOSTAT

|

LED12

L1 Phase Assembly heatsink temperature

L1 STACK THERMOSTAT

|

LED13

normal

L2 Phase Assembly heatsink temperature

HEATSINK TRIP

L2 STACK THERMOSTAT

|

LED14

normal

L3 Phase Assembly heatsink temperature

L3 STACK THERMOSTAT

|

LED15

normal

Fans stalled

L* FAN

|

Fan LEDS

* In the event of a trip due to a stalled fan, an unlit fan LED will indicate the failed fan. With the drive stopped, operate the fan fail override switch

and restart the drive. Diagnose the failed fan from the fan LEDs status.

7-12 Trips and Fault Finding

Frame H

The power board has six LEDs indicating further trip information, and general status of the unit.

The LEDs go out to indicate a problem (note that LED1 may also flash as the SMPS attempts to power-up repeatedly, indicating a fault).

Trips

Power Board

switched mode power supply on

SMPS OK

LED1

trigger board connection status

TRIGGER BOARD PRESENT

LED4

ACCTS FAILED

ac current transformer connection status

ACCTS PRESENT

LED3

3 PHASE FAILED

thyristor fuses status

THYRISTOR FUSES

LED6

field heatsink temperature normal

FIELD HEATSINK

LED2

HEATSINK TRIP

armature heatsink temperature normal

STACK THERMOSTATS

LED5

Trips and Fault Finding

7-13

Using the MMI to Manage Trips

Trip Messages

Most of the alarms have a delay timer so that the Drive only trips if the condition persists for the whole of the delay period.

If the Drive trips, then the display immediately shows a message indicating the reason for the trip. The possible trip messages are given in the table

below.

Trip Message and Meaning

Possible Reason for Trip

OVERSPEED

Motor overspeed - the speed feedback signal has

Badly adjusted speed loop (alarm only operates with encoder or armature volts

exceeded 125% of rated speed.

feedback selected)

Alarm time delay : 50 milliseconds

MISSING PULSE

A missing pulse from the 6-pulse armature current

Firing plug failure

waveform. This trip is only enabled when the motor

Connection failure

loading exceeds 1.5 times the DISCONTINUOUS

Alarm time delay : 60 seconds

parameter value.

Note that the MISSING PULSE trip is not intended or

able to protect the drive if a thyristor fails to function

during regenerative operation. This can result in

damage to the drive.

We recommend fusing the armature circuit if

regenerative operation is intended. The MISSING

PULSE trip is intended to detect firing circuit

connector problems during motoring operation of

the drive.

FIELD OVER I

The motor field current has exceeded 120% of the

External field has incorrect supply phases applied

calibrated value

(Alarm only operates with field current control mode selected)

Alarm time delay : 10 seconds

7-14 Trips and Fault Finding

Trip Message and Meaning

Possible Reason for Trip

HEATSINK TRIP

The Drive heatsink temperature is too high

The ambient air temperature is too high

Poor ventilation or spacing between Drives

Fan failure, check fuse on power board, wrong rotation (models above 70A bridge

rating)

Blocked ventilation slots

Clogged air filters

Excessive armature current - nominal armature current on motor nameplate

should be checked against the current calibration for the Drive.

Note: The stack must be allowed to cool in order to re-start the Drive.

Alarm time delay : 0.5 seconds

THERMISTOR

The motor temperature is too high

Inadequate ventilation

Blower failure -check for direction, clogged air filters (models above 70A bridge

rating)

Excessive armature current - check nominal armature current on nameplate

against current calibration)

Note: The motor must be allowed to cool in order to re-start the Drive.

Alarm time delay : 5 seconds

OVER VOLTS (VA)

Motor armature voltage has exceeded 120% of rated

Loose armature connection

volts

Badly adjusted field voltage setting

Badly adjusted field current loop

Badly adjusted field-weakening bemf loop

Badly adjusted speed loop

Alarm time delay : 1 second

SPEED FEEDBACK

The difference between speed feedback and

Analog tacho feedback polarity incorrect (terminals G3 and G4)

armature voltage feedback is greater than the

The ENCODER SIGN parameter’s polarity is incorrect

SPDFBK ALM LEVEL parameter value

Disconnection of wiring, including fibre optics

Armature voltage calibration has not been suitably reduced when running at

If FLD WEAK ENABLE parameter is enabled, speed

reduced field currents

feedback is less than 10% when in the field

Tachogenerator failure

weakening region

Tachogenerator coupling failure

Alarm time delay : 0.125 seconds

Trips and Fault Finding

7-15

Trip Message and Meaning

Possible Reason for Trip

ENCODER FAILED

No speed feedback signal

The SPEED FBK SELECT parameter is set to ENCODER but an optional Encoder

board is not fitted

Where applicable, check fibre optic cable for damage, bend radius, operating

length - refer to the Microtach handbook.

Check cable and connections on wire-ended encoder

FIELD FAIL

Field current is less than 6% of rated current when in

Open circuit motor field - check connection and measure field resistance

Current Control mode

Faulty operation of field controller

Field current is less than 50mA when in Voltage

Where an ac supply feeds the onboard field regulator, check connections FL1 &

Control mode (with default current burden of 15K)

FL2 for line-to-line voltage (rather than line-to-neutral) - L1 into FL1, L2 into FL2.

