Perfect Harmony GENIII/e Startup and Advanced Topics TROUBLESHOOTING AND MAINTENANCE

CHAPTER 7: TROUBLESHOOTING AND MAINTENANCE

7.1. Introduction
We have designed, built and tested the Perfect Harmony variable speed drive for long, trouble-free
service. However, periodic maintenance is required to keep the drive working reliably, to minimize
system down time, and to maintain safety.

DANGER—Electrical Hazard! Always switch off the main input power to the equipment before
attempting inspection or maintenance procedure.

Warning: Only qualified service personnel should maintain Perfect Harmony equipment and
systems.

This chapter is contains information that can be categorized as:

x Fault and Error troubleshooting (beginning)
x Supporting (technical) information (middle)
x Maintenance information (end).
The sections at the beginning of this chapter explain faults, how they are annunciated, fault messages,
fault logging, and troubleshooting techniques. The sections in the middle of this chapter provide
supporting information such as technical data, test point locations, and internal operations. Finally, the
sections at the end of this chapter provide maintenance information such as inspections, replacement
parts, etc. Review the section titles shown in the “In This Section” table above, then proceed to the
appropriate section to troubleshoot or maintain your drive as appropriate.

*
Note: Refer to Chapter 2: Hardware Components for locations and details of major hardware
components of the Perfect Harmony system.

7.2. Faults and Alarms

If a fault or alarm condition exists, it will be annunciated on the keypad. The Master Control software and
hardware sense faults and alarms and stored them within the fault logger. Faults are either detected via
direct hardware sensing or by software algorithm.
Cell faults are sensed by the cell control system logic located on the Cell Control Board (see Figure 7-2)
in each output power cell. Each power cell has its own sense circuitry (Refer to Chapter 6: Theory).
The Master Control software interprets the cell faults and displays them and logs them based on the 7
faulted cell and the specific fault within the cell.
Generally, all faults will immediately remove power from the motor and inhibit the drive from running.
Some faults that are user defined can be control the drive response via the system program. Alarms are
annunciated and logged but usually do not inhibit the drive from operation.
Refer to Table 7-1 for a determination of the drive response for the various fault and alarm conditions.
Table 7-1. Fault/Alarm Type and Drive Responses

Type Drive Responses

Fault All IGBT gate drives are inhibited.
Motor coasts to stop.
The fault is logged. Refer to the Fault Log Menu (6210).
The fault is displayed on the front panel.
The Keypad Fault LED is ON.

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Type Drive Responses

User Faults The motor either ramp stops or coast stops depending on the content of the System
Program.
The fault is logged. Refer to the Fault Log Menu (6210).
The fault is displayed on the front panel.
The Keypad Fault LED is ON.
Alarm Drive does not necessarily revert to the idle state via a coast or ramp stop unless
specifically required to by the system program.
The alarm is logged. Refer to the Fault Log Menu (6210).
The alarm is displayed on the front panel.
The Keypad Fault LED flashes.

The [FAULT RESET] key on the Keypad can be used to manually reset a fault. The drive must be
returned to the run condition by manual start or by forcing the RunRequest_I equal to “true” (refer to
Chapter 8: System Programming).
A fault can be reset automatically if enabled by the corresponding auto fault reset enable flag for the
specific fault, refer to Table 7-2. for a list of auto re-settable faults. If reset is successful, then drive will
return to the run state automatically only if the RunRequest_I is maintained at the value “true” (refer to
Chapter 8: System Programming). The [FAULT RESET] key of the Keypad can acknowledge alarms.

Table 7-2. Auto Re-settable faults

Back EMF Timeout Over speed fault

Encoder Loss Under load fault
Failed to magnetize Down transfer
IOC Up transfer
Keypad communication Loss of Signal 1-24
Line over voltage
Medium voltage low

7 Menu initialization
Motor over voltage
Output ground fault
Network 1 communication fault
Network 2 communication fault

7.3. Drive Faults and Alarms

The master control senses all drive faults and alarms, either from direct hardware or via software
algorithms. Use Table 7-3 to quickly locate major causes of fault conditions. The table also lists the type
of drive response, if it is a fault (F), alarm (A), or both (F/A), and whether it can be enabled or disabled
using the SOP program (SOP), or if it is permanently enabled (Fixed in software).

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Table 7-3. Drive Faults

Fault Display Type Enable Potential Causes and Possible Corrective Actions
Input Line Disturbance
Cause
Loss of input phase.
Action
Input Phase Loss A Fixed Check the input fuses and connection to verify
that the input phases are connected properly.
Using an Oscilloscope verify the presence of all
3 input voltages on test points VIA/TP1, VIB/TP2, VIC/TP3
of the System Interface board.
Cause
Estimated input ground voltage is greater than limit
set by the Ground Fault Limit (in the Drive Protection
Menu).
Input Ground A Fixed
Action
Using an Oscilloscope verify the symmetry of the 3
input voltages on test points (VIA/TP1, VIB/TP2,
VIC/TP3) of the System Interface board.
Cause
The drive-input RMS voltage is greater than 110% of
the drive rated input voltage.
Action
Using a voltmeter verify the input voltages on test
Line Over Voltage 1 A SOP points (VIA/TP1, VIB/TP2, VIC/TP3) of the System
Interface board are ~3.8V RMS. This is the expected
value for rated input voltage. Values greater than
~4.2v RMS will trigger over voltage conditions. Note:
This alarm can be caused by a transient condition,
and may not be present when the making the
measurements.
Cause
The drive-input RMS voltage is greater than 115% of 7
Line over voltage 2 A SOP the drive rated input voltage.
Action
Refer to Line over voltage 1 section above.
Cause
The drive-input RMS voltage is greater than 120% of
Line over voltage fault F Fixed the drive rated input voltage.
Action
Refer to Line over voltage 1 section above.

