Parker Variable Speed Drive AC30 series. User’s Manual (2017)

Trips & Fault Finding

10-9

Runtime Alerts

A Runtime Alert is a fault that indicates a permanent hardware error. The Runtime Alert display is of the form

RUNTIME ALERT

CODE 00000000 xx

CODE is a number in the range 0 to 65000. The following value is used to provide additional information to assist Parker Hannifin Technical
Support personnel.

CODE

ERROR

Possible Reason for Error

1 to

255

Internal exception

•

VCM not secured to power stack

•

Option not secured correctly to VCM control card

•

Earth bonding failure.

•

Fault during firmware upgrade

Memory access

•

Attempt to read or write to protected memory. Most likely this will be due to a configuration error. Press
OK several times until the drive resets correctly, then replace the configuration using PDQ.

•

Record the error message and contact Technical Support

1001

1003

Processor overload

•

Select a lower switching frequency, (

Parameters::Motor Control::Pattern Generator::Stack Frequency)

•

Record the error message and contact Technical Support

1006

Memory overflow

•

Reduce the complexity of the application

•

Reduce the number of parameters being accessed via the on board Modbus TCP protocol

•

Reduce the number of parameters being accessed by the fieldbus communications option.

1007

Uninitialized pointer

•

Record the error message and contact Technical Support

1010,

1101

1113

Initialization error

•

Record the error message and contact Technical Support

1200

1299

Communications option
error

•

Ensure the communications option is correctly fitted

•

Update the firmware in the inverter.

•

Replace the communications option

10-10

Trips & Fault Finding

CODE

ERROR

Possible Reason for Error

1300

Ethernet fault

•

Record the error message and contact Technical Support

1301

Modbus server

•

Record the error message and contact Technical Support

1302

HTTP server fault

•

Record the error message and contact Technical Support

1303

DCT server fault

•

Record the error message and contact Technical Support

1311

Ethernet PHY

•

Record the error message and contact Technical Support

1312

Precision Time
Protocol

•

Record the error message and contact Technical Support

1313

EtherNet IP

•

Record the error message and contact Technical Support

1401
1402

Control Module test

•

Control module self-test error

1403
1404

Power stack test

•

VCM not secured to power stack

•

Power stack self-test error

1501
1502
1503

IO Option identity
IO Option processor
Unknown IO Option

•

Ensure the IO option is correctly fitted

•

Update the firmware in the inverter.

•

Replace the IO option

1504

IO Option watchdog

•

The IO Option has become disconnected

•

Option reset problem. Upgrade drive firmware to 1.11 or greater to improve the option reset control.

1601

Stack internal fault

•

Return the power stack to Parker Hannifin repair center.

1602

Incompatible stack

•

Return the power stack to Parker Hannifin repair center.

1801

Heatsink thermsistor
unplugged

•

Return the power stack to Parker Hannifin repair center.

1901

System Board Data

•

The identifying data on the system board is corrupt

1902

System Board Type

•

The system board type is not recognized by this version of drive firmware. Update the firmware to the
latest version.

2002 Memory allocation error

•

Record the error message and contact Technical Support

Trips & Fault Finding

10-11

Autotune Alerts

If the autotune fails to complete for any reason, an alert will be displayed and the autotune abandoned. Alerts are as follows:

Alert message

Possible Cause

Remedy

LEAKAGE L TIMEOUT

The autotune has attempted to
determine the leakage inductance of the
motor, but cannot make the required
test current.

Problem with motor connection.

MOTOR TURNING ERROR

The autotune is trying to find the
encoder direction by spinning the motor,
but the motor is already spinning.

Wait till the motor stops.

NEGATIVE SLIP FREQ

Autotune has calculated a negative slip
frequency, which is not valid. Nameplate
rpm may have been set to a value higher
than the base speed of the motor.

Check nameplate rpm, base frequency, and pole pairs
are correct.

TR TOO LARGE

The calculated value of rotor time
constant is too large.

Check the values of Nameplate Speed and Base
Frequency.

TR TOO SMALL

The calculated value of rotor time
constant is too small.

Check the values of Nameplate Speed and Base
Frequency.

MAX SPEED TOO LOW

During Autotune the motor is required
to run at the nameplate speed of the
motor. If 100% Speed in RPM parameter
limits the speed to less than this value,
an error will be reported.

Increase the value of 100% Speed in RPM parameter
up to the nameplate rpm of the motor (as a minimum).
It may be reduced, if required, after the Autotune is
complete.

