Related Manuals for Allen-Bradley Bulletin 2364F
Summary of Contents for Allen-Bradley Bulletin 2364F
- Page 1 Allen-Bradley Troubleshooting Regenerative DC Bus Supply Unit Guide (RGU) Bulletin 2364F...
- Page 2 Since there are many variables and requirements associated with any particular installation, Allen-Bradley does not assume responsibility or liability (to include intellectual property liability) for actual use based upon the examples shown in this publication.
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Page 3: Table Of Contents
Table of Contents Preface Preface Contents ..........P-1 Who Should Use This Manual . - Page 4 toc-ii Chapter 4 Testing Components Components ..........4-1 Testing and Replacing Parts in the Power Structure .
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Page 5: Contents
Who Should Use This Manual This manual is intended for qualified personnel who are responsible for servicing the Bulletin 2364F Regenerative DC Bus Supply Unit (RGU). If you do not have a basic understanding of this unit, please refer to the... -
Page 6: Safety Precautions
Preface Safety Precautions The following general precautions apply to Bulletin 2364F RGUs and to drive systems lineups. ATTENTION: Only those familiar with the drive system, the products used in the system, and the associated machinery should plan or implement the installation, startup, and future maintenance of the system. -
Page 7: Contents Of This Manual
Service Manuals to 6.15 Information for wire sizes, grounding, and other electrical topics National Electrical Code ANSI/NFPA70 A list of all the documentation available through Allen-Bradley Allen-Bradley Publication Index SD499 A glossary of industrial automation terms and abbreviations Industrial Automation Glossary AG-7.1... -
Page 8: Rockwell Automation Support
Preface Rockwell Automation Support Rockwell Automation offers support services worldwide, with Sales/ Support offices, authorized distributors, and authorized Systems Integrators located throughout the United States, plus Rockwell Automation representatives in every major country in the world. Local Product Support Please contact your local Rockwell Automation representative for: •... -
Page 9: Introduction
Chapter Introduction Using This Manual This manual provides information to help service personnel troubleshoot and correct the most common RGU conditions. This troubleshooting guide is laid out with the following topics: • Troubleshooting RGU Conditions • Troubleshooting Warnings and Faults •... -
Page 10: Basic Troubleshooting Techniques
Introduction Basic Troubleshooting When troubleshooting, refer to the system schematics and determine the components that are critical to the process. Test each of the critical Techniques components to determine the problem. Also, consider how the RGU’s programming parameters may be affecting the situation. Consider upgrading to the latest version of firmware available. - Page 11 Introduction The data nameplate shown in Figure 1.3 is located on the power structure and signifies the ratings and the catalog string for the power structure. Figure 1.3 also shows the basic catalog string format. Note: For more catalog string information, refer to publication 2364F-5.01, Regenerative DC Bus Supply (RGU)–User Manual.
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Page 12: Starting And Operating The Rgu
Introduction Starting and Operating the RGU Figure 1.4 shows the process that should be used to start a unit which has been serviced. If the unit is set for local mode, the unit will automatically enable when started. Figure 1.4 Starting and Operating the RGU Setting Up Local M ode Prestart Inspection... -
Page 13: Troubleshooting The Rgu
Chapter Troubleshooting The RGU RGU Conditions This chapter provides troubleshooting instructions for the most common RGU conditions. Choose the topic that most closely represents the condition of your unit. Conditions Handled in This Chapter Unit Will Not Start Unit Will Not Enable Unit Overvoltage/Overcurrent Trips Damaged Components Handling Unresolved... -
Page 14: Unit Will Not Start
Troubleshooting The RGU Unit Will Not Start After the disconnect lever and start switch have been turned on, the RGU should power any connected HIM or GPT devices and perform its precharge routine to raise the voltage of the capacitors on the DC bus. Check the following items if the unit will not operate. -
Page 15: Unit Will Not Enable
Troubleshooting The RGU Unit Will Not Enable After the disconnect lever and start switch have been turned on, the RGU should power any connected HIM or GPT devices and perform its precharge routine to raise the voltage of the capacitors on the DC bus. If the Remote/Local Selector (P8) is set to ‘Local Only’, the RGU should automatically enable when the precharge routine finishes. -
Page 16: Unit Overvoltage/Overcurrent Trips
Troubleshooting The RGU Unit Overvoltage/Overcurrent Check the following items if the unit frequently has an overvoltage or overcurrent trip. Trips Set P4 to match the catalog number shown Does the Frame Catalog Number (P4) show on the data nameplate (see Chapter 1). the appropriate catalog number for the unit? Does the AC Line Inductance (P12) show Calculate the total inductance and set P12. - Page 17 Troubleshooting The RGU Damaged Components Damaged components may be suspected if a loud discharge or melting smell has come from the RGU. Check the following items to find damaged components. ATTENTION: Push the disconnect lever to off and verify zero volts across the DC bus before testing the following items.