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
The drive-input RMS voltage is less than 90% of the
drive rated input voltage.
Action
Using a voltmeter verify the input voltages on test
Medium voltage low 1 A SOP points (VIA/TP1, VIB/TP2, VIC/TP3) of the System
Interface board are ~3.8V RMS. This is the expected
value for rated input voltage. Values less than ~3.4v
RMS (90% of rated) will trigger Medium voltage low
conditions. Note: This alarm can be caused by a
transient condition, and may not be present when
making the measurements.
Cause
The drive-input RMS voltage is less than 70% of the
Medium voltage low 2 A Fixed drive rated input voltage.
Action
Refer to Medium voltage low 1 section above.
Cause
The drive-input RMS voltage is less than 55% of the
Medium voltage low Flt F Fixed drive rated input voltage.
Action
Refer to Medium voltage low 1 section above.
Cause
(1) Possible fault on the secondary side of the
transformer, or (2) inrush current is too high and
creating a nuisance fault.
Input One Cycle (or
excessive input reactive F/A Fixed Action
current) (1) Remove medium voltage and visually inspect all
the cells and their connections to the transformer
secondary; contact ASI Robicon for field support, (2)
Reduce the 1 Cyc Protect integ gain (7080) and the 1
Cycle Protect Limit (7081) to avoid nuisance trips.
7 Cause
Drive input (line) current imbalance is greater than the
setting in the Phase Imbalance Limit parameter (in
Drive Protection Menu).
Input Phase Imbal SOP Fixed
Action
Verify proper symmetry of the input voltages and
currents on test points VIA/TP1, VIB/TP2, VIC/TP3, IIB/TP12
and IIC/TP13.
Motor/Output Related

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
The motor speed is greater than 95% of the
Overspeed parameter setting (1170) in the Limits
Menu (1120). An improperly set-up or mistuned drive
usually causes this fault.
Over Speed Alarm A SOP
Action
Verify that the motor and drive nameplate settings
match the corresponding parameters in Motor
Parameter Menu (1000) and Drive Parameter Menu
(2000).
Cause
The motor speed exceeds the Overspeed setting
(1170) parameter in the Limits Menu (1120). An
improperly set-up or mistuned drive usually causes
this fault.
Action
Over Speed Fault F Fixed Verify that the motor and drive nameplate settings
match the corresponding parameters in Motor
Parameter Menu (1000) and Drive Parameter Menu
(2000).

Cause
This fault is caused (due to an output ground fault
condition) when the estimated ground voltage
exceeds the Ground Fault Limit parameter (1245) in
the Motor Limits Menu.
Action
Output Ground Fault A Fixed Verify proper symmetry of voltages on test points
VMA/TP5, VMB/TP6, and VMC/TP7.

If voltages are not a problem, check the divider

resistors in the Motor Sense Unit or replace the 7
System Interface Board.
Disconnect the motor from the VFD. Use a Meger to
verify motor and cable insulation.

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
The software has detected an encoder signal loss
due to a faulty encoder or faulty encoder interface.
Action
Verify that the information in the Encoder menu
(1280) is correct for the encoder being used. Run the
Encoder loss Menu Menu drive in Open Loop Vector Control mode (select
OLVC in the Control loop type, ID 2050) of the Drive
parameter menu (2000). Go to Meter Menu (8); select
Display Parameters Menu (8000) and set one of the
display parameters (8001-8004) to ERPM or %ESP
and observe if ERPM follows motor speed (also refer
to Section 5.*).
Cause
Motor temperature (or motor current, depending on
choice of overload method) above Overload pending
setting.
Mtr Therm Over Load 1 A SOP Action
Verify if the Overload pending parameter (1139) is set
correctly. Check load conditions and, if applicable,
verify that the speed derate curve (submenu 1151)
matches the load conditions
Cause
Motor temperature (or motor current, depending on
choice of overload method) above Overload setting.
Mtr Therm Over Load 2 A SOP Action
Check if the Overload parameter (1140) is set
correctly. Refer to Mtr Therm Over Load 1 section
above.
Cause
Motor temperature (or motor current, depending on
choice of overload method) has exceeded the
Overload setting for the time specified by the
Mtr Therm Over Ld Fault F Fixed Overload timeout parameter.
Action
7
Check if the Overload timeout parameter (1150) is set
correctly. Refer to Mtr Therm Over Load 1 section
above.
Cause
If motor voltage exceeds 90% of the Motor over
voltage limit in the Motor limit menu
Motor Over Volt Alarm A SOP
Action
Check menu settings for correct motor rating, and
limit setting.

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
The measured motor voltage exceeds the threshold
set by the Motor trip volts (1160) parameter in the
Limits Menu (1120). An improperly set-up or tuned
drive usually causes this fault.
Actions
Verify that the motor and drive nameplate settings
Motor Over Volt Fault F Fixed match the corresponding parameters in Motor
Parameter Menu (1000) and Drive Parameter Menu
(2000).
Verify that the signals on the VMA/TP5, VMB/TP6, and
VMC/TP7 test points on the System Interface Board are
operating properly with in +/-6V. If an incorrect
voltage is noted, check the voltage divider in the
Motor Sense Unit or replace the System Interface
Board.
Cause
Drive instantaneous over-current (IOC) faults usually
result when the signal from test point IOC on the System
Interface Board exceeds the level set by the Drive IOC
setpoint (7110) parameter in the Input Protect
Menu (7000).
Actions
Verify that the motor current rating (1050)is below the
IOC F Fixed
Drive IOC setpoint (7110) in the Drive Protect Menu
(7). Check if the output current scaler (3440) is set to
a number that is close to 1.0.
Verify that the signals on test points IMB and IMC on
the System Interface Board match the percentage of
full-scale signals.
Perform the tests listed in Section 5.5 to verify the
operation of hall effect transducers.
Cause
The torque producing current of the drive has 7
dropped below a preset value set by the user.
Under Load Alarm A SOP Actions
This alarm usually indicates a loss of load condition.
If this not the case verify the settings in I underload
menu (1182) within the Limits menu (1120).
Cause
This fault usually indicates a loss of load condition
when the torque producing current of the drive has
dropped below a preset value set by the user for the
specified amount of time.
Under Load Fault F Menu
Actions
If this not an unexpected condition then verify the
setting of the I underload (1182) and the Under Load
Timeout (1186) parameters within the Limits Menu
(1120).

