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Parker 590+ series Frame 1, 2, 3, 4, 5, 6 & H. Product Manual (2012) - page 14

Trips and Fault Finding

7-19

Test Points

The following test points are located on the control board and can be accessed through the Technology Option housing. When used with a meter, they

will provide valuable information in the event of a fault. Refer to Parker SSD Drives for further information.

IF

VA

Technology Box

IA

Option

0V

Test Points viewed through the front of the drive.

Test Point

Description

IF

Field current feedback

0.0V = 0% 4.0V =100% (mean voltage),

value of FIELD I FBK diagnostic, Tag No. 300

IA

Armature current feedback ± 1.1V ≡ ±100% (mean current),

value of CURRENT FEEDBACK diagnostic, Tag No. 298

VA

Armature volts feedback +5V ≡ +100%, +2.5V ≡ 0%, 0V ≡ -100% calculated VA (mean voltage),

value of TERMINAL VOLTS diagnostic, Tag No. 57

0V

Control board 0V reference

Routine Maintenance and Repair 8-1

Maintenance

Because of its solid state design, the DC590+ Digital drive has few items requiring service or maintenance. Service is typically a matter of replacing

fuses, checking electrical contacts, and isolating problems in the overall system application.

WARNING

Service procedures must be performed by qualified personnel with an understanding of the dangers inherent in high voltage applications and the

precautions necessary when servicing industrial equipment. The customer is responsible for assessing the technical competency of in-house service

personnel.

Service Procedures

Required Tools and Equipment

Tools needed for routine service operations include basic hand tools — screwdrivers, wrenches, etc.

WARNING

Only qualified service personnel should attempt to repair or replace parts in the 590+.

Isolate the entire 590+ drive from electrical power before attempting to work on it.

Preventive Maintenance

You should perform regular preventive maintenance every six months to ensure long life and continued usefulness of the 590+. Keep the drive and its

components clean, check auxiliary fans if fitted, and make sure connections and mounting bolts have not loosened from vibration.

The control and field wires can be checked by gently attempting pulling the wires out of the terminals. The terminals should hold the wires firmly in

place.

All the remaining wires should be checked with a torque wrench. Refer to Appendix E: "Technical Specifications" - Termination Tightening Torque

tables.

8-2 Routine Maintenance and Repair

Repair

There are no user-serviceable components. This section contains information for repair work that may be undertaken.

Saving Your Application Data

The Drive retains saved settings during power-down. You can download and upload this back into the repaired unit, if necessary. You may, depending

upon your knowledge of the fault, attempt the back-up of your application data now, refer to Chapter 6: “The Keypad” - Copying an Application.

If the fault clearly lies within the MMI, then return the unit for repair.

Returning the Unit to Parker SSD Drives

Before calling Parker SSD Drives Customer Service, make sure you have the following information available:

Information

Source

Model number and serial number

DC590+Digital drive rating label

Motor horsepower, armature current and voltage, field current and voltage, base and top

Motor nameplate

speed ratings

Speed voltage feedback per 1000 RPM (analog device), or counts per revolution(digital device)

Speed feedback device nameplate

Applications information and operating environment

System drawings.

Contact your nearest Parker SSD Drives Service Centre to arrange return of the item.

You will be given a Returned Material Authorisation. Use this as a reference on all paperwork you return with the faulty item.

Pack and despatch the item in the original packing materials; or at least an anti-static enclosure. Do not allow packaging chips to enter the unit.

Warranty Information

Warranty information precedes the Contents at the front of this manual.

Routine Maintenance and Repair 8-3

Disposal

This product contains materials which are consignable waste under the Special Waste Regulations 1996 which complies with the EC Hazardous Waste

Directive - Directive 91/689/EEC.

We recommend you dispose of the appropriate materials in accordance with the valid environmental control laws. The following table shows which

materials can be recycled and which have to be disposed of in a special way.

Material

Recycle

Disposal

metal

yes

no

plastics material

yes

no

printed circuit board

no

yes

The printed circuit board should be disposed of in one of two ways:

1. High temperature incineration (minimum temperature 1200°C) by an incinerator authorised under parts A or B of the Environmental Protection Act

2. Disposal in an engineered land fill site that is licensed to take aluminium electrolytic capacitors. Do not dispose of in a land fill site set aside for

domestic waste.

