Chapter 6 Ch6
User Manual: Chapter 6 DURApulse GS4 AC Drives User Manual
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Maintenance and Troubleshooting Table of hapter CChapter 6 Contents Maintenance and Inspections ��������������������������������������������������������������������������������������������������������������6–2 Monthly Inspection�������������������������������������������������������������������������������������������������������������������������������������������6–2 Annual Inspection����������������������������������������������������������������������������������������������������������������������������������������������6–2 Recharge Capacitors (for drives not in service)����������������������������������������������������������������������������������������������6–3 Recommended Inspection Schedules�������������������������������������������������������������������������������������������������������������6–4 Troubleshooting��������������������������������������������������������������������������������������������������������������������������������������6–8 Warning Codes��������������������������������������������������������������������������������������������������������������������������������������������������6–8 Fault Codes������������������������������������������������������������������������������������������������������������������������������������������������������6–16 Typical AC Drive Problems and Solutions������������������������������������������������������������������������������������������6–26 Grease and Dirt Problems������������������������������������������������������������������������������������������������������������������������������6–26 Fiber Dust Problem�����������������������������������������������������������������������������������������������������������������������������������������6–27 Corrosion Problem������������������������������������������������������������������������������������������������������������������������������������������6–28 Industrial Dust Problem ���������������������������������������������������������������������������������������������������������������������������������6–29 Wiring and Installation Problem��������������������������������������������������������������������������������������������������������������������6–30 Digital Input/Output Terminal Problems������������������������������������������������������������������������������������������������������6–31 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–1 Chapter 6: Maintenance and Troubleshooting Maintenance and Inspections Modern AC drives are based on solid state electronics technology, including ICs, resistors, capacitors, transistors, cooling fans, relays, etc. These components have a limited life under normal operation. Preventive maintenance is required to operate the GS4 drive in its optimal condition, and to ensure a long life. We recommend that a qualified technician perform a regular inspection of the GS4 drive. Some items should be checked once a month, and some items should be checked yearly. NOTE: All inspections should be accomplished with Safety in mind with due and required caution. Some of these Inspection items may require the Drive to be powered down, while others may require power to be applied. Proper safety precautions including the use of PPE are/may be required. Please review cautionary statements in each section Monthly Inspection Check the following items at least once a month. 1) Make sure the motors are operating as expected. 2) Make sure the drive installation environment is normal. 3) Make sure the enclosure and drive cooling systems are operating as expected. 4) Check for irregular vibrations or sounds during operation. 5) Make sure the motors are not overheating during operation. 6) Check the input voltage to the GS4 drive and make sure the voltage is within the operating range. Check the voltage with a voltmeter. Annual Inspection Check the following items once annually. 1) Check the torque of the GS4 power and control terminal screws and tighten if necessary. They may loosen due to vibration or changing temperatures. 2) Make sure the conductors and insulators are not corroded or damaged. 3) Check the resistance of cable insulation with a megohmmeter. 4) Clean off any dust and dirt with a vacuum cleaner. Pay special attention to cleaning the ventilation ports and PCBs. Always keep these areas clean. Accumulation of dust and dirt in these areas can cause unforeseen failures. 5) Recharge the capacitors of any drive that is in storage or is otherwise unused. Page 6–2 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Recharge Capacitors (for drives not in service) Recharge the DC link before using any drive that has not been operated within a year: 1) Disconnect the motor from the drive. 