- Page 18 Troubleshooting The RGU Handling Fault Conditions Typically, a fault condition can be resolved through the process shown in flowchart below. See chapter 3 for details on handling specific faults and warnings. Resume normal operation. Clear the fault Not OK Send an enable command (by HIM, GPT, SCANport device) Not OK Reset or restart the unit...
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Page 19: Troubleshooting Faults And Warnings
Chapter Troubleshooting Faults and Warnings Contents This chapter covers the faults and warnings which may indicate troubled conditions in the RGU. When the RGU indicates a warning, fault, or status condition, you may need to take remedial action as stated in this chapter. Topics in this chapter Faults and Warnings How to Check the Warning and Fault Queues... -
Page 20: How To Check The Warning And Fault Queues
Troubleshooting Faults and Warnings How to Check the Warning and When a fault condition occurs, the RGU will store the fault information in the fault queue. The fault queue will indicate the fault condition, the Fault Queues sequence number of the fault, and will display ‘Trip’ if the fault caused the RGU to trip. - Page 21 Troubleshooting Faults and Warnings To view the warning or fault queue with a GPT, go to the main menu by pushing F1, then choose either Fault Queue or Warning Queue. The fault queue should appear as shown in Figure 3.5. The fault queue can be cleared by entering the fault queue and pressing F1 to clear the fault or F2 to clear the queue.
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Page 22: Resetting The Rgu
Troubleshooting Faults and Warnings Resetting the RGU If a fault is the result of a hardware or software failure, the unit may need to be reset to reinitialize the hardware and software before the unit can be enabled. The RGU can be reset by: •... -
Page 23: Troubleshooting Faults And Warnings
Troubleshooting Faults and Warnings Troubleshooting Faults and The following list provides information for understanding and trouble- shooting each fault or warning condition in the RGU. Warnings Parameters can be stored in the internal memory of a GPT or Series B HIM, or can be stored and printed out using DriveTools software. - Page 24 Troubleshooting Faults and Warnings Number Fault Indicates Action M1 Open M1 contactor opened while the RGU is in Clear the fault and try resetting/restarting the RGU. Check all P174 bit 6 ready or running state. feedback wiring. Verify that the door-mounted start switch is turned on.
- Page 25 Troubleshooting Faults and Warnings Number Fault Indicates Action Board Intlk The voltage feedback connector (J1) or the Verify that the J1 and J7 connections on the isolation board are P177 bit 1 current feedback connector (J7) is not secure and that the wiring is in good condition. Check the AC line plugged into the isolation board.
- Page 26 Troubleshooting Faults and Warnings Number Fault Indicates Action DualPort TO The DSP did not receive any data from the Clear the fault and try resetting/restarting the RGU. Verify that all P177 bit 12 host processor. The DSP assumes that the connections to the main control board are in place, and check the host is not running.
- Page 27 Troubleshooting Faults and Warnings Number Fault Indicates Action DPRAM Error An error has been detected in the dual port Clear the fault and try resetting/restarting the RGU. Verify that all P180 bit 8 RAM between the host processor and the connections to the main control board are in place, and check the DSP.