Packaging

During transport our products are protected by suitable packaging. This is entirely environmentally compatible and should be taken for central disposal

as secondary raw material.

Technical Support Checks

The results of the following checks will be very useful to Parker SSD Drives’ Technical Support.

WARNING

Please only attempt these checks if you are electrically competent.

9 or 8

Miscellaneous Checks

Check 24V present at Terminals C1 to C9 (C1 is 0V) - dc

Check ±10V present at Terminals B3 and B4 (B1 is 0V) - dc

Check auxiliary supply present at Neutral & Line, 110/240V ac

Check the fans rotate, where applicable

8-4 Routine Maintenance and Repair

WARNING

Now isolate the unit completely from all supplies. It may be necessary to remove an armature and field

connection to carry out the following checks.

Continuity Test on Fuses Using a Meter

9

or 8

Check the coding fuses on the power board

Check the auxiliary fuses etc. (fan fuse, if applicable)

Diode Check on Power Terminals Using a Meter

9

or 8

A+ to L1, L2, L3 and Earth Terminal = Open Circuit

A- to L1, L2, L3 and Earth Terminal = Open Circuit

Internal Field Check Using a Meter

9

or 8

All the coding fuses must be OK before continuing with the following checks since the fuses are in the circuit.

-ve to L1 & +ve to F+ = Diode Drop (approximately 0.5V)

-ve to L2 & +ve to F+ = Diode Drop (approximately 0.5V)

-ve to F- & +ve to F+ = Diode Drop (approximately 0.5V)

-ve to L1 & +ve to F- = Open Circuit

-ve to L2 & +ve to F- = Open Circuit

External Field Check Using a Meter

9

or 8

-ve to FL1 & +ve to F+ = Diode Drop (approximately 0.5V)

-ve to FL2 & +ve to F+ = Diode Drop (approximately 0.5V)

-ve to F- & +ve to F+ = Diode Drop (approximately 0.5V)

-ve to FL1 & +ve to F- = Open Circuit

-ve to FL2 & +ve to F- = Open Circuit

Make a note of the Serial Number and Model Number.

Serial Number

Model Number

Re-establish all connections. All terminals should be secure and not over-torqued.

Routine Maintenance and Repair 8-5

Repairs for Frames 4 & 5

Replacing the Fan (Frames 4 & 5)

WARNING!

Ensure that all wiring is

electrically isolated and cannot be

made “live” unintentionally by other

personnel.

Remove the terminal cover. Unscrew the three

screws securing the baffle and remove. Disconnect

the fan supply cable. Remove the two M8

earth/ground screws on the back of the drive

(Frame 5). Remove the fan cover. Remove the fan

assembly and screws as detailed above.

Reverse the procedure for refitting the fan

assembly - refer to the refitting note in the diagram

above. The replacement fan assembly includes the

fan, cover and capacitor, requiring just a simple

connection of the supply cable.

Heatsink Cooling Fan

Connections

These fans are connected on the power board to the

cooling fan supplies, CONN 2 or 3 as described

below:

•

380, 500, 725, 830A models have a single fan

matched to the auxiliary supply and connected

to CONN 2.

1580A models have two fans matched to the

auxiliary supply connected to CONN 2 & 3.

8-6 Routine Maintenance and Repair

Repairs for Frame 6

WARNING!

The phase assembly metalwork (L1, L2 & L3) is LIVE when the unit is switched on. Isolate the entire DC590+

drive from electrical power before attempting to work on it.

Only qualified service personnel should attempt to repair or replace parts in the 590+.

AC Fuse Replacement (Frame 6 Non-Regen Unit - 2Q)

The AC fuse can be replaced in-situ. With the front of the drive removed (the Control Panel Assembly), the replacement should take about 20 minutes.

Removing the Control Panel Assembly from the cubicle completely will make access easier, but requires the removal of all connections made to it. It

may be possible to support the Control Panel Assembly (11.25kg/25 lbs) and sling it away from the Phase Assemblies far enough to gain access.

Removal

1. Loosen the retaining screws in the Field Controller plug. Unplug all connections to the Door Assembly

(control connections) and the Field Controller (Auxiliary Plug and Field Plug).

