1

888 Displayed on Front panel display

This can be caused by, loss of communication between the Display board and Control board, or if the display board does not ‘boot up’ properly

Check which status LEDs on the front panel are lit.  Check the LCD display on the control board for fault code.  Ensure good ribbon cable connection between boards.

1a

Electrical Noise

Press the E-stop on the front panel.  Wait for the DC Buss to bleed down (light on power board and control board will not be lit).  Pull E-stop.  If 888 Clears, the problem was probably caused by transient noise.  Check grounding of power supply and treater station.  Ensure interlock wires, speed sensor wires, and any other interconnecting wires are properly shielded or run in grounded metal conduit.  Ensure these wires are not routed closely to high voltage or the P6000 output cable.  888 can be the result of a current surge caused by arcing in the treater station.  See Current Trip Fault.

1b

Power Board

Ensure the orange light on the back of the power board is illuminated. 

1c

Control Board

Ensure the Red LED (D28), on the control board is lit.  Check the LCD display on the control board for fault code.  If D28 is not lit, Replace control board.

1d

Control Board displays F51 Fault

Install a jumper at J5, on the control board.  If the F51 does not clear, replace the control board.  Remove J5 jumper.

1e

Control Board displays F01 Fault

Check the voltage at +VBUS to –VBUS, on the power board.  Ensure voltage is approx. 330VDC.  If voltage is not present, replace power board.  Check the power connection between boards by measuring the same 330VDC at the Left side of R40, on the control board, and –VBUS.  If voltage is not present, remove all power from the P6000.  Wait for DC Bus to bleed down (light on power board and control board will not be lit).  Ensure the control board is properly seated, and connection pins and receptacles are in good condition.

1f

Display Board

Check the status of status LEDs on the front panel.  If all LEDs are lit, replace Display board.

1g

Ribbon Cable

Ensure ribbon cable is properly and securely plugged into the display board and the control board. 

2

Interlock Fault

Treater station interlock is open.  Roll speed is below minimum speed. Customer supplied interlock is open.  Display board

Ensure all interlocks between TB-501 and TB-506 are closed.  Line speed above minimum speed set point.  ½ power inputs are satisfied.

2a

Interlocks Open

Connect a jumper between TB-501 and TB-506.  If interlock fault clears, troubleshoot treater station interlocks and any customer supplied interlocks.

2b

Below minimum speed

Check dip switches on the display board.  If Dip switch #8 is down, skip to the next step.  Press E-Stop on the front panel.  Wait for DC Bus to bleed down (light on power board and control board will not be lit).  Turn off (down) dip switch #8.  Pull E-stop.  If interlock fault clears, re-set minimum speed (Step 12d).

2c

½ power inputs

On the component side of the Display board, Ensure LEDs D10 and D15 are lit.  If treater station is equipped with Electrode High Voltage selector switches, ensure both switches are in the ON position.  If fault does not clear, connect a jumper between TB-1221 to TB-1231, and TB-1241 to TB-1251.

2d

Loose electrical connection

Turn off all power to the P6000.  Wait for DC Bus to bleed down (light on power board and control board will not be lit).  Check all electrical connections at the main terminal strip and on the display board.

2e

Display board

Ensure all connectors on the display board are tight.  Connect a jumper between TB-501 and TB-506, Turn off (down) dip switch # 8 on the display board.  Connect a jumper between TB-1221 to TB-1231, and TB-1241 to TB-1251.  If Interlock fault does not clear, replace the display board.

3

Current Trip Fault

Arcing caused by pinhole in dielectric, dirty insulators, roll, electrode, HV transformer. Power board or control board

Isolate treater station, and HV transformer

3a

Impedance Mismatch

Check Electrode gap. Re-tap output transformer.  See impedance matching section of your manual.

3b

Arcing in Treater station or HV wiring

Remove all power from the P6000.  Wait for DC Bus to bleed down (light on power board and control board will not be lit).  Remove high voltage wire from the transformer nose cone.  Re-energize P6000.  Press Start. If current trip does not light, the problem is in the treater station or high voltage wiring.  Look for signs of arcing, burning and carbon tracking in the treater station.

3c

HV Transformer

Remove all power from the P6000.  Wait for DC Bus to bleed down (light on power board and control board will not be lit).  Disconnect the P6000 output wires 1073 and 1074 from the terminal block in the P6000 cabinet.  Re-energize P6000.  Press Start.  If the Current Trip light does not light, replace the HV transformer

3d

Control Board and Power Board

Check the LCD display on the control board for fault codes. 

3e

Fault code F46

Replace the control board.

3f

Fault Code F52 or F53

Replace the power board.

4

No Lights lit on Front Panel

Loss of power or faulty display board

Trace line voltage through the P6000.

