If the fault cannot be located using the messages received at the
terminal strips, then the diagnostic displays on the front side of each modular unit,
beginning with the supply module, need to be checked. This can be quickly accomplished by
using the figures in Chapter 9. The most practical thing to do first is to check to
see whether the light emitting diodes are displaying the condition „working", as
indicated in these figures. In the presence of a malfunction, the green lamps generally
light up, while the red lamps should be off.
Clearing a Fault:
A reset-key makes it possible to clear all stored fault messages without having to
shutdown the mains auxiliary power/control voltage on the supply module. It is located on
the front on the right hand side at the top above the diagnostics display. The fault
messages are automatically cleared and reset after the control voltage has been turned
back on.7.3.1. Diagnostic Displays on the Power
Supply Modules
If the diagnostic displays on the supply or driving modules indicate a fault, then the
following measures can be taken individually:
The diagnostic displays are only valid if lamp „24V, plus/minus 15V" is
completely lit up.
Power o. k.
With fault -> off No power or fault present.
Possible fault causes and measures:
->
Link circuit throttle connection of the supply module not allocated(does not apply to TVM
1 and 2)
-> No mains power
-> Mains voltage too low
-> Mains power phase
missing
– Link
circuit throttle connection of the supply module not allocated(does not apply to TVM 1 and
2).
-> Check whether the throttle on the link circuit throttle connecting terminals 1L+,
2L+, 1L-, 2L- has been properly attached, or whether a wire strap has been clamped on.
– No mains power
-> Check three-phase mains power connection (Look for fault between mains connection
and supply unit.)
-> Check the mains contactor control
– Mains voltage too low
-> Test mains power at connecting terminals L1, L2, L3 of the supply module.
-> Incorrect transformer connection or fault in mains
– Mains power phase missing
-> Check and re-measure 3-phase mains power at the supply module
-> Check link circuit short-circuit
-> Check mains fuse
– Only applies to KDV2, 3 and 4:
No right rotational field present (fault only occurs the first time the machine or the
drives are connected to the mains).
-> Check rotational field direction at connecting terminals L1, L2, L3 of the supply
module (e.g., with the use of rotational field measuring equipment, or the succession of
phases with an oscilloscope). Exchange leads L1 and L2 on the supply module if there is no
right rotational field. Absolute attention must be paid that mains auxiliary power
connections L1, or L3 remain connected inphase to power connections L1, or L3 of the
supply module KDV, in accordance with connection plans.
– Supply module defective
-> Remove intermediate circuit busbars and bus cable X1 between the supply module and
the driving module, then repeat the above check. If no fault can be found now, and the LED
„power OK" of the supply module is lit up, then the fault is in the connected
drive modules.
-> Exchange supply modules.
+24V, ±15V
With fault -> off
(Only units: TVD 1, KDV 3, KDV 4)
The control voltage for the signal electronics is faulty, or exceeds tolerance (the values
should range between plus/minus 15V : 14.75 ... 15.25 volts, 24V: 22.3 ... 32 volts).
Should this LED flash or not light up, then all other diagnostic messages are invalid!
Possible fault causes and measures:
Short-circuit
in the signal electronics in at least one of the connected drives
Maximum
load of the control voltage plus/minus 15 V or 24 V is being exceeded
– Only applies to KDV3 and KDV4:
No mains auxiliary power at supply module input
-> Check mains connection for auxiliary power
– Short-circuit
in the signal electronics in at least one of the connected drives (in drive module,
feedback cable, or motor feedback).
-> Remove the individual line connections (bus connection X1, feed-back cable, wiring
on the terminal strips) and then
-> measure the 24V, plus/minus 15V voltages at the connection points or terminals and,
in this way, begin to limit the fault (generally short-circuit).
– Maximum
load of the control voltage plus/minus 15 V or 24 V is being exceeded.
-> Check current load via the connected drives in accordance with the data sheet
(current input).
– Only applies to KDV3 and KDV4:
Defective unit fuse in the supply module
-> check fuses,
-> if fault remains, find the fault on the 24 volts or in the fans, and eliminate it,
-> put in new fuses.
AUX. VOLT
With fault -> off
(Only units: KDV 2, KDV 3, KDV 4)
No auxiliary mains power at terminal L1-L3 and fans not working (risk from excessive
temperature). Possible fault causes and measures:
-> Mains failure
-> Supply module
fuses defective
– Mains failure
-> Nothing needs to be done Drives will continue only as long as there is sufficient
power in the link circuit
– Supply module fuses defective
-> Check fuses,
-> See LED "24V, +15V"
-> Insert new fuse
– Supply module fuses defective (Line break, circuit contact defective)
-> Check connection and controller of the mains auxiliary voltage between mains and
supply module.
-> Do not run drives for longer periods of time at full load because fan switched off.