Note that the 3-phase supply must be present for mains synchronisation purposes.

For loads where no field supply is required, e.g. a permanent magnet motor, set

the FIELD ENABLE parameter to DISABLED to suspend this alarm.

Alarm time delay : 1 second

3-PHASE FAILED

3-phase supply failure

Total failure of supply, or missing phase of 3-phase supply (detected under most

circumstances) - check supply to the controller, check high-speed thyristor stack

protection fuses, check power chassis coding fuses.

Check the mains voltage of the Drive (refer to the Product Code). This alarm may

not operate properly with controller if the voltage is incorrect, i.e. wrong unit or

controller.

PHASE LOCK

Supply frequency is outside the frequency band limits

Check supply frequency

45 - 65Hz

Synchronisation errors caused by distorted supply

5703 RCV ERROR

Invalid data received via P3 port from another Drive

(Alarm only operates when MODE parameter is set to 5703 SLAVE)

STALL TRIP

With motor stationary (AT ZERO SPEED parameter

(Alarm only operates when the STALL TRIP parameter is enabled).

shows TRUE), current has exceeded the STALL

THRESHOLD parameter value for longer than the

STALL TRIP DELAY parameter value

OVER I TRIP

Current feedback value has exceeded 280% of rated

(300% loading not exceeding 15ms or 325% not exceeding 6.6ms is acceptable)

current

Motor armature windings failure - check insulation resistance.

Badly tuned current loop

Faulty Drive - refer to Parker SSD Drives

7-16 Trips and Fault Finding

Trip Message and Meaning

Possible Reason for Trip

ACCTS FAILED

AC current transformer plug connection to Drive

Check armature current transformer plug for correct installation.

power board missing

Frame 5 only : Load imbalance between the two parallel power stacks

Note: The trip prevents the contactor closing and the current loop activating

without armature current feedback - important in the case of external stack

controllers where the thyristor stack is remote from the control board.

AUTOTUNE ERROR

Error has been encountered during the Autotune

The motor shaft was rotating, or was caused to rotate.

process to include:

The field current was seen to exceed 6%, when a field-off Autotune had been

Speed feedback has exceeded 20% of rated speed

selected, or the field current stopped during a field-on Autotune.

Field current feedback has exceeded 6% of rated

The drive to armature wiring was open-circuit.

field current

The discontinuous current boundary was found to exceed 200% of either the stack

rating or the nominated motor armature current rating (refer to Chapter 5:

"Control Loops" - Manual Tuning)

Large imbalance in the three-phase voltages of the supply (refer to Chapter 5:

"Control Loops" - Manual Tuning)

A hardware fault relating to current feedback was detected on the control board.

AUTOTUNE ABORT

The Autotune sequence has been aborted.

Coast Stop, Program Stop, Enable or Start Run terminal(s) disabled during

Autotune sequence

The AUTOTUNE parameter reset during the Autotune sequence

Autotune sequence has timed-out (approximately 2 minutes).

SEQ PRE READY

Coding not present.

Replace power board or chassis.

CONTACTOR DELAY

The internal auxiliary 3-phase contactor failed to

Check the position of the Calibration Scaling Switch - refer to Calibration Checks,

close.

page 7-3.

EXTERNAL TRIP

Customer alarm! Trip operates if input open or high impedance.

Alarm time delay : 0.2 seconds

Device not wired to drive or device open circuited : check C1 to C2 connections to

drive - connect C1 to C2 if customer device not fitted.

REMOTE TRIP

REM. SEQUENCE parameter Remote Trip flag set to zero.

ENABLE LOW

Local Mode run with Enable input low

Trips and Fault Finding

7-17

Trip Message and Meaning

Possible Reason for Trip

SEQUENCING

Internal sequencing error

Contact Parker SSD Drives

COMMS TIMEOUT

Remote comms timeout

See COMMS TIMEOUT parameter in the SEQUENCING function block

CONFIG ENABLED

The drive was requested to start whilst in Configuration mode

CALIBRATION FAIL

Signal calibration fault

If powering the unit off and on does not remove the problem, a hardware failure is

suspected. Refer to Parker SSD Drives.

NO OP STATION

Keypad has been disconnected from Drive whilst Drive is running in local control.

AUX SUPPLY

Check auxilliary supply and/or mains input

COMMS FAULT CODE x

Keypad faulty

Remote cable to keypad faulty

Drive firmware not running

CRITICAL ERROR

xxxx::xxxxxxxx

Contact Parker SSD Drives

Table 7-2 Trip Messages

Self Test Alarms

Self Test Alarm and Meaning

Possible Reason for Alarm

(EEPROM) CHECKSUM FAIL

Parameters not saved, or are corrupted.

(The alarm appears at power-up or at the end of “Upload” UDP Transfer)

Corrupted UDP file loaded - press the E key and perform a PARAMETER SAVE.

The Drive will be returned to its factory default values.

LANGUAGE CHECKSUM FAIL

Incorrect language selected, or corrupted

(The alarm appears at power-up or at the end of “Upload” UDP Transfer)

Corrupted UDP file loaded - press the E key and reload the correct language or

de-select the second language.

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