SUPPLY VOLTS LOW

The autotune will compensate for low
supply volts, down to 70% of motor
rated volts. Below this value it will stop
the autotune and raise an alert.

Re-try when mains volts are within specification.

NOT AT SPEED

The motor was unable to reach the
required speed to carry out the
Autotune.

Possible reasons include: motor shaft not free to turn;
the motor data is incorrect.

10-12

Trips & Fault Finding

Alert message

Possible Cause

Remedy

MAG CURRENT ERROR

It was not possible to find a suitable
value of magnetising current to achieve
the required operating condition for the
motor.

Check the motor data is correct, especially nameplate
rpm and motor volts. Also check that the motor is
correctly rated for the drive.

KE TOO LARGE

Ke value calculated during the autotune
(stationary) is too large (the max value is
840V)

Check the motor data is correct, especially nameplate
rpm, rated amps and motor volts.
If low speed motor with a Ke value higher than 840V,
enter by hand the corresponding value after the
autotune completion.

KE TOO SMALL

Ke value calculated during the

autotune

(stationary) is too small (the min value is
1V)

Check the motor data is correct, especially nameplate
rpm, rated amps and motor volts.

ALL TESTS DISABLED

All auto tune tests are disabled

Check parameter 0257: Autotune Test Disable

Trips & Fault Finding

10-13

Other Alerts

Alert message

Possible Cause

Remedy

** ALERT **

DEFAULTS LOADED

First power up with new control module

Initialise all parameters using the GKP setup wizard or
PDQ

** ALERT **

APPLICATION MISSING

Fault during application download.
Application deleted by the drive

Re-install the application from PDQ or PDD
Custom applications only: check the application for any
delays or loops that may cause the application task to
“hang”.

** ALERT **

POWER STACK MISMATCH

Parameter 0987 “Power Stack Required”
does not equal the ID of the stack.

Change “Power Stack Required” to match “Power Stack
Fitted”. After doing this it may be necessary to restore
parameters to default and reconfigure the drive. This is
to ensure that all parameters have appropriate values.

** ALERT **

APPLICATION DELETED

Application deleted by the drive

Custom applications only: check the application for any
delays or loops that may cause the application task to
“hang”.

** ALERT **

FIRE MODE

Fire Mode has been activated

If this message is not expected, use PDD to check if the
Fire Mode block is in the configuration.

COAST TO STOP

Attempting to start the drive in local
mode with Coast To Stop active.

The Coast To Stop input is active low. This input needs
to be driven high.
The input may be ignored in the standard application
by setting “Disable Coast Stop”.

ENABLE VOLTAGE

Attempting to start the drive in local
mode with the Enable input is inactive

The Enable input needs to be driven high. This is done
in the default application.

QUICKSTOP ACTIVE

Attempting to start the drive in local
mode with Quick Stop active.

The Quick Stop input is active low. This input needs to
be driven high.
The input may be ignored in the standard application
by setting “Disable Quick Stop”.

OPERATION ENABLED

Attempting to change from Local control
to Remote control with the Run signal
true

To change to Remote control, (terminals), ensure that
the Run input is false.

MAX SPD GT ATN SPD

Parameter 0464 “100% Speed in RPM”
has been increased since auto-tune.

Check the value of “100% Speed in RPM”.
It may be necessary to repeat the auto tune with the
higher value of max speed.

10-14

Trips & Fault Finding

Alert message

Possible Cause

Remedy

** ALERT **

UNKNOWN STACK

The stack is understood by the firmware

Upgraded the drive firmware.

** ALERT **

APPLICATION LOAD FAILED

Fault during application download.
Application deleted by the drive

Re-install the application from PDQ or PDD
Custom applications only: check the application for any
delays or loops that may cause the application task to
“hang”.

COMMS OPTION

HARDWARE MISMATCH

Parameter 0044 “Comms Required” is
not compatible with the fitted
communications option

Fit the correct communications option.
Change the application to be compatible with the
fitted option, (setting “Comms Required” to NONE will
avoid this alert).

COMMS OPTION

CONFIGURATION ERROR

The configuration settings are not
compatible with the selected option

Refer to the communications option manual,
“Troubleshooting”.

IO OPTION

HARDWARE MISMATCH

Parameter 1178 “Option IO Required” is
not compatible with the fitted IO option

Fit the correct IO option.
Change the application to be compatible with the
fitted option, (setting “Option IO Required” to NONE
will avoid this alert).