4a

Display Board

Check for 115vac on wires # 2 and 1303 at TBB1-1 and TBB1-3 on the display board.  If voltage is present, replace the display board.

4b

Line voltage problems

Check the line voltage at the top of the disconnect switch.  Input voltage should measure 230VAC phase to phase.

4c

Defective disconnect switch.

Check for 230 VAC on wires L1 and L2 on the bottom of the disconnect switch.  If voltage is not correct, replace the disconnect switch.

4d

Defective line filter

Check for 230 VAC on L1 and L2 on the top side of the line filter.  If voltage is not correct, replace the line filter

4e

Open line fuse

Check for 230VAC on 1021 and 1031 on the top of contactor K1.  If voltage is not correct, replace fuses.

5

High temp Fault

(F02 Fault)

IGBT temperature is too high

Check for proper cabinet fan operation, dirty air filters and ensure heat sink fins are clean.

5a

Cooling fans not operating

Check operation of the heat sink cooling fan, also check the fans mounted to the side of the cabinet.  Clean air filters.

5b

Heat Sink Dirty

Remove control board and power board.  Check the back side of the heat sink.  Ensure the heat sink cooling fins are clean.

5c

Cabinet Mounting

At least 1 foot of free space must be allowed on all sides of the treater cabinet.  If mounted near heat producing equipment, allow more space.

5d

Power Board

Replace power board.

5e

High Ambient Temperature

Provide additional cooling to the cabinet if possible.

6

DC Bus Trip

(F40 or F41 Faults)

DC Bus voltage is too high or too low

Check incoming line voltage, fuses, disconnect and contactor. 

6a

Line voltage problems

Check the line voltage at J1 to J2 on the power board.  Input voltage should measure 230VAC phase to phase.

6f

Power Board

Check for about 330vdc on the power board at +VBUS to -VBUS.  If the DC voltage is too low, replace power board.

6g

Control Board

If all other checks are OK, replace the control board.

7

Overvoltage Trip

(F42 Fault)

Output exceeds maximum voltage

7a

Impedance Mismatch

Check electrode gap.  Re-tap output transformer.  See impedance matching section of your manual.

7b

Control Board

Replace Control Board

7c

Power Board

Replace Power Board

8

Alarm Fault

This “fault” will light when the interlock fault is lit and when the actual power output is more than 5% away from the power setpoint

Alarm fault may be on when P6000 is not running.  If alarm fault is lit while generating corona, check for limit lights that may be lit.  If a limit light is lit, Check for proper gap between the electrode and the treater roll.  Change taps on the HV transformer.  See Impedance matching section of you manual.  Also check the status of the power control and inverter on Lamps.

9

Frequency Limit

P6000 is operating at maximum output frequency

If unable to achieve full power, Check for proper gap between the electrode and the treater roll.  Change taps on the HV transformer.  See Impedance matching section of your manual.

10

Voltage Limit

P6000 is operating at maximum output voltage

If unable to achieve full power, Check for proper gap between the electrode and the treater roll.  Change taps on the HV transformer.  See Impedance matching section of your manual

11

Current limit

P6000 is operating at maximum output current

If unable to achieve full power, Check for proper gap between the electrode and the treater roll.  Change taps on the HV transformer.  See Impedance matching section of your manual

11a

Current Limit has been inadvertently changed

Press the Current button on the front panel.  Monitor the output current on the display.  Maximum current for 2.0KW and smaller units is 30 amps.  Maximum current for 2.5KW and 3.0KW units is 45 amps.  If your unit is limiting below this, contact Pillar Technologies Service Dept.

12

No power output.  Inverter on light flashes

Line speed below minimum speed, Auto start input open, Faulty display board.

12a

Display board

Press and hold the Stop button.  If Inverter On continues to flash, while Stop is depressed, replace the display board.

12b

Auto Start contacts open

If dip switch #8 is in the down position, remove all power.  Wait for the DC Bus to bleed down (light on power board and control board will not be lit).  Connect a jumper between TB-801 and TB-802.  Re-energize and start P6000. 

12c

Speed sensor

If dip switch #8 is in the up position, check the encoder LED, D14, on the component side of the display board.  D14 should flash each time the speed sensor senses a target, if not, check your speed sensor.

12d

Below minimum speed

If Dip switch #8 is in the up position, re-set minimum speed:  Run the line speed at least 3mpm (10fpm) below the minimum production speed.  Press and hold the Alarm Silence button and Frequency Button simultaneously, until the Front Panel displays encoder frequency.  Note display.  Press and hold the Alarm Silence button and Stop button simultaneously, until front panel displays encoder frequency again.  This sets the minimum speed.  Increase speed.  Ensure interlock light extinguishes.