2) Apply input power to the drive for 2 hours. If the drive is stored or is otherwise unused for more than a year, the drive’s internal DC link capacitors should be recharged before use. Otherwise, the capacitors may be damaged when the drive starts to operate. We recommend recharging the capacitors of any unused drive at least once per year. Disconnect AC power and ensure that the internal capacitors have fully discharged before inspecting the GS4 drive! Wait at least two minutes after all display lamps have turned off. ☑ Wait 5 seconds after a fault has been cleared before performing reset ☑ CAUTION ☑ ☑ ☑ via keypad or input terminal. When the power is off after 5 minutes for ≤ 30hp models and 10 minutes for ≥ 40hp models, please confirm that the capacitors have fully discharged by measuring the voltage between + and -. The voltage between + and - should be less than 25VDC. Only qualified personnel can install, wire and maintain drives. Please take off any metal objects, such as watches and rings, before operation. And only insulated tools are allowed. Never reassemble internal components or wiring. Make sure that installation environment complies with regulations without abnormal noise, vibration and smell. DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–3 Chapter 6: Maintenance and Troubleshooting Recommended Inspection Schedules Before the check-up, always turn off the AC input power and remove the cover. Wait at least 10 minutes after all display lamps have gone out, and then confirm that the capacitors have fully discharged by measuring the voltage between DC+ and DC-. The voltage between DC+ and DC-should be less than 25VDC. Ambient environment Check Items Methods and Criteria Check the ambient temperature, humidity, vibration and see if there are any dust, gas, oil or water drops Visual inspection and measurement with equipment with standard specification If there are any dangerous objects Visual inspection Maintenance Period Half One Daily Year Year Voltage Check Items Methods and Criteria Check if the voltage of main circuit and control circuit is correct Measure with multimeter with standard specification Maintenance Period Half One Daily Year Year Digital Keypad Display Check Items Methods and Criteria Is the display clear for reading Visual inspection Any missing characters Visual inspection Maintenance Period Half One Daily Year Year Mechanical parts Check Items Page 6–4 Methods and Criteria If there is any abnormal sound or vibration Visual and audible inspection If there are any loose screws Tighten the screws If any part is deformed or damaged Visual inspection If there is any color change due to overheating Visual inspection If there is any dust or dirt Visual inspection Maintenance Period Half One Daily Year Year DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Recommended Inspection Schedules (continued) Main circuit Check Items Methods and Criteria If there are any loose or missing screws Tighten or replace the screw If any drive or wiring insulation is deformed, cracked, damaged or has changed color due to overheating or aging Visual inspection NOTE: Ignore any color change of copper plate If there is any dust or dirt Visual inspection Maintenance Period Half One Daily Year Year Terminals and wiring of main circuit Check Items If the terminal color or the placement has changed due to overheating If the wiring insulation is damaged or there has been a color change If there is any damage Methods and Criteria Maintenance Period Half One Daily Year Year Visual inspection Visual inspection Visual inspection DC capacity of main circuit Check Items If there is any liquid leaking, color change, crack or deformation If the capacitor safety vent is bulging or inflated. Measure static capacity when required (if drive overloads/faults during normal operation) Methods and Criteria Maintenance Period Half One Daily Year Year Visual inspection Visual inspection Measure with multimeter with standard specification DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–5 Chapter 6: Maintenance and Troubleshooting Recommended Inspection Schedules (continued) Resistor of main circuit Check Items Methods and Criteria If there is any peculiar smell or insulation cracks due to overheating If there is any disconnection or discoloration Maintenance Period Half One Daily Year Year Visual inspection, smell Visual inspection Measure with a multimeter with standard specifications If the connection is damaged Transformer and reactor of main circuit Check Items Methods and Criteria If there is any abnormal vibration or peculiar smell Maintenance Period Half One Daily Year Year Visual, audible inspection and smell Magnetic contactor and relay of main circuit Check Items Methods and Criteria If there are any loose screws Visual and audible inspection If the contact works correctly Visual inspection Maintenance Period Half One Daily Year Year Printed circuit board and connector of main circuit Check Items Methods and Criteria If there are any loose screws and connectors If there is any peculiar smell and/or color change If there is any crack, damage, deformation or corrosion If there is any liquid leakage or deformation in capacity Page 6–6 Maintenance Period Half One Daily Year Year Tighten the screws and press the connectors firmly in place Visual and smell inspection Visual inspection Visual inspection DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Recommended