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
The software has detected an imbalance in the motor
currents.
Action
Output Phase Imbal A Fixed Verify proper symmetry of the motor currents on test
points VMA/TP5, VMB/TP6, VMC/TP7, IMA/TP21, IMB/TP22,
and IMC/TP23. If the currents are unsymmetrical, verify
if the burden resistors for the Hall Effect Transducers
are connected correctly on the Signal Conditioning
board.
Cause
The software has detected an open phase condition
at the drive output to the motor.
Output Phase Open A SOP Action
Verify all connections to the motor are secure.
Verify the presence of motor voltages and currents on
test points VMA/TP5, VMB/TP6, VMC/TP7, IMA/TP21,
IMB/TP22, and IMC/TP23 during drive operation.
Cause
This alarm is issued when the drive is in speed
rollback (due to a torque limit condition) for more than
In Torque Limit A SOP one minute.
Action
Check load conditions. Check proper settings for
drive and motor ratings.
Cause
This fault or alarm (depending on the SOP program)
is issued when the drive is in speed rollback (due to a
torque limit condition) for more than thirty minutes.
In Torq Limit Rollback SOP SOP Action
Check load conditions. Check proper settings for
drive and motor ratings.
7

Cause
Motor speed is below the Zero speed setting (2200).
This is either due to a motor stall condition (if speed
demand is higher than the Zero speed setting) or a
low speed demand condition (where speed demand is
Minimum Speed Trip F/A SOP lower than the Zero speed setting).
Action
Increase motor torque limit (ID 1190, 1210 or 1230) if
it is a stall condition or adjust the Zero speed setting
to avoid the desired low speed operating region.

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
This occurs only with synchronous motor control due
to field exciter failure or loss of power to the exciter.
Action

Loss of Field Current F/A SOP Check if the power supply to the exciter is energized
To determine if the field exciter is operating correctly,
reduce Flux demand (3150) to 0.40, increase Accel
time 1 (2260) to a larger value and run the motor with
5% speed demand. If the drive magnetizing current
reference (Idsref) does not go to zero, then the field
exciter is not working (or is not adjusted) properly.
Cause
This occurs only with induction motors due to high
magnetizing current (or poor power factor).
Action
Failed to magnetize F/A SOP
Increase the flux ramp time to give more time for
magnetizing current to settle down at startup. Verify if
motor stator resistance parameter (1060) is not set
too high for the application; reduce it if continuous
operation at very low speed is not desired.
System Related
Cause
Estimated drive losses are too high, due to (1) internal
problem in the cells, or (2) scaling error in voltage and
current measurement on input and output side.
Action
Excessive Drive Losses SOP Fixed Remove medium voltage and visually inspect all
the cells and their connections to the transformer
secondary. Contact ASI Robicon for support.
With the drive operating above 25% power, verify
if estimated drive efficiency is above 95%. If this is not
the case, then voltage and current scaling needs to
be checked.
7
Cause
The software detected a menu entry for Carrier
Frequency Menu (3580) was below the lowest
possible setting based on the system information.
Action
Carrier Frq Set Too Low A Fixed
Change the value enter in Carrier Frequency
Menu (3580).
Check the value of the Installed Cells/phase
Menu (2530).
Consult factory.

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
The software detected an error in the system program
file.
System Program F Fixed
Actions
x Reload system program.
x Consult factory.
Cause
The software detected an error in one of the files
Menu Initialization F Fixed stored on the CPU board Compact FLASH disk.
Action
Consult factory.
Occurs if system not able to write a master or slave
Config File Write Alarm A Fixed
config file.
Occurs if system not able to read data from a master
Config File Read Error F Fixed
of slave config file.
Cause
CPU Temperature is > 70 C.
CPU Temperature Alarm A Fixes Action
x Check air flow and chassis fans.
x Check CPU heatsink.
Cause
CPU Temperature is > 85 C.
CPU Temperature Fault F SOP Action
x Check air flow and chassis fans.
x Check CPU heatsink.
Cause
A/D board indicated a hardware error
A/D Hardware Alarm A Fixed
Action
Replace A/D board
Cause
A/D board hardware error persists for more than 10
A/D Hardware Fault F Fixed samples.
Action
Replace A/D board
Modulator related
7 Cause
Modulator Configuration F Fixed The software detected a problem when attempting to
initialize the Modulator.
Action Replace Modulator board.
Cause
The software detected a Modulator board fault.
Modulator Board Fault F Fixed
Action
Replace Modulator board.
Cause
Cell Fault/Modulator F Fixed Modulator has an undefined fault from a cell.
Action
Check cell, modulator board

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
Cell data packet mode bits incorrect.
Bad Cell Data F Fixed
Action
Check cell control board
Cause
Modulator Cell configuration does not agree with
Menu setting of Installed cells.
Cell Config. Fault F Fixed
Action
Insure correct number of cells are entered into menu
setting. Check modulator board
Cause
Modulator detected that the CPU stop communicating
Modulator Watchdog Flt F Fixed with it.
Action
Reset drive control power
Cause
Modulator detected loss of drive enable.
Loss of Drive Enable F SOP
Action
Reset drive control power.
Cause
The software detected a weak battery on the
Modulator board. This battery is used to power the
Weak Battery A Fixed memory for the fault and historical logger.
Actions
x Replace battery on Modulator board.
x Replace Modulator board.
x Consult factory.
Low Voltage Power Supply Related
Cause
One or both of the supplies that power the Hall Effects
on the drive output has failed.
Actions
Verify +/-15V on the Hall Effect Power supplies.
Hall Effect Pwr Supply F Fixed Verify +/-15V on the System Interface Board
Connector P4 pins 31 and 32. If +/-15V is not present,
check wiring from Hall Effect Power Supplies to the
System Interface Board.
7
If these signals are incorrect, replace the System
Interface Board.
Cause
The chassis power supply has indicated a loss of
power. This can either be due to loss of AC or a failed
Power Supply F Fixed power supply.
Action
Verify control power outputs
System I/O Related

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
The software detected a Loss of Signal on one of the
0-20mA inputs (1 through 24).
Menu/ Actions
Loss of Signal (1-24) A
SOP Check connection to the Wago 0-20mA input
corresponding to the Loss of signal message.
Replace effected Wago module.
Consult factory.
Cause
The software was unable to establish or maintain
communication with the Wago I/O system. The fault
is triggered when the lack of communication exceeds
timeout.
Actions
Wago Communication Alarm A Fixed
x Verify that the cable between the CPU board and
Wago Communication Alarm module is connected
properly.
x Replace Wago Communication Alarm module.
x Replace the CPU board.
x Consult factory.
Cause
The software was unable to establish or maintain
communication with the Wago I/O system. The fault
is triggered when the lack of communication exceeds
timeout.
Actions
Wago Communication Fault F SOP
x Verify that the cable between the CPU board and
Wago Communication alarm module is connected
properly.
x Replace Wago Communication Alarm module.
x Replace the CPU board.
x Consult factory.
Cause
Number of Wago modules does not equal number set
in menu
Wago configuration F Fixed
7 Action
Insure correct number of Wago modules are set in the
menu. Check Wago modules.
External Serial Communications Related
Cause
Tool is not communicating to drive
Tool communication SOP SOP Action
Check PC connecting cable, CPU BIOS settings, and
correct TCP/IP address agrees in Tool and Drive.
Cause
Keypad is not communicating to drive
Keypad Communication SOP SOP
Action
Check keypad cable, connections.