- Page 28 3-10 Troubleshooting Faults and Warnings Number Fault Indicates Action I2t Overload The I2t wire protection has tripped the unit The internal wiring may be at risk of overheating. Check that the P183 bit 1 since the heatsink to power module junction door fans are operating properly, and verify that the RGU is operating temperature has exceeded the maximum at the appropriately derated current (see the specifications appendix...
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Page 29: Testing Components
Chapter Testing Components Components This chapter provides instructions for testing RGU components. The topics listed below are covered in this chapter. Topics in this Chapter Testing and Replacing Parts in the Power Structure Testing the Main Control Board Testing the Gate Driver Board Testing the Isolation Board Testing the Control Power Filter Testing the Line RC Suppressor... -
Page 30: Testing And Replacing Parts In The Power Structure
Testing Components Testing and Replacing Parts in The RGU power structure design is based on the 1336 FORCE drive. To test or replace parts in the power structure, refer to the instructions in this the Power Structure publication, and refer to the appropriate 1336 FORCE service manual, listed in Table 4.A, for additional details. -
Page 31: Testing The Main Control Board
Testing Components Testing the Main Control Board The main control board regulates the power structure operation, and is capable of communication with external devices through SCANport and analog I/O. Figure 4.1 Main Control Board Main Control Board TP4 (+5V) LEDs TP20 (+15V) TP23 (AGND) TP26 (-15V) - Page 32 Testing Components 1. With power applied to the unit, check the LED indicators on the main control board (see Figure 4.2). Figure 4.2 LED Indicators Normal Operation The LEDs should be illuminated as shown when +15V Host Enable SCAN port R2R OK -15V the unit is enabled.
- Page 33 Testing Components 3. Set meter for AC voltage. Check the AC line feedback by testing the voltage of TP32, TP33, and TP34 with respect to AGND. Table 4.C shows the typical voltages that should be seen for these test points. Table 4.C: AC Line Feedback Test Points–Main Control Board Rated Line Voltage Typical Voltage at Test Points...
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Page 34: Replacing The Battery For The Battery-Backed Memory On The Main Control Board
Testing Components Replacing the Battery for the Battery-Backed Memory on the Main Control Board Replacing the battery on the main control board (U11) will erase all modified parameters. Record parameters before replacing the battery. 1. Push the disconnect lever to off and wait for all voltage to discharge from the unit. -
Page 35: Testing The Gate Driver Board
Testing Components Testing the Gate Driver Board The gate driver board turns the IGBT gates on and off and supplies power to the main control board and isolation board. Figure 4.4 Accessing the Gate Driver Board Remove screws and nuts Publication 2364F-5.05 - March 1999... - Page 36 Testing Components Figure 4.5 Gate Driver Board Gate Driver Board TP5 (+15V) TP7 (DGND) TP6 (-15V) TP4 (+5V) Note: A full listing of test points and a detailed illustration of the gate driver board can be found in Appendix A. 1.
- Page 37 Testing Components 7. Set meter(s) to test for DC voltage. 8. Connect meter leads to the test points indicated in Table 4.E (if necessary, test only one set of test points at a time). Table 4.E: Power Supply Test Points–Gate Driver Board Test Points Typical Voltage TP4 to DGND...
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Page 38: Testing The Isolation Board
4-10 Testing Components Testing the Isolation Board The isolation board receives feedback from the AC line, DC bus, current transducers, main contactor (M1), and reset button. This feedback is passed to the main control board for processing. Figure 4.6 Isolation Board Isolation Board Burden Resistors... - Page 39 Testing Components 4-11 4. Set meter to test resistance. 5. Check the resistance of each burden resistor. Replace any burden resistors that do not comply with the specifications give in Table 4.G. Table 4.G: Burden Resistor Specifications Current Rated Input Rated Resistance Code Voltage...