Eliminate fault.
MAINS FAULT or MAINS
O.K.
(Only units: TVD 1, KDV 4)
With fault -> off
Mains fault displayed. Mains power disrupted or improperly connected (voltage too low,
phase missing, no right rotational field)
Possible fault causes and measures:
-> No mains voltage
-> Mains voltage too low
-> No phase
– No mains voltage
-> Measure whether there is mains voltage at connecting terminals L1, L2, L3 of the
supply module. (Look for fault between mains connection and supply unit.)
-> Check controller of the mains contactor.
– Mains voltage too low
-> Measure mains voltage at connecting terminals L1, L2, L3 of supply module.
-> Improper transformer connected or fault in mains.
– Only applies to KDV4:
Right rotational field present (fault only occurs the first time the drives or the motor
connected to the mains).
-> Check rotational field direction at connecting terminals L1, L2, L3 of the supply
module (e.g., using rotational field measuring equipment or the succession of phases with
an oscilloscope). If there is no right rotational field, then exchange lines L1 and L2 on
the supply module.
– No phase
-> Re-measure the three phases of the mains connection voltage
-> Check mains connection
-> Check mains fuses
– Supply module defective
-> Separate link circuit busbars and bus cable X1 between the supply and drive modules
and repeat the above test. If the mains voltage is working after the above test has been
run and the LED „power OK" of the supply module is off, then the supply module
is defective. If „power OK" is lit up, then the fault is in the connected drive
modules.
-> Exchange supply modules
OVERVOLTAGE or
OVERVOLT FUSE
(Only units: TVM, TVD 1, KDV 1)
With fault -> on
Temperature of the loading resistance (bleeder) too high or power section is defective.
After the fault has been eliminated, press the black reset key on front above the
diagnostic display to re-start.
Possible faults and measures:
-> Mains voltage too
high
->
Deceleration energy of all drives too high
– Mains voltage too high:
-> Re-measure the voltage at terminals L1-L2
– Only applies to TVM, TVD 1: Incorrect wiring of the additional bleeder module TBM
-> Check wiring in accordance with connection plan
– Only applies to KDV1:
Fan not running or air inlet and outlet obstructed
-> Check the fan behind the heatsink
-> Check fan fuses or Internal temperature of control cabinet too high
-> Improve ventilation/cooling of control cabinet
– Deceleration energy of all
drives too high:
1. The fault does not occur until after several deceleration procedures. (The deceleration
energy fedback over a mean period is too high.)
-> Check the load and processing cycles of the drives and reduce if necessary.
-> Only applies to TVM: An additional bleeder module TBM or additional capacitance TCM
must be additionally installed.
2. Fault already occurs after the first drive deceleration (generally in an
emergency-off). (The deceleration energy occuring short-term and fedback is too high.)
-> Only applies to TVM: An additional bleeder module TBM must be installed.
-> Reduce energy content of the drives (moment of inertia or max. speed).
– Only applies to TVM, TVD 1: Additional bleeder module TBM defective
-> Exchange additional bleeder module TBM
– Supply module defective
-> Exchange supply module
BLEEDER OVERLOAD
(Only units: TVD 1, KDV 2, KDV 3, KDV 4)
With fault -> on
Deceleration energy of all drives too high (especially in emergency-off) or the supply
module is defective.
After the fault has been corrected, press the black reset key on the front of the
disagnostics display to re-start.
Possible fault causes and measures:
-> Mains voltage too
high
->
Fan not working or air inlet or outlet obstructed
->
Control cabinet internal temperature (ambient temperature) is too high
->
Deceleration energy of all drives too high
– Mains voltage too high
-> Re-measure voltage at terminal L1-L2
– Fan not working or air
inlet or outlet obstructed
-> check fan
-> check fan fuses
– Control
cabinet internal temperature (ambient temperature) is too high
-> improve ventilation/cooling in control cabinet
– Only applies to KDV2 and TVD1: deceleration
energy of all drives too high
1. Fault does not occur until after several drive decelerations. (The deceleration energy
fedback over a mean period of time is too high.)
-> Check the load and processing cycles of the drive and reduce, if necessary.
2. Fault already occurs after the first drive deceleration (generally in emergency-off).
(The short-term deceleration energy fedback is too high.)
-> An additional TBM bleeder module must be installed.
-> Reduce the energy content of the drives (moment of inertia or max. speed).
– Supply module defective
-> Exchange supply module
EARTH CON.
(Only units: KDV 2, KDV 3, KDV 4)
With fault -> on
Ground leak in the supply module, drive module, cables, motor or power wiring.
After fault has been eliminated, press black reset key on front of diagnostics display to
re-start.