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
The drive is not communicating with the active
external network.
Actions
x Verify all network connections are secure.
Network 1 Communication SOP SOP
x Verify that the UCS board #1 and
Communications board are properly seated. If the
source of the problem is not found, then replace
the UCS board #1 and then the Communications
board.
Cause
The drive is not communicating with the active
external network.
Actions
Network 2 Communication SOP SOP x Verify all network connections are secure.
x Verify that the UCS board #2 and
Communications board are properly seated. If the
source of the problem is not found, then replace
the UCS board #2 and then the Communications
board.
Synch Transfer Related
Cause
Time-out has occurred from request to up synch
transfer.
Up Transfer Failed A SOP
Action
Increase menu setting, or set to zero to disable time
out.
Cause
Time-out has occurred from request to down synch
transfer.
Down Transfer Failed A SOP
Action
Increase menu setting, or set to zero to disable time
out.
Cause
Sign of input frequency and operating frequency are
Phase Sequence SOP SOP
opposite. 7
Action
Swap one pair of motor leads and change sign of
speed command
User Defined Faults
Cause
The UserFault_1 through UserFault_64 flags in the
system program have been set to the value “true”.
User Defined Fault (64) SOP SOP
Refer to Chapter 8: System Programming.
Action
Refer to the section on User Faults (on page 7-26).
Cooling Related
One Blower Not Avail A SOP See description for system program user faults above
All Blowers Not Avail F/A SOP See description for system program user faults above.
Clogged Filters SOP SOP See description for system program user faults above
One Pump Not Available A SOP See description for system program user faults above

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Both Pumps Not Available F/A SOP See description for system program user faults above
Coolant Cond > 3 uS A SOP See description for system program user faults above
Coolant Cond > 5 uS F/A SOP See description for system program user faults above
Coolant Inlet Temp > 60° C SOP SOP See description for system program user faults above
Coolant Inlet Temp < 22° C SOP SOP See description for system program user faults above
Cell Water Temp High SOP SOP See description for system program user faults above
Coolant Tank Level < 30° C A SOP See description for system program user faults above
Coolant Tank Level < 20° C F/A SOP See description for system program user faults above
Low Coolant Flow < 60% A SOP See description for system program user faults above
Low Coolant Flow < 20% F SOP See description for system program user faults above
Loss One HEX Fan A SOP See description for system program user faults above
Loss All HEX Fans SOP SOP See description for system program user faults above
All HEX Fans On A SOP See description for system program user faults above
Input Transformer Temperature Related
Xformer OT Alarm A SOP See description for system program user faults above
Xformer OT Trip Alarm A SOP See description for system program user faults above
Xformer OT Fault F/A SOP See description for system program user faults above
Xfrm Cool OT Trip Alarm SOP SOP See description for system program user faults above
Input Reactor Temperature Related
Cause
Programmable via the System Program
Reactor OT Alarm A SOP
Action
Check output current waveform for sinusoidal shape.
Cause
Programmable via the System Program
Reactor OT Trip Alarm A SOP
Action
Check output current waveform for sinusoidal shape.
Cause
Programmable via the System Program
Reactor OT Fault F/A SOP
Action
Check output current waveform for sinusoidal shape.
Cell Bypass Related
Cause
7 The Master Control system is not communicating with
the MV Bypass board.
Action
Cell Bypass Com Fail F Fixed
Verify the Fiber Optic connection between the
Modulator board and MV Bypass board is intact.
Replace Modulator board.
Replace MV Bypass board.
Cause
The Master Control issued a command to bypass a
cell, but the MV bypass board did not return an
Cell Bypass Acknowledge F Fixed acknowledgement.
Action
Verify that the bypass contactor is working properly.
Check wiring between MV bypass board an contactor.
Replace MV bypass board or Contactor.

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
The Master Control system is not
communicating with the MV Bypass board.
Cell Bypass Link F Fixed
Action
Refer to “Cell Bypass COM Fail” above.
Cause
The Master Control system is not communicating with
Cell Bypass COM Alarm A Fixed the MV Bypass board, but the bypass system is not in
use.
Action
Refer to “Cell Bypass COM Fail” above.
Cause
The Master Control system is not communicating with
Cell Bypass Link Alarm A Fixed the MV Bypass board, but the bypass system is not in
use.
Action
Refer to “Cell Bypass COM Fail” above.
Cause
The Master Control system is not communicating with
Cell Bypass Fault F Fixed the MV Bypass board.
Action
Refer to “Cell Bypass COM Fail” above.
Cause
xx Bypass Verify Failed F Fixed Bypass contactor closure verify failed
xx=cell that is faulted
Action
Check bypass system
Cause
xx Bypass Ack Failed Bypass contactor closure acknowledge failed
F Fixed
xx=cell that is faulted Action
Check bypass system
Cause
Cell level bypass available alarm. Only if
xx Bypass Avail Warning
xx=cell that is faulted
A Fixed bypass is not used 7
Action
Check bypass system
Cell Related
Cause
The software detected a difference in the number
of cells detected versus the Installed Cells/phase
Menu (2530).
Action
Cell Count Mismatch F Fixed x Verify that the Installed Cells/phase Menu (2530)
matches the actual number of cells in the system.
x Verify all fiber optic cable connections are correct.
x Replace Modulator board.
x Replace Fiber Optic board(s).

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
The software timed out waiting for the Motor Back
Back EMF Timeout F Fixed EMF Voltage to decay to a safe level for cell device
testing.

VI VI VI A V V V V A AI A IIB IIC A IF IF IF A IO A IM IM IM A
A B C G M M M O G G G A B C G C G A B C G
N A B C N N N N N N N

7 15-pin Ribbon 37 Pin D-shell

to Modulator 50-pin Ribbon
to A/D Board to External
Board Conditioning
Board
Figure 7-1. Connections and Test Points on the System Interface Board

7.4. Cell Faults/Alarms

Cell faults/alarms are logged by the Microprocessor Board following a power cell fault indication. These
faults are available for inspection through the keypad display or can be uploaded to a PC via the serial
port. All active cell faults/Alarms are displayed on the keypad display. Use the arrow keys to scroll up and
down through the faults. The Alarm/Fault log upload function (Parameter ID 6230) in the Alarm/Fault Log
Menu (6210) can be used to upload the log to a PC for analysis and for sending to the appropriate ASI
Robicon or plant personnel.
All cell faults are generated by circuitry located on the Cell Control Board (CCB) of each power cell and
are received by the Microprocessor Board through circuitry on the Digital Modulator Board. Table 7-4

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can be used as a quick troubleshooting guide to locate the cause of the fault condition. This table lists
faults that may occur in multiple-cabinet and GEN III and GENIIIe styles of Perfect Harmony drives unless
otherwise noted. All cell faults are initiated by the Cell Control Board or CCB (see Figure 7-2) located in
each power cell.