** ALERT **

FEEDBACK MISSING

Attempt to run in Encoder Feedback
control mode with no feedback device
fitted, (or configured).

Change the control mode to VHz or Sensorless
Fit the correct feedback option
Check parameter 1178 “Option IO Required”

** ALERT **

IO OPTION CHANGED

The IO Option has been changed.

IO Option removed, IO Option attached or different IO
Option fitted. This alert is for information only and
occurs just once following the change.

** ALERT **

COMMS OPTION CHANGED

The Communications Option has been
changed.

Comms Option removed, Comms Option attached or
different Comms Option fitted. This alert is for
information only and occurs just once following the
change.

** ALERT **

UPDATING LANGUAGE

Updating the translations held in the
GKP. This may happen the first time a
language is selected.

No action required. The language update should
complete within one minute.

PCR NOT CLOSED

The pre-charge relay is not closed,
(probably due to low DC Link volts)

Check the 3-phase input or common supply.

SYSTEM BOARD

HARDWARE MISMATCH

Parameter 1739 “System Board
Required” not correctly set.

This indicates that the drive has never been
commissioned. It is advised to reset all parameters to
their default values.

10-16

Trips & Fault Finding

Fault Finding

Problem

Possible Cause

Remedy

Drive will not power-up

Fuse blown

Check supply details, fit correct fuse.
Check Product Code against Model No.

Faulty cabling

Check all connections are correct/secure.
Check cable continuity

Drive fuse keeps blowing

Faulty cabling or connections wrong

Check for problem and rectify before replacing with
correct fuse

Faulty drive

Contact Parker

Cannot obtain power-on state

Incorrect or no supply available

Check supply details

Motor will not run at switch-on Motor jammed

Stop the drive and clear the jam
Safe Torque Off circuit active. Check the STO
connections then power the drive off and on to clear
any latched STO fault.

Motor runs and stops

Motor becomes jammed

Stop the drive and clear the jam

Open circuit speed reference
potentiometer

Check terminal

Trips & Fault Finding

10-17

Black Box Feature

The Black Box feature can be used to help find the source of a trip. Data is saved automatically whenever a trip occurs that causes the drive to
stop running. The data records the moments leading up to the trip and the state of the drive when the trip occurs. This may then be transferred to
an SD card for off line analysis.

BLACK BOX FILE FORMAT

When copied to an SD card, the black box feature creates one file for each trip event, or record. The files are called “blackbox_xxxx.csv” where
xxxx is replaced with a decimal number that is incremented automatically by the drive every time a trip occurs.
The data recorded in the lead up to the trip is:

•

Up to four user defined parameters

•

Output Current in phases U and V expressed as a percent of motor rating

•

The rotor electrical frequency in Hz.

•

The demanded electrical frequency in Hz

•

The DC Link volts, (parameter

0392 DC Link Voltage

)

•

The temperature of the control card PCB in centigrade, (parameter

0406 CM Temperature

)

•

The temperature of the heatsink in centigrade, (parameter

0407 Heatsink Temperature

)

•

The sequencing control word, (parameter

0644 Control Word

)

•

The sequencing status word, (parameter

0641 Status Word

)

•

The input and output digital signals on the stack, words 1 and 2.

•

The control card digital output and input latches.

•

Various digital inputs to the micro-controller.

•

Trip latch state

•

Motor sequencer state

•

Motor sequencer start and stop states.

•

Main sequencer state, (parameter

0678 Sequencing State

)

•

High current limit activity

•

Stall trip torque limit state

•

Stall trip current limit state

10-18

Trips & Fault Finding

The data recorded at the instant of the trip is output at the end of the file. This consists of:

•

Control module serial number, (parameter

0977 Control Module Serial

)

•

Time of the trip. This is either the control board age, or the time from the optional Real Time Clock if fitted.

•

State of all other trips, active or warning.

•

Count of total motor starts, (parameter

1732 Motor Start Count

)

•

Count of total times the 3-phase has been powered

•

For each trip, a count of the total times that trip has been activated.

•

A record of near trip events for Over Current, Over Voltage and Under Voltage.

•

The product code of the drive, expressed as a number in internal format.