Inspection Schedules (continued) Cooling fan of cooling system Check Items Methods and Criteria If there is any abnormal sound or vibration Visual, audible inspection and turn the fan with hand (turn off the power before operation) to see if it rotates smoothly If there is any loose screw Tighten the screw If there is any color change due to overheating Change the fan Maintenance Period Half One Daily Year Year Ventilation channel of cooling system Check Items If there is any obstruction in the heat sink, air intake or air outlet Methods and Criteria Maintenance Period Half One Daily Year Year Visual inspection Please use a clean lint free cloth for cleaning and use a dust cleaner to remove dust when necessary. DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–7 Chapter 6: Maintenance and Troubleshooting Troubleshooting Warning Codes The GS4 drive has a comprehensive diagnostic system that includes several different warning codes. The most common warning codes can be read on the digital keypad display. LOCAL ① Warning ② CE1 ③ Comm. Error 1 Display on GS4-KPD Keypad n/a Warning Codes Warning Code in 2108h Descriptions Active Warning 0 LOCAL Warning No error Modbus function code error 1 CE1 Comm. Error 1 ① Display error signal type ② Abbreviated error code The code is displayed as shown on GS4-KPD ③ Display error description This error is generated if any command code other than 0x03, 0x06, 0x08 or 0x10 is seen. LOCAL Warning CE2 Comm. Error 2 2 Address of Modbus data error 3 Modbus data error 4 Modbus communication error 5 Modbus transmission time-out 6 Keypad transmission time-out LOCAL Warning CE3 Comm. Error 3 LOCAL Warning CE4 Comm. Error 4 LOCAL Warning CE10 Comm. Error 10 LOCAL Warning CP10 Keypad Time Out (continued next page) Page 6–8 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Display on GS4-KPD Keypad Warning Codes (continued) Warning Code in 2108h Descriptions Active Warning LOCAL Warning SE1 Save Error 1 7 Keypad COPY error 1 Keypad transfer (check) error, including communication delays, communication error (keypad received error FF86) and parameter value error. P9.06 must be set to 1 for a keypad to drive copy. 8 Keypad COPY error 2 Keypad transfer (check) done, parameter write error 9 IGBT over-heating warning 10 Capacitor over-heating warning 11 PID feedback error LOCAL Warning SE2 Save Error 2 LOCAL Warning oH1 Over heat 1 warn LOCAL Warning oH2 Over heat 2 warn LOCAL Warning PID PID FBK Error LOCAL Warning AIx 4~20mA Signal Loss 12 ANL Analog Loss AI1 or AI2 signal drops below 4mA when P4.05 or P4.06 are set to 1 (4~20mA). Enabled with P4.63 and P4.64 (AIx 4~20mA Loss Detection). LOCAL Warning uC Under Current 13 Low current 14 Auto tuning error LOCAL Warning AUE Auto-tune Error n/a 15~18 reserved (continued next page) DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–9 Chapter 6: Maintenance and Troubleshooting Display on GS4-KPD Keypad Warning Codes (continued) Warning Code in 2108h Descriptions Active Warning LOCAL Warning PHL Phase Loss Warn 19 Input phase Loss 20 Over torque 1 21 Over torque 2 22 Motor over-heating 23 Current clamp warning 24 Over Slip 25 Auto tuning processing LOCAL Warning ot1 Over Torque 1 LOCAL Warning ot2 Over Torque 2 LOCAL Warning oH3 Motor Over Heat LOCAL Warning c.c. cc Warn LOCAL Warning oSL Over Slip Warn LOCAL Warning tUn Auto tuning n/a 26~27 reserved LOCAL Warning OPHL Output PHL Warn n/a 28 29 Output phase loss reserved (continued next page) Page 6–10 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Display on GS4-KPD Keypad Warning Codes (continued) Warning Code in 2108h Descriptions Active Warning LOCAL Warning 30 SE3 CopyEn/Model Err n/a 31~46 Keypad COPY error 3 P9.06 is not set to 1 before the copy function is started. If COPYing from Keypad to VFD (AC drive), make sure P9.06 Parameter Copy is set to 1 before copying. reserved LOCAL Warning PLrA RTC Adjust n/a 47 The Real Time Clock has been adjusted. 48 reserved 49 Keypad Real Time Clock timout Turn power on and off after making sure that the keypad is securely connected. 50 Drive PLC requesting register address or block of addresses that is out of range or does not exist. 51 Save error of PLC download 52 Data error during PLC operation 53 Function code of PLC download error (occurs on PLC register overflow. Also occurs if the PLC is set to RUN, and there is no program installed) 54 PLC register overflow LOCAL Warning PLrt Keypad RTC TOut LOCAL Warning PLod PLC Out of Range LOCAL Warning PLSv Save mem defect LOCAL Warning PLdA Data defect LOCAL Warning PLFn Function defect LOCAL Warning PLor Buf overflow (continued next page) DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–11 Chapter 6: Maintenance and Troubleshooting Display on GS4-KPD Keypad Warning Codes (continued) Warning Code in 2108h Descriptions Active Warning LOCAL Warning PLFF Function defect 55 Function code of PLC operation error 56 PLC checksum error 57 PLC end command is missing 58 reserved 59 PLC download fail 60 PLC scan time exceed LOCAL Warning PLSn Check sum error LOCAL Warning PLEd No end command n/a LOCAL Warning PLdF Download fail LOCAL Warning