Not Safe
PL1-4 PL1-7 PL1-5 PL1-2
PL1-8 PL1-6 PL1-3 PL1-1

PL1

VAVAIL
VT1
XMTR1
VT2 RCVR1
VAUX VDC V- V+
PL1-12 LNKON
+10VREF / Q1
+5V
PL1-11 / Q2
-15V
+15V / Q3
+24V / Q4
IC27 / BYP
COM1
COM1 FLT

PL2 PL3

Figure 7-2. Connectors and Diagnostic Components of a Model 430 Cell Control Board

Note:
x Model 430 Cell Control Boards are only used in the multiple-cabinet versions of Perfect Harmony
drives (not GEN III or GENIIIe). Cell Control Boards for GEN III and GENIIIe drives use a single
board which contains all control, power supplies and gate drive and is different from the board
depicted in Figure 7-2.
*
x If a spare Cell Control Board is ordered for a drive that contains a model 430 board, a model N15
board will be shipped with an adapter harness for proper connection.

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Table 7-4. Cell Faults

Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
One or more of the input power fuses to a cell are
open.
Power Fuse Blown F Fixed
Action
Determine the reason for the fuse failure then repair
(if required) and replace the fuse.
Cause
Cell temperature above fault limit (fixed)
xx Over Temp Warning
F SOP Action
xx=cell that is faulted
Check condition of the cooling system. Check motor
load conditions.
Cause
Each cell sends a PWM signal to the Modulator
Board. This signal represents the heat sink
Over Temperature temperature.
F Fixed
Action
Check the condition of the cooling system.
Refer to Section 7.4.1:on page 7-24.
Cause
One or more of the local power supplies (+24, +15,
+5, or -5 VDC) on a Cell Control Board (see
Figure 7-2) has been detected to be out of
Control Power F Fixed specification.
Action
If this occurs, the Cell Control Board should be
repaired or replaced. Refer to Section 7.4.1 on page
7 7-24.
Cause
Each Gate Driver Board includes circuits which verify
that each IGBT has fully turned on. This fault may
indicate a shorted IGBT, an open IGBT, or a failure in
the detection circuitry (i.e., logic low signals on
IGBT OOS n opto-couplers IC12, IC22, IC32, and IC42 pin 7 on Gate
F Fixed Drive Board usually as a result of a Q1, Q2, Q3, or Q4
(n=1,2,3,4)
collector-to-emitter short in the cell’s power bridge).
The cell’s power components and Gate Driver Board
should be checked.
Action
Refer to Section 7.4.1 on page 7-24.

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
A capacitor share fault usually indicates that the
voltage shared by the two DC link capacitors is not
being shared equally (i.e., the voltage on an individual
Cap Share F Fixed capacitor in a cell has been detected over 425 VDC).
This can be caused by a broken bleeder resistor (or
wire) or a failed DC link capacitor (C1 and/or C2).
Action
Refer to Section 7.4.1 on page 7-24.
Cause
xx Link Cell communication link failure
F Fixed
xx=cell that is faulted Action
Check fiber optic cable. Cell may need serviced.
Cause
An error in the optical communications was detected
by a cell (i.e., a logic low signal is detected on pin 13
of IC37). This is usually a parity error caused by
Communication F Fixed noise, but can also be a time-out error caused by a
faulty communications channel on the Cell Control
Board (see Figure 7-2).
Action
Refer to Section 7.4.4: on page 7-25.
Cause
xx Control Fuse Blown Cell control power fuse blown
F Fixed
xx=cell that is faulted Action
Check cell fuses, replace if necessary.
xx DC Bus Low Warning Cause
xx=cell that is faulted Cell DC bus below alarm level
A Fixed Action
Check for single phase input, low input line
7
conditions, blown input fuses.
Cause
Cell DC bus below fault level
Cell DC Bus Low F Fixed Action
Check for single phase input, low input line
conditions, blown input fuses.

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Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
The bus voltage in a cell has been detected over
800 VDC (for 460VAC cells) or 1200VDC (for
690VAC cells) (i.e., the signal on the VDC test point is
DC Bus Over Volt F Fixed >8.0 VDC). This is usually caused by a regeneration
limit that is too high, or improper tuning of the drive.
Action
Refer to Section 7.4.3: on page 7-25.
Cause
The DC bus voltage detected in a cell is abnormally
low (the signal on test point VDC on the Cell Control
Board is <3.5 VDC). Refer to Figure 7-2. If this
DC Bus Under Volt F Fixed symptom is reported by more than one cell, it is
usually caused by a low primary voltage on the main
transformer T1.
Action
Refer to Section 7.4.1 on page 7-24.

*
Note: Fault class designations in the previous table are shown in parentheses and are explained
in Figure 7-2 on page 7-17.

The following cell faults will occur only during the cell diagnostic mode (immediately following initialization
or reset). All IGBTs in each cell are sequentially gated and checked for proper operation (blocking/not
blocking). See Table 7-5.
Table 7-5. Diagnostic Cell Faults

Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
During cell diagnostic mode, the Perfect Harmony
checks the voltage across each IGBT under “gate off”
conditions. A blocking failure is reported if insufficient
voltage is detected, i.e., voltages on test points VT1
7 Blocking Qn
F Fixed and VT2 on the Cell Control Board (see Figure 7-2)
(n = 1,2,3,4) are < ±0.5 VDC when power transistors Q1-Q4 are
gated. This may indicate a damaged IGBT, or a
malfunctioning gate driver board or cell control board.
Action
Refer to Section 7.4.1 on page 7-24.