2. Undo the fixings to remove the front cover from the Control Panel Assembly.

3. Disconnect the flying leads of the Control Panel Assembly from the three Phase Assemblies. Remove the

external earth connection(s) made to the Front Cover.

4. Remove the 12mm x M6 fixings in the four corners that secure the Control Panel Assembly. Loosen the

top and bottom central support screws (but do not remove) and lift the Control Panel Assembly away

from the three Phase Assemblies.

5. Remove the fixings that secure the failed Phase Assembly front cover.

6. Disconnect the fishplate connected to the AC Busbar.

7. Slowly remove the ACCT's fixing bolt and washer from the AC Busbar, supporting the ACCT and large

(rubber) washer as you do so. Lower the ACCT to one side and remove the rubber washer.

8. The fuse is mounted on a plate. Remove this Fuse Assembly from the Phase Assembly.

9. On the bench, undo the central bolt from the Fuse Assembly taking note of the placement of washers and

other parts.

8-8 Routine Maintenance and Repair

5. Remove the four screws that secure the failed Phase assembly front panel. Remove

the front panel.

6. Remove the bolts securing the fishplates to the DC Busbar nearest the failed fuse.

7. If the failed fuse is located underneath the AC busbar: slowly remove the ACCT's

fixing bolt and washer from the AC Busbar, supporting the ACCT and large

(rubber) washer as you do so. Remove the rubber washer and lower the ACCT to

one side.

8. Unplug the lead connected to the microswitch that is fitted to the side of the Fuse

Assembly.

9. The fuse is mounted on a plate. Remove the two bolts and washers that secure this

plate to the Phase Assembly and lift away the Fuse Assembly and DC Busbar.

10. On the bench, undo the central bolt from the Fuse Assembly taking note of the

placement of washers and other parts. Re-build the assembly with the new fuse.

Tighten the DC Busbar bolt to 45Nm (33 ft.lbf).

Refitting

1. Refit the Fuse to the Mounting Plate. Torque to 45Nm (33 ft.lbf). Fix the mounting

plate to the Phase Assembly, securing it with the two bolts and washers. Torque to 32Nm (23.6 ft.lbf).

2. Plug the lead back onto the microswitch (removed earlier).

3. Slide the AC busbar into in the Phase Assembly and secure with the bolt and washer. Torque to 45Nm (33 ft.lbf).

4. Refit the fishplates that connect to the DC Busbars. Torque to 55Nm (40.6 ft.lbf).

5. Offer up the Control Panel Assembly to the three Phase Assemblies and hang on the central support screws. Secure with 12mm x M6 screws and

washers.

6. Reconnect the flying leads of the Control Panel Assembly to the three Phase Assembly units. Tighten the retaining screws in the Field Controller

plug. Refer to Chapter 3: "Installing the Drive" - Frame 6: Assembly and Installation - Terminals.

7. Refit the front cover to the Control Panel Assembly, securing with the screws and washers. Connect the external earth to the Front Panel.

Routine Maintenance and Repair 8-9

Replacing a Phase Assembly (Frame 6)

NOTE

The Non-Regen Phase Assembly (2Q) weighs 28kg (62 lbs)

The Regen Phase Assembly (4Q) weighs 33kg (73 lbs)

With the front of the drive removed (the Control Panel Assembly), the replacement should take

about 20 minutes. Removing the Control Panel Assembly from the cubicle completely will make

access easier, but requires the removal of all connections made to it. It may be possible to support

the Control Panel Assembly (11.25kg/25 lbs) and sling it away from the Phase Units far enough to

gain access.

Removal

1. Remove the plugs for the control wiring, auxiliary supply and field connections (loosen the

screws to remove the field plug). Remove the Protective Earth connections (PE).

2. Undo the fixings to remove the front cover from the Control Panel Assembly.

3. Disconnect the flying leads of the Control Panel Assembly from the three Phase Assemblies.

4. Remove the 12mm x M6 fixings in the four corners that secure the Control Panel Assembly.

Loosen the top and bottom central support screws (but do not remove) and lift the Control Panel Assembly away from the three Phase Assemblies.