PLSF Scan time fail n/a 61~69 reserved LOCAL Warning ECid ExCom ID failed 70 Duplicate MAC ID error Node address setting error 71 Low voltage of communication card 72 Communication card in test mode LOCAL Warning ECLv ExCom pwr loss LOCAL Warning ECtt ExCom Test Mode (continued next page) Page 6–12 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Display on GS4-KPD Keypad Warning Codes (continued) Warning Code in 2108h Descriptions Active Warning LOCAL Warning ECbF ExCom Bus off 73 ExCom Bus off 74 ExCom No power 75 Factory default setting error 76 Serious internal error 77 IO connection break 78 ExCom Pr data 79 ExCom Conf data 80 Ethernet Link fail. If a communications card is installed but not connected to an active network, this warning will appear. Please connect to valid network link. Reset card to default and/or re-flash comm card firmware if problem persists. LOCAL Warning ECnP ExCom No power LOCAL Warning ECFF ExCom Facty def LOCAL Warning ECif ExCom Inner err LOCAL Warning ECio ExCom IONet brk LOCAL Warning ECPP ExCom Pr data LOCAL Warning ECPi ExCom Conf data LOCAL Warning ECEF ExCom Link fail (continued next page) DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–13 Chapter 6: Maintenance and Troubleshooting Display on GS4-KPD Keypad Warning Codes (continued) Warning Code in 2108h Descriptions Active Warning LOCAL Warning ECto ExCom Inr T-out 81 Communication time-out for communication card and drive 82 Check sum error for communication card and drive 83 Communication card returns to default setting 84 Modbus TCP exceeded maximum communication value 85 EtherNet/IP exceeded maximum communication value 86 IP fail 87 reserved 88 Communication card busy 89 Loss of communication between Communication Card and GS4 drive. To recover: Power down the drive and remove all communication cables. Remove and reseat the comm card. Do not reconnect any comm cables. Power up the drive. If the ECCb fault still exists, replace the comm card. LOCAL Warning ECCS ExCom Inr CRC LOCAL Warning ECrF ExCom Rtn def LOCAL Warning ECo0 ExCom MTCP over LOCAL Warning ECo1 ExCom EIP over LOCAL Warning ECiP ExCom IP fail n/a LOCAL Warning ECbY ExCom Busy LOCAL Warning ECCb ExCom Card brk (continued next page) Page 6–14 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Display on GS4-KPD Keypad Warning Codes (continued) Warning Code in 2108h Descriptions Active Warning LOCAL Warning WdCPLP Copy PLC Pass 90 Copy PLC password error 91 Copy PLC read mode error 92 Copy PLC write mode error 93 Copy PLC version error 94 Copy PLC capacity size error LOCAL Warning RdCPL0 Copy PLC Mode LOCAL Warning WtCPL1 Copy PLC Mode LOCAL Warning CPLv Copy PLC Version LOCAL Warning CPLS Copy PLC Size LOCAL Warning Copy PLC: Disable PLC functions to copy 95 CPLF Copy PLC Func Warning Code 95 could also show up as ERR7 if the PLC is in STOP mode. Disable the PLC before copying. LOCAL Warning CPLt Copy PLC TimeOut 96 Copy PLC time-out Resettable only by cycling power to the drive 97 Ethernet communication has not been received from the external controller (within the Ethernet Timeout window). LOCAL Warning CD10 Card TimeOut DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–15 Chapter 6: Maintenance and Troubleshooting Fault Codes The GS4 drive has a comprehensive fault diagnostic system that include a variety of fault messages. When a fault is detected, the GS4 drive will shut down in order to protect internal components. The following faults are displayed as shown on the GS4 digital keypad display. LOCAL ① Fault ② ocA ③ OC at Accel ① Display error signal type ② Abbreviate error code The code is displayed as shown on GS4-KPD ③ Display error description Gaps in the fault ID numbers below are set aside as “reserved” faults for possible future use. Should your GS4 drive repeatedly display a reserved fault, please note the fault ID number and contact AutomationDirect technical support. Fault Codes Display on GS4-KPD Kepad n/a Fault Code in Status Fault Description Corrective Action Monitor 1 0 LOCAL Fault 1 ocA OC at Accel LOCAL Fault 2 ocd OC at decel LOCAL Fault 3 ocn OC at Speed no error Over-current during acceleration (Output current exceeds triple rated current during acceleration.) Over-current during deceleration (Output current exceeds triple rated current during deceleration.) Over-current during steady state operation (Output current exceeds triple rated current during constant speed.) LOCAL Fault GFF Ground Fault 4 Ground fault Can be Bypassed in Fire Mode (Yes / no) none needed n/a 1) Short circuit at motor output: Check for possible poor insulation at the output. 2) Acceleration Time too short: Increase the Acceleration Time. Yes 3) GS4 drive output power is too small: Replace the GS4 drive with the next higher power model. 1) S hort circuit at motor output: Check for possible poor insulation at the output. 2) Deceleration Time too short: Increase the Deceleration Time. Yes 3) GS4 drive output power is too small: Replace the GS4 drive with the next higher power model. 1) S hort circuit at motor output: Check for possible poor insulation at the output. 