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Perfect Harmony GENIII/e Startup and Advanced Topics TROUBLESHOOTING AND MAINTENANCE

Fault Display Type Enable Potential Causes and Possible Corrective Actions
Cause
During cell diagnostic mode, the Perfect Harmony
turns each IGBT on one-by-one, and verifies the
collapse of voltage across the devices. A switching
failure is reported if a device is supporting voltage
Switching Qn while it is gated on (i.e., voltages on test points VT1
F Fixed and VT2 on the Cell Control Board are > ±0.5 VDC
(n = 1,2,3,4)
when power transistors Q1-Q4 are gated). Usually,
this fault is caused by a malfunctioning gate driver
board, IGBT, or cell control board.
Action
Refer to Section 7.4.1 on page 7-24.
xx Blocking Timeout Cause
xx=cell that is faulted Blocking Test timeout
F Fixed
Action
Check cell, or back EMF too high
xx Switching Timeout Cause
xx=cell that is faulted Switching Test timeout
F Fixed
Action
Check cell, or back EMF too high

*
Note: Fault class designations in the previous table are shown in parentheses and are explained in
Figure 7-2 on page 7-17.

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Output
To Power
Bypass
Board
T2’ T1’

NOTE: Each semiconductor is

Optional Bypass shown as one device for
Contactor simplicity, but may actually be
several parallel devices.

T2 T1

Q3
Q4

Ribbon Cable

PL1 PL2
Q1 F10 Q2

Fiber Optic
Data Link

IGBT Gate
Driver

Cell Control
Board

S2
TAS2B

TAS2A

7 PL1
C1 C2
3
DDC 12
11

DDB 2
10
1
DDA 8

4
F12 F13
F11 F3
7

F2 6
Input Power 5
from T1 F1

Figure 7-3. Typical Power Cell with Optional Mechanical Bypass

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Fuses mounted
external to cell
on GENIIIe Cells

Figure 7-4. Typical Power Cell Schematic (GEN III and GENIIIe Design)

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9 Cells 12 Cells 15 Cells 18 Cells

Cell Cell Cell Cell Cell Cell

A1 A2 A3 A4 A5 A6

Cell Cell Cell Cell Cell Cell

B1 B2 B3 B4 B5 B6

Cell Cell Cell Cell Cell Cell

C1 C2 C3 C4 C5 C6

Future Expansion

A1 B1 C1 A2 B2 C2 A3 B3 C3 A4 B4 C4
A5 B5 C5 A6 B6 C6
Fiber Optic Interface Board
Fiber Optic Interface Board

Fiber Optic Interface Boards in Control Chassis

Figure 7-5. Typical Fiber Optic Interface Boards Connection Diagram

7.4.1. Troubleshooting General Cell and Power Circuitry Faults

The types of faults addressed in this section include the following:
x AC fuse(s) blown faults
x control power faults
x device out of saturation (OOS) faults
x capacitor sharing faults
x Q1-Q4 OOS faults
x bypass failed faults
x VDC undervoltage faults
x blocking failure faults
x switching failure faults.

7.4.2. Troubleshooting Cell Over Temperature Faults

Water Cooled
7 Cell Over Temperature faults are typically caused by problems in the cooling system. Use the following
steps to troubleshoot this type of fault:
x Check the cooling system for proper flows and temperatures.
x Inspect cell cooling paths for kinked hoses or major leaks.
x Be sure all Cell Cabinet manifold valves are fully open.

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Perfect Harmony GENIII/e Startup and Advanced Topics TROUBLESHOOTING AND MAINTENANCE

7.4.3. Troubleshooting Overvoltage Faults

This fault is usually caused by an improperly set-up or tuned drive. Use the following steps to
troubleshoot this type of fault.
x Verify that the motor and drive nameplate settings match parameters in the Motor Parameter Menu
(1000) and Drive Parameter Menu (2000).
x Reduce the regen torque limit parameters (1200, 1220, 1240) in the Limits Menu (1120).
x Reduce Flux Regulator Proportional Gain (3110) and Flux Regulator Integral Gain (3120) parameters
in the Flux Control Menu (3100).
x If the failure is occurring in bypass mode, increase the Energy Saver Minimum Flux (3170) parameter
in the Flux Control Menu (3100) to at least 50%.
x If the measured signals (from the previous section) seem to be correct, change the Modulator board.
7.4.4. Troubleshooting Cell Communications and Link Faults
Faults of this variety can be the result of circuit failures on either the Digital Modulator Board or Cell
Control Board (see Figure 7-2).
x If the fault indication persists after replacing the Digital Modulator Board, see Section 7.4.1 above.
7.4.5. Status Indicator Summaries for MV Mechanical Bypass Boards
The MV Mechanical Bypass Board includes 3 LEDs that provide complete status of the MV board. These
LEDs are summarized in the following table.
Table 7-6. LED Status Indicators for MV Mechanical Bypass Boards

LED Function Color Description

CommOK green Indicates active communication link established with LV board.
Fault red Indicates that a bypass fault is active.
PwrOK green This LED is hardware controlled and indicates that the 5/15VDC
supplies are in tolerance.

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7.5. User Faults

*
Attention! User faults are closely tied to the system program configuration. Refer to
Chapter 8: System Programming for more information.

User faults occur due to conditions defined in the system program. User faults are displayed on the
keypad in the form of user defined fault #n, where n equals 1 to 64. The faults can also be displayed
through user defined text strings. Most user-defined faults are written to respond to various signals from
the Wago I/O such as the analog input modules (through the use of comparators) as well as the digital
input modules.
A copy of the system program is required to specifically define the origin of the fault. In the example
program found in the Chapter 8: System Programming, the UserFault_1 flag is used to display the
event of a blower fault. Note that the UserText1 string pointer is used to display the specific fault
message. If this string pointer is not used, then the fault displayed would be “user defined fault #1”.
7.6. Unexpected Output Conditions
In some cases, the Perfect Harmony VFD will revert to operating conditions which limit the amount of
output current, output speed, or output voltage, but with no apparent fault condition displayed. The most
usual causes of these conditions are described in the subsections that follow.
The mode display shown in Table 7-7 can sometimes be used to troubleshoot the cause of the output
limitation. The first column of the table lists the abbreviated message that is shown on the display of the
drive. The second column lists the meaning of the abbreviated message. The third column lists
descriptions of the operating modes. Further descriptions of possible limit situations and troubleshooting
tips are listed in the subsections that follow.
Table 7-7. Summary of Operation Mode Displays

Display Meaning Description

CR3 CR3 Relay CR3 relay is not picked. The drive is inhibited (cr2_picked is not “true”).
Rgen Regeneration VFD is decreasing output speed due to a change in the speed
command.
Rlbk Rollback VFD is attempting to limit output speed due to torque output limitations.
Off Off Indicates that the VFD is in idle state A.
7 Hand Hand Normal operating mode while drive is running motor. Usually indicates
that operation is controlled from the front cabinet.