•

The IO Option fitted, (parameter

1179 Option IO Fitted

)

•

The Communications Option fitted, (parameter

0045 Comms Fitted

)

•

The System board type, (parameter

1740 System Board Fitted

)

•

The motor control type, (parameter

0511 Motor Type or AFE

)

•

The control strategy, (parameter

0512 Control Stragegy

)

•

The control type, (parameter 1

533 Control Type

)

•

The firmware version

•

The version of CoDeSys used to create the application.

Trips & Fault Finding

10-19

Diagnostic LEDs

There are two diagnostic LEDs fitted next to the SD Card slot. The Health LED is on the left, closest to the connector for the GKP. The flash
period is 1s when the drive firmware is active and 2s in the Firmware Update mode

HEALTH LED

RUN LED

STOPPED

RUNNING

STOPPING, (NORMAL)

QUICKSTOPPING

FAULTED

INITIALISING

CONFIGURATION MODE

CONFIGURATION FAULT

FIRMWARE UPDATE – Idle

FIRMWARE UPDATE - Erasing firmware

FIRMWARE UPDATE – Writing firmware

11-1

Routine Maintenance & Repair

Chapter 11:

Routine Maintenance & Repair

Routine Maintenance

Periodically inspect the drive for build-up of dust or obstructions that may affect ventilation of the unit. Remove this using dry air.

Preventative Maintenance

FAN CASSETTE (FRAMES D – J ONLY)

The power stack cooling fan is designed to be field replaceable by a competent person. For preventative maintenance replace the fan cassette

every 5 years operation, or whenever the drive trips on ‘heatsink overtemperature’ under normal operation. Spare fan cassettes are available to

order from your local Parker sales office.

Fan Cassette Removal Instructions

1. Remove the two retaining screws and lift off fan guard.

2. Lift out the fan(s) and then disconnect wiring

before replacing with the new fan(s) assembly:

AC50 & Frame D - LA501683

Frame E - LA501684

Frame F - LA501683

Frame G - LA502287 (x 2)

Frame H – 2 types: 45kw LA502429 (x 2)

55kw–75kw LA502287 (x 2)

Frame J – LA502560 (x 3)

making sure the fan is correct way up.

3. Replace the fan guard and tighten the screws

to 1.3Nm.

Frame D, E

Frame F, G, H

Frame J

Routine Maintenance & Repair

11-2

DC LINK CAPACITORS

For preventative maintenance the DC link capacitors must be replaced every 10 years operation, or when the drive trips on ‘DC link ripple’ under

normal operating conditions. The unit must be returned to your local Parker sales office for replacement.

Repair

There are no user-serviceable components. Only Parker trained personnel are permitted to repair this product to maintain certifications, reliability

and quality levels.

MAKE NO ATTEMPT TO REPAIR THE UNIT - RETURN IT TO PARKER

SAVING YOUR APPLICATION DATA

In the event of a repair, application data will be saved whenever possible. However, we advise you to backup your application settings before

returning the unit.

RETURNING THE UNIT TO PARKER

Please have the following information available:



The model and serial number - see the unit’s rating label



Detailed information on the nature of the fault as well as a full description of the application and history. This is important to ensure

Parker can diagnose to root cause before return.

Contact your nearest please contact your local Parker Service Center to arrange return of the item and to be given a Authorisation To Return

(ATR) number. Use this as a reference on all paperwork you return with the faulty item. Pack and despatch the item in the original packing

materials; or at least an anti-static enclosure. Do not allow packaging chips to enter the unit. Please include the fault information described above.

12-1

Ethernet

To remove the cable first remove the GKP and
then insert a screwdriver to release the catch on
the Ethernet clip.

Ethernet LEDs

Activity Link

Chapter 12:

Ethernet

Communications to the inverter is via Ethernet on the Control Module. This allows access to:

•

The PDQ and PDD PC programming tools

•

The Modbus TCP server (see Appendix A - Modbus TCP)

•

The HTTP server (see section below)

•

Application access to the Ethernet including peer-to-peer communications

•

IEEE 1588v2 Precision Time Protocol

The Ethernet operates at 10/100 MHz, half/full duplex. Internet Protocol version 4 (IPv4) is supported.

The AC30P or AC30D has a built-in Ethernet switch with two external Ethernet ports allowing for daisy chaining of inverters.

Connecting to the Inverter

RECOMMENDED CABLE

CAT5e screened or CAT6 screened Ethernet cable is recommended.

AC30V

Insert the Ethernet cable as shown below on an AC30V. Connection is recommended via an Ethernet switch.

Parker Variable Speed Drive AC30 series. User’s Manual (2017) - page 11