2) Sudden increase in motor loading: Check for possible motor stall. Yes 3) GS4 drive output power is too small: Replace the GS4 drive with the next higher power model. When (one of) the output terminal(s) is grounded, short-circuit current is more than 50% of the GS4 drive rated current, the GS4 drive power module may be damaged. NOTE: The short-circuit protection is provided for AC motor drive protection; not for protecting the user. Yes 1) Check the wiring connections between the GS4 drive and motor for possible short circuits, also to ground. 2) Check whether the IGBT power module is damaged. 3) Check for possible poor insulation at the output. (continued next page) Page 6–16 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Fault Code Fault in Status Descriptions Monitor 1 Fault Name LOCAL Fault occ IGBT Short Ckt Corrective Actions Can be Bypassed in Fire Mode (Yes / no) 5 Short-circuit is detected between Replace the drive. If still under warranty, please upper bridge and contact AutomationDirect Returns Department. lower bridge of the IGBT module Yes 6 Hardware failure in Replace the drive. If still under warranty, please current detection contact AutomationDirect Returns Department. Yes 7 DC BUS overvoltage during 1) Check if the input voltage falls within the acceleration (230V: rated GS4 drive input voltage range. DC 450V; 2) Check for possible voltage transients. 460V: DC 900V) Yes 8 1) Check if the input voltage falls within the DC BUS overrated GS4 drive input voltage range. voltage during 2) Check for possible voltage transients. deceleration (230V: 3) If DC BUS over-voltage due to regenerative DC 450V; 460V: DC voltage, please increase the Deceleration 900V) Time or add an optional brake resistor. Yes 9 DC BUS over1) Check if the input voltage falls within the voltage at constant rated GS4 drive input voltage range. speed 2) Check for possible voltage transients. (230V: DC 450V; 460V: DC 900V) Yes 10 Hardware failure in voltage detection. 1) C heck if the input voltage falls within the rated GS4 drive input voltage range. 2) Check for possible voltage transients. Yes 11 DC BUS voltage 1) Check if the input voltage is normal. is less than P6.35 2) C heck for possible sudden load. during acceleration no 12 DC BUS voltage is less than P6.35 during deceleration no LOCAL Fault ocS OC at Stop LOCAL Fault ovA OV at Accel LOCAL Fault ovd OV at Decel LOCAL Fault ovn OV at Speed LOCAL Fault ovS OV at Stop LOCAL Fault LvA LV at Accel LOCAL Fault Lvd LV at Decel 1) C heck if the input voltage is normal. 2) Check for possible sudden load. (continued next page) DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–17 Chapter 6: Maintenance and Troubleshooting Fault Code Fault in Status Descriptions Monitor 1 Fault Name Corrective Actions Can be Bypassed in Fire Mode (Yes / no) LOCAL Fault Lvn LV at Speed 13 DC BUS voltage is less than P6.35 in constant speed 1) Check if the input voltage is normal. 2) Check for possible sudden load. no 14 DC BUS voltage is less than P6.35 at stop 1) Check if the input voltage is normal 2) Check for possible sudden load no 15 Output Ripple / Phase Loss Check Power Source Input if all 3 input phases are connected without loose contacts. For Yes models 40hp and above, please check if the fuse for the AC input circuit is blown. LOCAL Fault LvS LV at Stop LOCAL Fault OrP Input Phase loss LOCAL Fault 16 oH1 IGBT Over Heat LOCAL Fault 17 oH2 Cap Over Heat 1) Ensure that the ambient temperature falls within the specified temperature range. 2) Make sure that the ventilation holes are not obstructed. IGBT overheating IGBT temperature 3) Remove any foreign objects from the Yes exceeds protection heatsinks and check for possible dirty heat level sink fins. 4) Check the fan and clean it. 5) Provide enough spacing for adequate ventilation. Heatsink 1) Ensure that the ambient temperature falls overheating within the specified temperature range. Capacitance 2) Make sure heat sink is not obstructed. temperature Yes Check if the fan is operating exceeds cause 3) Check if there is enough ventilation heatsink clearance for the GS4 drive. overheating. LOCAL Fault tH1o Thermister1 Open 18 IGBT Hardware Error Internal drive error. Replace the drive. If still under warranty, please contact AutomationDirect Returns Department. Yes 19 Capacitor Hardware Error Internal drive error. Replace the drive. If still under warranty, please contact AutomationDirect Returns Department. Yes 20 Power Loss (Power Check for loose input power connections. Down) Restore line power. LOCAL Fault tH2o Thermister2 Open LOCAL Fault PWR Power Reset Off no (continued next page) Page 6–18 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Corrective Actions Can be Bypassed in Fire Mode (Yes / no) 21 Overload The GS4 drive detects excessive drive output current. 1) Check if the motor is overloaded. 