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7.6.1. Output Speed Limit

If the mode display shows Rlbk (rollback mode), then the Perfect Harmony VFD is attempting to reduce
the output speed due to a torque limit condition. Use the following steps to troubleshoot this type of fault.
x Check the motor torque limit (1190, 1210, 1230) parameters in the Limits Menu (1120).
x Check all motor and drive nameplate ratings against parameters set in the Motor Parameter Menu
(1000) and the Drive Parameter Menu (2000).

*
Note: Spare parts are available through our Customer Service Center by calling (724)-339-9501.

7.7. Drive Input Protection

This section describes the routines used to detect abnormal conditions due to an internal drive failure and
thus provide protection to the drive. The faults generated by the routines may be used with suitable
interlocking, via a relay output and/or serial communication, to disconnect medium voltage from the drive
input.
7.7.1. One Cycle Protection (or Excessive Input Reactive Current Detection)
NXG Control utilizes input reactive current to determine whether a ‘hard’ fault on the secondary side of
the transformer has occurred. For example, a short-circuit in one of the secondary windings will result in
poor power factor on the high-voltage side of the transformer. A model of the transformer based on the
power factor at rated load (typically 0.95) is implemented in the control processor. The drive input
reactive current is continuously checked with the predicted value from the model. An alarm/trip is
generated if the actual reactive current exceeds the prediction by more than 10%. This check is avoided
during the first 0.25 seconds after medium voltage power-up to avoid the inrush current from causing
nuisance trips.
7.7.2. Excessive Drive Losses
The Excessive Drive Loss protection guards against low-level fault currents. Drive losses are calculated
as the difference between the measured input and output powers, and compared against reference
losses. For Liquid Cooled Drives, the reference losses are fixed at 3.5% during “Idle” State and at 5.5%
during “Run” State, while they are fixed at 5.0% and 7.0%, respectively, for Air Cooled Drives. When the
calculated losses exceed the reference losses, a drive trip is issued and this condition is annunciated as
an “Excessive Drive Loss Alarm”. In addition to this response, a digital output is set low in the System
Operating Program (SOP), which in the default drive configuration is used to open the input disconnect
device. The fixed reference limit is low enough to detect a fault in one set of transformer windings, and at
the same time is large enough to avoid nuisance trips. When the drive is not supplying power to the
motor, the losses in the system are primarily due to the transformer; the fixed limit is then lowered to 7
increase the sensitivity of the protection routine.
In earlier software versions up to version 2.22, the protection was such that when the calculated losses
exceeded the reference losses for more than one second, a trip was generated. For software versions
2.30 and higher, an inverse power loss function is implemented for Excessive Drive Loss protection. The
plots in Figure 7.6 show the time to trip as a function of calculated losses for Liquid and Air Cooled
Drives. Each plot contains two curves, one of which is used when the Drive is in “Idle” State (i.e. medium
voltage is applied, but the motor is not being operated) while the second curve (slightly longer time to trip)
is used during the “Run” State.

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Run State
Run State

Idle State
Idle State

Figure 7-6. Excessive Drive Loss Protection

7.7.3. Transformer Over-Temperature and Loss of Cooling

The temperatures of all the secondary windings are monitored using two (series-connected) sets of
(normally closed) thermal switches. The first set opens when the temperature exceeds 150qF (or 65qC)
while and the second set opens above 180qF (or 82qC). Two outputs, one output corresponding to each
set, are read through the WAGO by the control logic. A Xfrmr Temperature Alarm 1 is issued when one
or more 150qF switches open, and a Xfrmr Temperature Alarm 2 is issued when one or more 180qF
switches open. When both these conditions exist for 30 seconds, a Xfrmr Over Temp Fault is generated
that causes the drive to trip.
A vortex flow sensor monitors liquid coolant flow through the drive. This sensor is connected to a display
unit on the door of the Coolant Section, which displays flow rate, among other parameters, and outputs a
4-20 mA signal to the WAGO. A software comparator, interacting with the control logic, monitors this 4-
20 mA signal. As a standard default, the alarm "Loss of Coolant Flow" is issued whenever the detected
flow rate is below 40 percent of rated for 7 seconds.
The SOP program can be used to trip the input Medium Voltage Breaker when the conditions of Xfrmr
Temperature Alarm 1, Xfrmr Temperature Alarm 2, and Loss of Coolant Flow exist simultaneously.

7 7.8. Portable Harmony Cell Tester

ASI Robicon can supply the necessary equipment to perform on-site cell testing at a customer’s site.
This test is essentially a duplication of the cell test done at the factory prior to installation into the Cell
Cabinet. Since each cell operates independently within the Perfect Harmony system, it is possible to fully
test the performance of each cell and thus verify the proper performance of the cell system without having
to actually apply rated voltage to the motor.
The following equipment is required for on-site cell testing:
x Portable Harmony Cell Tester (PCT) (P/N 469939.00)
x IBM compatible computer (286 or greater with Centronics port and EGA capability)
x 480 VAC, 30 A variable auto transformer variable voltage source (STACO type 6020-3 or
equivalent)
x Load reactor (refer to Table 7-8).
x DVM capable of measuring 500 VAC (Beckman 3030A or equal).
x Clamp on ammeter (Beckman CT-232 or equal).

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Perfect Harmony GENIII/e Startup and Advanced Topics TROUBLESHOOTING AND MAINTENANCE