Possible fault causes and measures:
->
Check all drive modules for fault message „BS"
-> Ground leak in
supply module
-> Ground leak
in the power wiring
-> Ground leak in a
motor
->
Ground leak in the motor cable or drive module
-> Check all drive
modules for fault message „BS" to immediately determine a drive with a
defective drive module, cable or motor.
– Ground leak in supply module
-> Remove intermediate circuit busbars. If fault should occur again, then the supply
module is defective. If it does not, then the ground leak is in the connected drive
components.
-> Exchange supply module
– Ground leak in the power wiring
-> Visual check of all connections and terminal connections (e.g., intermediate circuit
busbars L+, L- cable connection A1, A2, A3 motor terminal box) for earth contact as well
as all lines for insulation failure.
– Ground leak in a motor
-> Remove all motor cables at the motors. If no ground leak occurs, then ground leak is
in motor.
-> Exchange motor
– Ground leak in the motor
cable or drive module
-> Clamp off motor cable of the drive modules. If ground leak does not occur, then the
motor cable is defective. Otherwise, there is probably a ground leak in the drive module.
-> Exchange motor cable
-> Exchange drive module
OVERCURRENT
(Only units: TVD 1, KDV 3, KDV 4)
With fault -> on
Excess current or short-circuit in the power section of the supply or drive modules or in
the motor.
After the fault has been eliminated, press the black reset key on the front of the
diagnostics display to switch back on.
Possible Faults and Measures:
->
Check all drive modules for fault message „BS"
->
Short-circuit at connecting terminals 1L+, 2L+, 1L-, 2L-
->
Fault only occurs when decelerating the drives
->
Programming module MOD does not fit
->
Short-circuit in the supply module
->
Short-circuit in the power wiring
->
Short-circuit in a drive module
->
Short-circuit in a motor cable or the motor
-> Check all drive
modules for fault message „BS" to quickly find a drive with defective drive
module, cable or motor.
– Short-circuit at
connecting terminals 1L+, 2L+, 1L-, 2L- of the supply module for the link circuit
throttle.
-> Check whether the link circuit throttle or the wire strap at this terminal has been
properly connected in accordance with the connecting plans.
– Fault only occurs when
decelerating the drives: mains inductance too high.
– Programming module MOD does not fit
into the drive module - motor combination
-> Check the rating plate information of all drives with the respective drive module
and motor type to see whether they match.
– Short-circuit in the supply module
-> Remove link circuit busbars from supply module. If fault occurs again, then supply
module is defective. Otherwise, the short-circuit is in the connected drive components.
-> Exchange supply module.
– Short-circuit in the power wiring
-> Visual check of all connections and terminal connections (e.g., link circuit busbars
L+, L-, cable connections A1, A2, A3) as well as all lines for insulation damage.
– Short-circuit in a drive module
-> If the red LED „BS" of a drive module should also light up, then the
fault, in the case of this drive, is in the amplifier, motor or cable.
-> Clamp off the motor cables on drive modules at A1, A2, A3. If a short-circuit should
still occur, then the drive module is defective. Otherwise, the short is in the cable or
motor.
-> Exchange defective drive module
– Short-circuit in a motor
cable or the motor
-> Disconnect the motor cable at the motors. Bridge thermostat contact. If short occurs
now, then the fault is in the motor cable. Otherwise, the motor has an interturn
short-circuit.
-> Measure motor inturn resistance and exchange defective motor.
TEMP. FAULT
(Only units: TVD 1, KDV 3, KDV 4)
With fault -> on
Shutdown due to excessive temperature. The temperature pre-warning via contact TVW was
ignored.
After the fault has been eliminated, press the black reset key on the front of the
diagnostics display to re-start.
Possible fault causes and measures:
-> Fan not working
->
Inside temperature of control cabinet (ambient temperature) too high
->
Overall efficiency of connected drives too high
– Fan not working, air inlet and outlet obstructed or
the heatsink is dirty.
-> Check fan
-> Check fan fuse
-> Clean heatsink, if necessary.
– Inside
temperature of control cabinet (ambient temperature) too high
-> Improve control cabinet ventilation/cooling
– Overall efficiency of
connected drives too high
-> Check the overall efficiency of the drives, a second supply module may be needed.
– Supply module defective
-> Exchange unit
Bb1 CLOSED
(Only units: TVD 1)
With fault -> off
Ready-to-operate contact is open because there is a fault in the supply module or in
drive.
After the fault has been eliminated, press the black reset key on the front of the
diagnostics display to re-start.
Possible fault causes and measures:
– Fault in supply module:
-> Check the other diagnostics lamps to see what fault is present. The green lamp
„+24V/+15V" must be lit up. All red LED’s must be off.
-> Exchange supply module
– Fault in drive module:
-> Check all diagnostic displays on the front of all drive modules, to see which fault
is present. All red LED’s must be off. |
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