2) Use the next higher HP drive model. no 22 Electronic thermal relay 1 protection 1) Check the setting of electronics thermal relay (P6.01) 2) Use the next higher HP drive model. no 23 Electronic thermal relay 2 protection 1) Check the setting of electronics thermal relay (P6.03) 2) Use the next higher HP drive model. no 24 Motor overheating 1) Make sure that the motor is not The GS4 drive obstructed. detecting internal 2) Ensure that the ambient temperature falls temperature within the specified temperature range. exceeds the setting of P6.40 (PTC level) 3) Use the next higher HP drive model. Yes 25 reserved n/a Fault Code Fault in Status Descriptions Monitor 1 Fault Name LOCAL Fault oL Overload LOCAL Fault EoL1 Mtr1 Thermal OL LOCAL Fault EoL2 Mtr2 Thermal OL LOCAL Fault oH3 Mtr Overheat-PTC n/a LOCAL Fault 26 ot1 Over Torque 1 LOCAL Fault 27 ot2 Over Torque 2 LOCAL Fault uC Under Current n/a These two fault codes will be displayed when no output current exceeds the over- 1) Check whether the motor is overloaded. torque detection 2) Check whether motor rated current setting level (P6.15 or (P0.01) is suitable P6.18) and exceeds 3) Use the next higher HP drive model. over-torque detection (P6.16 or no P6.19) and it is set to 2 or 4 in P6.14 or P6.17. 28 Low current detection (uC does not cause Check P6.52, P6.53, P6.54. drive to stop if in Fire Mode) no 29 reserved n/a n/a 30 Internal EEPROM can not be programmed. 1) R eset to factory settings. 2) Replace the drive. If still under warranty, please contact AutomationDirect Returns Department. no LOCAL Fault cF1 EEPROM Write Err n/a (continued next page) DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–19 Chapter 6: Maintenance and Troubleshooting Corrective Actions Can be Bypassed in Fire Mode (Yes / no) 31 Internal EEPROM can not be read. 1) Reset to factory settings. 2) Replace the drive. If still under warranty, please contact AutomationDirect Returns Department. no 32 reserved n/a n/a Fault Code Fault in Status Descriptions Monitor 1 Fault Name LOCAL Fault cF2 EEPROM Read Err n/a Power cycle the drive allowing the capacitor bank to discharge. LOCAL Fault 33 cd1 Amp Err: U Phase U-phase error 34 cd2 Amp Err: V Phase V-phase error 35 cd3 Amp Err: W Phase W-phase error LOCAL Fault 36 Hd0 CC HW Error CC (current clamp) 37 Hd1 OC HW Error OC hardware error 38 Hd2 OV HW Error OV hardware error LOCAL Fault Hd3 OCC HW Error Should this fault be consistently displayed, the drive is most likely damaged and needs repair or replacement. no Power cycle the drive allowing the capacitor bank to discharge. Should this fault be consistently displayed, the drive is most likely damaged and needs repair or replacement. no Should this fault be consistently displayed, the drive is most likely damaged and needs repair or replacement. no Power cycle the drive allowing the capacitor bank to discharge. LOCAL Fault no Power cycle the drive allowing the capacitor bank to discharge. LOCAL Fault Should this fault be consistently displayed, the drive is most likely damaged and needs repair or replacement. Power cycle the drive allowing the capacitor bank to discharge. LOCAL Fault no Power cycle the drive allowing the capacitor bank to discharge. LOCAL Fault Should this fault be consistently displayed, the drive is most likely damaged and needs repair or replacement. 39 OCC hardware error Should this fault be consistently displayed, the drive is most likely damaged and needs repair or replacement. no Power cycle the drive allowing the capacitor bank to discharge. Should this fault be consistently displayed, the drive is most likely damaged and needs repair or replacement. no (continued next page) Page 6–20 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Fault Code Fault in Status Descriptions Monitor 1 Fault Name Corrective Actions Can be Bypassed in Fire Mode (Yes / no) LOCAL Fault AUE Auto Tuning Err 40 Auto tuning error 1) C heck cabling between drive and motor 2) Try again. no 41 PID loss (ACI) 1) C heck the wiring of the PID feedback. 2) Check the PID parameters settings. no LOCAL Fault AFE PID Fbk Loss n/a 42~47 LOCAL Fault 48 ACE Analog Loss Err reserved n/a n/a 1) Check the 4~20mA signal wiring (AI1 or AI2). 2) Check if the analog signal is less than 4mA. NOTE: P4.63 or P4.64 must be set to 3 to enable the Analog Signal Loss Analog Loss Fault. no Error (4~20mA) This fault can be temporarily bypassed by switching Local/Remote Mode. (The Fault is active only if the drive is actively looking for the analog signal). LOCAL Fault External Fault 1) Input EF (N.O.) on external terminal is closed to GND. Output U, V, W will be turned off. 2) Press Reset after fault has been cleared. no 50 Emergency stop 1) W hen the multi-function input terminals DI1 to DI6 are set to emergency stop, the GS4 drive stops output U, V, W and the motor coasts to stop. 2 Press RESET after fault has been cleared. no 51 1) When the external input terminal (B.B) is active, the GS4 drive output will be turned External Base Block no off. 2) Deactivate the external input terminal (B.B) to operate the GS4 drive again. 