5. Remove the bolts securing the fishplates to the DC Busbars.

6. Fit an M10 x 20mm long "temporary hanging" bolt to the "temporary hanging" mounting hole (top-centre) of the phase assembly to be removed.

Screw it in loosely, leaving a few millimetres of thread still showing.

7. Remove the fixing bolts that hold the failed Phase Assembly onto the back panel. Lift it off the "temporary hanging" bolt. Refer to the note about

weights at the top of the page.

Refitting

1. Hang the new Phase assembly onto the "temporary hanging" bolt. The fans should be at the bottom of the unit. Fit the 4 off M10 bolts and torque to

32Nm (23.6 ft.lbf).

2. Remove the "temporary hanging" bolt.

3. Refit the fishplates to the DC Busbars. Torque to 55Nm (40.6 ft.lbf).

4. Refit the front panel and secure with four screws and washers.

5. Offer up the Control Panel Assembly to the three Phase Assemblies and hang on the central support screws. Secure with M6 x12mm long screws

and washers.

6. Reconnect the flying leads of the Control Panel Assembly to the three Phase Assembly units. Refer to Chapter 3: "Installing the Drive" - Frame 6:

Assembly and Installation - Terminals.

7. Refit the front cover to the Control Panel Assembly, securing with the screws and washers.

8. Connect the plugs for the control wiring, auxiliary supply and field connections (tighten the screws to secure the field plug). Remake the Protective

Earth connections (PE).

8-10 Routine Maintenance and Repair

Replacing a Fan (Frame 6)

There are two fans mounted inside the base of each Phase Assembly. These are hard-wired together and are supplied as an assembly. Replacement of

both fans is easy and should take about 15 minutes.

Removal

1. Remove the four screws that hold the bottom fan grille in place.

2. Remove the two screws from each fan.

3. Trace the route of the fan cable back to the front of the phase assembly and remove the fan

connector from the phase assembly.

4. Remove the fans and cable assembly from phase assembly.

5. Fit the two fans to the phase assembly and secure with the screws. Hand-tighten.

6. Fit the new fan connector to the front of the phase assembly.

Routine Maintenance and Repair 8-11

Repairs for Frame H

Fuse Replacement (Frame H)

1. Remove the front cover.

2. Unplug the ribbon cables to the trigger boards.

3. Open the swing-frame using the two quick-release fixings at the right hand end.

590+ 4Q Product (Regenerative)

FRONT VIEW

SIDE VIEW

Phase Assembly

Current

Upper Phase Assembly

Connection Screws

Transformer

B

C

Screw

F

G

Fuse

Handles

A

H

I

Fuse

CT Plate

D

E

Phase Assembly

Lower Phase Assembly

Connection Screws

AC Incoming

Busbar

Figure 8-1 590+ (Frame H) Fuse Replacement Diagram

Routine Maintenance and Repair 8-13

591+ 2Q Product (Non-Regenerative)

FRONT VIEW

SIDE VIEW

Phase Assembly

D

E

Fuse Assy/Phase Assy

Fixing Screws

B

C

Fuse

CT Plate/Fuse

Fixing Screws

A

CT Plate/CT Boss

Fixing Screw

Current

Transformer

AC Incoming

Busbar

Figure 8-2 591+ Fuse Replacement Diagram

IMPORTANT

When re-assembling the unit, apply a `zinc-loaded’ jointing compound between the fuses and busbars, and between the

busbars and phase assemblies (BICC BX1 - Parker SSD Part No. EA466241)

Observe all tightening torque levels, refer to Appendix E: “Technical Specifications” - Termination Tightening Torque (Frame H).

Bench-Top Replacement Procedure

Working on the relevant fuse assemblies:

1. Remove the M12 screw (A).

2. Release the two M12 screws (B, C) and remove the CT plate.

3. Remove the two M10 screws (D, E) fixing the fuse assembly to the phase assembly.

4. On the bench, replace the relevant fuse on the fuse assembly.

5. Reverse the procedure for re-fitting.

8-14 Routine Maintenance and Repair

Phase Assembly Replacement (Frame H)

Phase Assembly

Dummy Board

(one only shown

for clarity)

Busbar

Stack of

interconnecting

plates

A-

Trigger Board

(one only shown

for clarity)

4Q

(upper phase assemblies only shown)

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