Table 7-8. Load Reactor Information

Cell Size Reactor P/N Reactor Configuration

NBH 70 161661.13 1 Unit with Series windings L=8mH
NBH100 161661.13 1 Unit with Series windings L=8mH
NBH 140 161661.13 1 Unit with Series windings L=8mH
NBH 200 161661.13 1 Unit with single windings L=4mH
NBH 260 161661.13* 1 Unit with parallel windings L=2mH
3I 161661.13* 1 Unit with single winding L=4mH
360H 161661.13* 1 Unit with parallel windings L=2mH
4I (300H) 161661.13* 1 Unit with parallel windings L =2mH
4B 161661.13* 1 Unit with parallel windings L=2mH
5C 161661.13* 1 Unit with parallel windings L=2mH
5B 161661.13* 2 Units in parallel with series windings L= 1mH
315H 161661.13* 1 Unit with parallel windings L=2mH
375H 161661.13* 1 Unit with parallel windings L=2mH
500H 161661.13* 2 Units in parallel with series windings L= 1mH
660H 161661.13* 2 Units in parallel with series windings L= 1mH
* Requires small cooling fans that are not included.
The portable cell tester (PCT) comes equipped with cables and software required to interface the PCT
with the cell’s optical communications port and the PC. The individual tests are menu driven with go and
no go features.
The load reactors will allow each cell to attain full rated current with a minimal input service requirement
to the variable voltage source.
The clamp-on ammeters and voltmeters will allow evaluation of the proper output voltages and cell
currents during the test.
The procedure for testing an installed cell is listed below.
x If possible, switch off the source of the medium voltage power at the switchgear. Make sure the
drive's medium voltage input switch is open, and lock it out. Rack out any output contactors in the
system and lock them out. Take any other necessary steps to release the interlock key that allows
access to the cell cabinet. Keep the transformer cabinet and power input cabinet closed and locked.
Be sure the cooling system pump is operational.
x Isolate the cell to be tested by removing the series links from the output at T1 and T2.
x Unplug the fiber optic cable from this cell at the Fiber Optic Interface Board and plug it into the PCT.
Connect the PCT to the parallel printer port of the computer. Turn on the power to the portable cell
tester.
x Disconnect the 3-phase input from the cell and connect the 3-phase output of the variable voltage 7
source to the input of the cell. Connect the input of the variable voltage source to the load side of the
460 VAC control breaker (CB1).
x Execute the 1CELL.EXE program on the computer. From the Main Menu (5) choose #1. The
preliminary test will go through a step-by-step go/no go procedure. This will verify that the
communications are working and the transistors are blocking (not shorted).

Attention! At this point of the test, the functionality of the IGBTs has been determined. When
prompted to use a resistor, the operator should cancel the program by following the instructions
on the screen.

x Turn off the variable voltage source. Connect the load reactor to output connections T1 and T2 of the
cell. If the cell is operated externally from the cabinet, a separate water supply is required.
x From the Main Menu [5] choose #2 Burn-in Test Menu. Make sure that the pot on the tester is turned
fully in the counter-clockwise direction. From the Burn-in Test Menu start the burn-in. The bottom of
the screen will indicate that the cell is running. LED’s Q1-Q4 on the cell should be illuminated. This
verifies that all four transistors are firing. Connect an ammeter to T1 or T2. Turn the pot on the tester
clockwise and note that the output current increases. Continue until output current reaches the rated

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current of the cell. Run the cell for 1 hour. Turn the pot fully in the counter-clockwise direction. Stop
the burn-in test and exit to the Main Menu.
x If faults occur while the cell is running, the PC will display all faults detected.
x Install the cell in the Cell Cabinet and reconnect all power cables, hoses and fiber optic cables.

7.9. Removing Power Cells

Lethal Voltages--DANGER!! Verify that the input power is fully locked in the off position
and that the bus LED on each cell is off.

If it is necessary to remove a single power cell from a drive that is filled with coolant, follow the procedure
below:
1. Disconnect input and control power to the drive. Allow the cell capacitor bank to bleed down. This
usually takes 5 to 10 minutes after removal of input power.
2. Close valves BV4A and BV4B AND 16A to isolate the cell cooling liquid from the rest of the system.
Disconnect the fiber optic cable from the cell.
3. Using two temporary clamps (ASI Robicon P/N 088145.00), clamp off the two hoses to the cell to
minimize spillage when the hose quick disconnect fittings are uncoupled.
4. Disconnect the two cooling liquid lines from the cell using the quick disconnects. The fittings are
disconnected by pushing the hose side of the fitting inward and pulling the ring around the cell side
fitting from the hose side. When the ring is moved, the hose side of the fitting can be pulled out.
5. Protect the two open hose connectors and the two open cell connectors to prevent entry of dirt or
debris. Dummy connectors or a plastic sheet and tape can be used. See Figure Figure 7-7.
6. Disconnect the three phase input connections by removing the links at the bottom of the cell power
fuses F11, F12 and F13 (shown in Figure 7-9). Disconnect the output link to each adjacent cell.
7. Position the cell lift device (e.g., a fork lift truck or ASI Robicon P/N163469.01) in front of the cell
with the lifting rails aligned both horizontally and vertically with the cell mounting frame rails. Lock
the cell lift device in position on the floor.
8. Remove the cell retaining angle brackets at the front bottom of the cell (see Figure 7-9). Roll the
cell onto the lift device rails and lock it in place prior to moving the lifting device. Refer to Figure 7-
8.)

Figure 7-7. Protecting an Open Cell Connector Using Plastic and a Wire Tie

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Figure 7-8. Installation/Removal of a Cell Using a Fork-style Lifting Device

Cell Coolant Outlet to

Next Cell Cell Coolant Inlet

Cell Output T2 Cell Output T1

Power fuses (3)

Input Connection
Links

Retaining Angle Cell Input

Connectors
7
Bracket Retaining Angle
Bracket not
Installed Yet

Figure 7-9. Front View of a Cell in Cabinet

Attention! When placing power cells into service which have been stored for more than two (2)
years without application of rated input voltage, it is advisable to use the following procedure to
reform the cell’s electrolytic capacitor bank: follow the procedure in section 7.8, and apply rated
voltage from the variable 690VAC voltage source for at least one hour prior to installation of the
cell into the cell cabinet.

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7.10. Six Month Inspection

x Check operation of fans in the top rear portion of the Cell Cabinet. Clean or replace them if
necessary.
x Inspect cooling system for leaks. Repair or replace components as necessary.
x Use touch-up paint as required on any rusty or exposed parts.
x Test coolant for presence of required glycol concentration. Reference Table 9-4 in Section 9.12 of
this manual. Note: a minimum of 5% concentration by weight is recommended to control bacteria.

7.11. Replacement of Parts

Replacement of component parts may be the best method of troubleshooting when spare parts are
available. Use troubleshooting guidelines found elsewhere in this chapter when attempting to locate a
failed sub-assembly. When any sub-assembly is to be replaced, always check that the part number of
the new unit matches that of the old unit (including the dash number).
x Failures traced to individual PC boards within the Control Cabinet are best serviced by replacement
of the entire board.
x Failures traced to individual power cells are best serviced by replacement of the entire cell.

*
Note: For spare parts lists for customized drives, refer to the custom documentation package
shipped with the drive or call ASIRobicon Customer Service Department at (724) 339-9501.
When calling for spare parts information, please have your sales order number.

Attention! The disposal of any failed components (for example, CPU battery, capacitors, etc.)
must be done in accordance with local codes and requirements.

’ ’ ’

7-32 ASIRobicon Version 1.1 (19000404)