52 Keypad will be locked. Power cycle the drive Password is locked then re-enter the correct password. See P8.06 and P8.07. no 53 Software version error no 49 EF External Fault LOCAL Fault EF1 Emergency Stop LOCAL Fault bb Base Block LOCAL Fault Pcod Password Error LOCAL Fault ccod SW Code Lock The firmware version is corrupt. Please re-download the firmware. (continued next page) DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–21 Chapter 6: Maintenance and Troubleshooting Fault Code Fault in Status Descriptions Monitor 1 Fault Name Corrective Actions Can be Bypassed in Fire Mode (Yes / no) Check if the function code is correct (function code must be 03, 06, 10, 63). no LOCAL Fault CE1 PC Cmd Error 54 Illegal function code 55 Illegal data address Check if the communication address is correct. (00H to 254H) no 56 Illegal data value Check if the data value exceeds max/min value. no 57 Data is written to read-only address Check to see if the correct communication address is being utilized. no LOCAL Fault CE2 PC Address Error LOCAL Fault CE3 PC Data Error LOCAL Fault CE4 PC Slave Fault For a CE10 Fault to be displayed, the User must first have enabled the communication time out detection (P9.03 is not 3 and P9.05 is not 0). LOCAL Fault 58 CE10 PC TimeOut Should the drive not receive a message from the Modbus host computer (such as PC, HMI, PLC…) for the transmission time- time set in P9.05 the drive will trigger the CE10 no out fault. Corrective action is to restore the communication between the host computer and the drive with messaging set lower/faster than the time set in P9.05. For a CP10 Fault to be displayed the User must first enable the communication time out detection (P8.13 is not 3 and P8.14 is not 0). LOCAL Fault 59 CP10 Keypad Timeout Should the drive not receive a message from Keypad for the time set in P8.14, the Drive will Keypad trigger the CP10 fault. transmission timeout Corrective action is to restore the communication between Keypad and the drive. Typical use for this parameter is for Remote Keypad use and monitoring of healthy Keypad to Drive communication. no LOCAL Fault bF Braking Fault 60 If the fault code is still displayed on the keypad Brake resistor fault after pressing “RESET” key, please return to the factory. no (continued next page) Page 6–22 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Fault Code Fault in Status Descriptions Monitor 1 Fault Name LOCAL Fault ydc Y-Delta Connect dEb 62 When P6.61 is not set to 0 and momentary power 1) Set P6.61 to 0. is turned off, it will 2) Check if input power is stable. display dEb during accel/decel stop. 63 It will be displayed when slip exceeds 1) Check if motor parameter is correct (please P2.26 setting and no decrease the load if overload). time exceeds P2.27 2) Check the settings of P2.26 and P2.27. setting. LOCAL oSL Over Slip Error LOCAL Fault 64 ryF Emag SwitchError n/a no Y-connection/Δconnection switch error DEB Error Fault 1) Check the wiring of the Y-connection/Δconnection. 2) Check the parameters settings. 61 LOCAL Fault Corrective Actions Can be Bypassed in Fire Mode (Yes / no) 65~71 Electric valve switch error when executing Soft Start. (This warning is for frames E and higher frame of GS4 drives) reserved no Do not disconnect RST when drive is still operating. no n/a n/a STO1~SCM1 internal hardware detect error. (See Appendix E for corrective action.) no LOCAL Fault 72 STL1 STO Loss 1 STL1 LOCAL Fault 73 S1 Emergency stop for external safety ES1 E-Stop Fire In Fire Mode n/a 74 In Fire mode 75 reserved LOCAL Fault STO STO The corrective action is to restore the E-Stop input to the drive at ES1. no Fire fault is due to the multi-function input set as 40 or 41 and that DI is ON. LOCAL Fault Fault S1 is generated upon a loss of the E-Stop input at ES1. 76 STO For some installations, particularly exhaust fan Yes operation where smoke is detected and requires evacuation, it is highly desired for the drive to run the fan as long as is needed to exhaust that smoke. n/a n/a Safety Torque Off function active. (See appendix E for corrective action.) If unknown STO faults occur, the onboard +24V might be getting shorted (+24V to DCM). no (continued next page) DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–23 Chapter 6: Maintenance and Troubleshooting Fault Code Fault in Status Descriptions Monitor 1 Fault Name Corrective Actions Can be Bypassed in Fire Mode (Yes / no) no LOCAL Fault STL2 STO Loss 2 77 STL2 STO2~SCM2 internal hardware detect error. (See appendix E for corrective action.) 78 STL3 STO1~SCM1 and STO2~SCM2 internal hardware detect error. no (See appendix E for corrective action.) 79 Phase U short circuit Yes 80 Phase V short circuit Yes 81 Phase W short circuit Yes 82 Output phase loss (Phase U) Check to insure that the motor cable is properly Yes connected to the drive. 83 Output phase loss (Phase V) Check to insure that the motor cable is properly Yes connected to the drive. 