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Page 40: Testing The Control Power Filter
4-12 Testing Components Testing the Control Power Filter The control power filter reduces the noise in the control power. The effectiveness of the filter can be checked by viewing the waveforms before and after the filter (there should be less noise seen after the filter, as shown in Figure 4.7). -
Page 41: Testing The Line Rc Suppressor
Testing Components 4-13 Testing the Line RC Suppressor The line RC suppressor discharges excess voltage from the AC lines. 1. Push the disconnect lever to off and wait for all voltage to discharge from the unit. Do not continue until all voltage has dissipated from the DC bus. -
Page 42: Testing The Dc Bus Suppressor
4-14 Testing Components Testing the DC Bus Suppressor The DC bus suppressor discharges excess voltage from the DC bus. 1. Push the disconnect lever to off and wait for all voltage to discharge from the unit. Do not continue until all voltage has dissipated from the DC bus. -
Page 43: Testing Movs
Testing Components 4-15 Testing MOVs MOVs provide surge, line-to-line, and line-to-ground protection for the RGU. 1. Push the disconnect lever to off and wait for all voltage to discharge from the unit. Do not continue until all voltage has dissipated from the DC bus. -
Page 44: Testing Igbts
4-16 Testing Components Testing IGBTs IGBTs can be checked by testing the resistance of the AC terminals with respect to the DC busbars. 1. Push the disconnect lever to off and wait for all voltage to discharge from the unit. Do not continue until all voltage has dissipated from the DC bus. - Page 45 Testing Components 4-17 Figure 4.12 Check Points on AC Line and DC Bus (J, K, and L-code RGUs) DC Bus + DC Bus - Figure 4.13 Check Points on AC Line and DC Bus (M and N-code RGUs) DC Bus - DC Bus + Publication 2364F-5.05 - March 1999...
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Page 46: Terminal Blocks
4-18 Testing Components Terminal Blocks The RGU includes two terminal blocks which are available for customer connections (TB1 and TB2, shown in Figure 4.14). These terminal blocks are located in the leftmost bay of the unit. The RGU also has an analog I/O terminal block available for customer connections (TB1, on the main control board). -
Page 47: Reference Information
Appendix Reference Information Contents This appendix includes reference information for the RGU, as indicated below. Reference Information in This Chapter Specifications Printed Circuit Boards Test Points Board-to-Board Schematics Firmware Diagrams Specifications Table A: Functional Specifications Efficiency AC Input Frequency Tolerance 45 to 65 Hz AC Input Voltage Tolerance ±10%... - Page 48 Reference Information Table B: Electrical Specifications–Part 1 Nominal Continuous Maximum Control Transformer Ratings Input AC Line Input Nominal DC Continuous DC Basic Standard ôRated DC Current Voltage Current Power Bus Voltage Bus Current Capacity Capacity Code (V AC) (A AC) (kVA) (V DC) (A DC)
- Page 49 Reference Information Electrical Specifications–Part 2 Input Internal Line Overcurrent Overcurrent Overvoltage Overvoltage Burden Warning Trip Current Voltage Capacitance Inductance Trip Trip Reference Trip Trip Reference Resistor Temperature Temperature Code (V AC) (uF) (uH) (Arms) (TP20 Volts) (V DC) (TP22 Volts) (Ohms) (ºC) (ºC)
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Page 50: Printed Circuit Boards
Reference Information Printed Circuit Boards Figure 1 Main Control Board Host SC AN port R 2R +15V -15V Enable Fault Fault To Gate Driver Board (J1) To NTC Bridge Thermal Sensor Digital Signal Processor (DSP) Flash Memory Host Processor TP10 TP11 TP12 TP13... - Page 51 Reference Information Figure 2 Gate Driver Board TP 8 TP17 To Main Control Board (J3) Used TP19 Used To Power Module Snubber Boards TP 2 To Power Module Snubber Boards TP 10 TP16 To PE TP18 TP 14 Not Used Not Used Not Used To DC Bus...
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Page 52: Test Points
Reference Information Test Points Table F: Test Points–Main Control Board Test Points Name Description Scale Typical Range AGND Analog Ground DGND Digital Ground DGND Digital Ground +5V Power Supply 4.8 to 5.5V DC DGND Digital Ground RESET Ground for Reset DGND Digital Ground ANIN8... - Page 53 Reference Information Table G: Test Points–Gate Driver Board Test Points Name Description Scale Typical Range +BUS Positive Bus Input ½ rated DC bus voltage -BUS Negative Bus Input ½ rated DC bus voltage +24V +24V Power Supply 23.7 to 24.3V DC +5V Reference 4.8 to 5.4V DC +15V...