84 Output phase loss (Phase W) Check to insure that the motor cable is properly Yes connected to the drive. reserved n/a LOCAL Fault STL3 STO Loss 3 LOCAL Fault Uoc U Phase Short LOCAL Fault Voc V Phase Short LOCAL Fault Woc W Phase Short LOCAL Fault UPHL U Phase Loss LOCAL Fault VPHL V Phase Loss LOCAL Fault WPHL W Phase Loss n/a 85~89 n/a (continued next page) Page 6–24 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Fault Code Fault in Status Descriptions Monitor 1 Fault Name LOCAL Fault 90 FStp PLC Force Stop n/a 91~96 n/a n/a no 98 99 CPU trap error Should a CPU Trap error fault persist, please no send the drive back to the factory for evaluation. reserved n/a 97 CD10 Card TimeOut If the GS4 drive is running in PLC mode, parameter P3.00 is equal to 1, 3 or 5, and Remote Operation is selected; or parameter P3.01 is equal to 1, 3, or 5, and Local operation is selected, the drive can be forced to stop by pressing the STOP key on the keypad. reserved Ethernet communication has not been received from the external controller (within the Ethernet Timeout window). reserved LOCAL Fault Corrective Actions Can be Bypassed in Fire Mode (Yes / no) n/a Initiate Ethernet communications from the master controller again, or Disable checking for Ethernet Timeout in P9.94. n/a n/a LOCAL Fault TRAP CPU Command Err n/a 100~111 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 n/a Page 6–25 Chapter 6: Maintenance and Troubleshooting Typical AC Drive Problems and Solutions Grease and Dirt Problems In those industries where grease and dirt are common. Please be aware of the possible damage that grease, oil, and dirt, may cause to your GS4 drive: 1) Electronic components that silt up with greasy oil may cause the drive to burn out or even explode. 2) Most greasy dirt contains corrosive substances that may damage the drive. Solution: Install the GS4 drive in a suitable enclosure to protect it from grease and dirt. Clean and remove grease and dirt regularly to prevent damage of the drive. Page 6–26 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Fiber Dust Problem Problems related to fiber dust are typical in the textile industry. Please be aware of the possible damage that fiber dust may cause to your GS4 drive: 1) Fiber dust that accumulates or adheres to the fans will result in poor ventilation and cause overheating problems. 2) Textile plant environments with high humidity levels may experience GS4 drive failure or damage as a result of wet fiber dust adhering to components within the drive. Solution: Install the GS4 drive in a suitable enclosure to protect it from fiber dust. Clean and remove fiber dust regularly to prevent damage to the drive. DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–27 Chapter 6: Maintenance and Troubleshooting Corrosion Problem Corrosion problems may occur if any fluids or liquid in vapor form flows into the GS4 drive. Please be aware of the damage that corrosion may cause to your drive. • Corrosion of internal components may cause the GS4 drive to malfunction and possibly explode. Solution: Install the GS4 drive in a suitable enclosure to protect it from fluids. Clean the drive regularly to prevent corrosion. Page 6–28 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Industrial Dust Problem Serious industrial dust pollution frequently occurs in stone processing plants, flour mills, cement plants, and so on. Please be particularly aware of any metal dust, filings or if metalized vapor is present as these may cause damage to your drives: 1) Dust accumulating on electronic components may cause overheating problems and shorten the service life of the drive. 2) Conductive dust may damage the circuit board and may cause the drive to explode. Solution: Install the GS4 drive in a suitable enclosure and protect it from dust. Clean the cabinet and ventilation filter regularly for good ventilation. DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–29 Chapter 6: Maintenance and Troubleshooting Wiring and Installation Problem When wiring the GS4 drive, the most common problems are connection to the wrong terminal or poor wiring practice. Please be aware of the possible damage that poor wiring practice may cause to your GS4 drive: 1) Screw terminals where the wire is not fully inserted or the terminal screw is not adequately tightened may result in sparking or high temperature due to a high resistance connection. 2) If circuit boards in the GS4 drive have been modified, components on the affected boards may have been damaged. Solution: Inspect all power and control terminal connections in the GS4 drive to ensure adequate wire insertion. Do not attempt to disassemble or repair control boards in the GS4 drive. Page 6–30 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Chapter 6: Maintenance and Troubleshooting Digital Input/Output Terminal Problems Problems with digital I/O are usually the result of improper termination, or failure to segregate control wiring from power wiring. This may result in errant signals due to induced voltage, capacitive coupling or electrical noise. Incorrect voltage levels applied to the digital I/O terminals can damage the I/O circuitry of the drive. • Input/Output circuit may burn out when the terminal usage exceeds its limit. Solution: Refer to the user manual for multi-function input output terminals usage and follow the specified voltage and current. DO NOT exceed the specification limits. DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017 Page 6–31 Chapter 6: Maintenance and Troubleshooting BLANK PAGE Page 6–32 DURApulse GS4 AC Drive User Manual – 1st Ed, RevB - 11/17/2017
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