- Page 54 Reference Information Board-to-Board Schematics Figure 4 Board-to-Board Schematics 20 19 18 17 16 15 14 13 12 11 10 9 8 AUXILIARY RELAY COM CLEARANCE AUXILIARY RELAY NC LEM INTERLOCK AUXILIARY RELAY NO -15V PHASE R CLEARANCE PHASE R LEM BUS CONTROL RELAY COM +15V PHASE R Isolation Board...
- Page 55 Reference Information NOT USED NOT USED NOT USED TO GATE INTERFACE BOARDS CONTACTOR INTERFACE 2 3 4 5 6 AC LINE /CHARGE AC FAN1 AC FAN2 COMMON 120VAC -15V 120RTN Gate Driver Board +15V 24V+ OUT USED 24V- OUT -SMPS +SMPS 4 5 6 13 14...
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Page 56: Firmware Diagrams
A-10 Reference Information Firmware Diagrams Figure 5 Firmware Block Diagram–Regulation Ref Change Rate Bus Rate Ref Bus Reference M ax M in Bus Rate M in Bus Ref M ax Bus Ref Aux Volt Cm d Volt M ode Sel Bus Volt Cm d Bus Ref Auto Ref Lim it... - Page 57 Reference Information A-11 pi Error Lim it pi Err Lim Step pi Err Gain Lim Err Lim iter Bus Error iq Pos Lim it Aux iq Cm d Error Lim iter iq Neg Lim it iq Com m and iq kp Gain pi Reg Out Linearizer Filtered iq Ref...
- Page 58 A-12 Reference Information Figure 6 shows the parameter settings that are made in response to a control mode selection. Figure 6 RGU Control Mode Selection Stand alone Param eter Nam e M aster Slave Notes R GU M ode RG U Control M ode Iq M ode Select S lave set to Aux Iq Com m and Current Loop Bandw idth...
- Page 59 Glossary 1336 FORCE Adjustable Frequency AC Drive An adjustable frequency AC drive produced by Rockwell Automation. Most of the construction and components of the RGU power structure are equivalent to the 1336 FORCE drive. Control Power Filter A filter used to reduce harmonics and noise in the 115V AC control power. Digital Signal Processor (DSP) The digital signal processor which is located on the main control board of the RGU.
- Page 60 Main Control Board The RGU main control board regulates the voltage and current, oversees activities in the unit, and processes I/O. This board is isolated from the power circuitry. Metal-Oxide Varistor (MOV) A component used to protect against voltage surges and excessively high line-to-line/line-to-ground voltages.
- Page 61 Index Numerics 2-5, 4-16 1336 FORCE IGBTs (power modules) 1-1, 4-2 4-10, 4-11 1336 FORCE service manuals Isolation board Automatically enabling the RGU LED indicators 4-13 Line RC suppressor Local mode 1-4, 2-3 Loud discharge 3-5, 3-8, 4-6 Battery-backed RAM Burden resistors 4-11 M1 Open...
- Page 62 Index Terminal blocks 4-18 1-2, 2-1, 3-1, 4-1, A-1 Troubleshooting 4-12 Control power filter Damaged components 4-14 DC bus suppressor 2-6, 3-2, 3-3, Faults and warnings 3-5, 3-6, 3-7, 3-8, 3-9, 3-10 4-7, 4-8, 4-9 Gate driver board 4-16 IGBTs (power modules) 4-10, 4-11 Isolation board 4-13...
- Page 63 Index Publication 2364F-5.05 - March 1999...
- Page 64 Publication 2364F-5.05 - March 1999 PN 192693 Supersedes Publication 2364F-5.05 - January 1999 ©1999 Rockwell International Corporation. Printed in the U.S.A.