PROBLEM |
POSSIBLE CAUSE |
SOLUTION |
Current trip
Resets when stop button is pressed.
|
Impedance mismatch |
Check electrode gap. Re-tap output transformer. See impedance matching section of your manual |
Current trip out of adjustment |
Adjust P18 on the control board 2 turns CCW. |
Note 1: |
High voltage failure at treater |
With power OFF, remove high voltage wire from output transformer secondary. Re-tap the transformer to XO-X4. Start the power supply. Frequency limit LED should lite with no current trip. |
Note 1: |
High voltage transformer failure |
With power OFF, remove output wires from terminal strip in the power supply. Start the power supply. Frequency limit LED should light with no current trip. |
. |
IGBT failure |
See “Testing an IGBT” |
Gate drive board |
Replace the gate drive board |
Main control board |
Replace the main control board |
Current trip
Does not reset when stop button is pressed |
Gate drive board |
Replace gate drive board. |
Main control board |
Replace the main control board |
| DC bus trip
|
Input 3-phase voltage low or 1 phase is missing. |
Measure incoming line voltage. It should be 460VAC +/- 10% line to line. |
DC bus fuse open |
With power OFF, remove DC bus fuse. Verify the resistance is 0 Ohms. If the DC bus fuse is open, you probably have a bad IGBT. See “Testing an IGBT”. |
Bridge rectifier |
With power OFF and your Ohmmeter set to diode scale, check the diode junctions on the rectifier. A sticker on the rectifier shows how the diodes are internally connected. |
Precharge board |
Remove the precharge board (small circuit board just above the contactors). Inspect for visible damage. Failures are usually obvious. Replace with a new one if damaged. |
| Over voltage trip |
Impedance mismatch |
Check electrode gap. Re-tap output transformer. See impedance matching section of your manual. |
Secondary winding open |
With power OFF, disconnect the secondary of the transformer. With an ohmmeter, measure the resistance between the output of the transformer and the ground stud. It should show a short. If it is open, the transformer is damaged and must be replaced. |
| High temp fault |
Cooling fan not functioning |
Check all cooling fans. Ensure that they are all spinning freely. Inspect and clean all filter screens. Check top and bottom grids on the plenum. Ensure they’re not blocked. |
Cabinet not mounted properly |
At least 1 ft. of free air space must be provided on all sides of the power supply. If mounted near heat-producing equipment, allow more space. |
Excessive ambient temperature |
The P6000 is rated for a 40˚C (104˚F) ambient temperature. |
Thermal switch |
With an ohmmeter, check for continuity between TBBO-0 and TBBO-10 on the control board. If it is open and the heat sink is not hot to the touch, you have a bad switch. |
| Interlock fault |
Interlock is open |
With power OFF, install a jumper between 501 and 510 on the terminal block. Power up the treater. If the fault clears, check your station interlocks. WARNING! It is unsafe to operate treater with safety interlocks bypassed. |
Loose wire or connector |
Verify wires 501 and 510 are connected to TBBO-5 and TBBO-6 on the control board. Power up. If the fault does not clear, replace the main control board. |
| Power supply stops intermittently |
Zero speed fault |
Make sure the roll is turning freely and is not slipping when the web material is running through it. All it takes is a momentary opening of the interlocks to shut the power supply down. |
Intermittent or bad interlock or switch |
See “Interlock Fault” above |
| No power output…or stays at minimum power “Interveter On” is lit |
Control mode not selected properly |
Select LOCAL MODE to control the power supply with the display board on the power supply itself. Select REMOTE MODE to control the power supply from the remote proportional speed/computer interface. Refer to the manual if you wish to enable or disable any of these modes. |
Display board |
Select LOCAL MODE. Set output level for full power. Connect a DC voltmeter between TBCO-9(+) and TP5(-) on the control board. You should see 10VDC. If voltage is missing, replace the display board. NOTE: Some 3.5 kW units may show approximately 7VDC instead of 10VDC. |
Control board |
On the control board, verify that there is a jumper between TBCO-13 and TBCO-14. Select LOCAL MODE. Set output level for full power. Connect a DC voltmeter between TBCO-14(+) and TP5(-) on the control board. You should see 10VDC (or 7, for some 3.5 kW units). If not, replace the control board. |
Gate drive board |
If both the control board and display board check out OK, replace the gate drive board. |
| No power control… runs either very high power or very low power. Power display reads very low. |
Feedbacks are out of phase. This should never occur unless you just replaced a gate drive board or wires #1073 and #1074 on the terminal strip got reversed. |
With power OFF, tap the ouput transformer to X0-X4. Connect a DC voltmeter between TP18(+) and TP5(-) on the main control board. Power up. Press START. You should see between –0.2 and –5 VDC. If this voltage is positive, power down and reverse wires #1073 and #1074 at the gate drive board. |
Gate drive board |
If the above step didn’t solve the problem, you probably have a bad Voltage Feedback Transformer. Connect a voltmeter between TP5 and TP35 on the control board. Set it to read 2VAC. Disconnect the output wires from the power supply. Start the unit. You should see 2.5 to 3VAC. If this voltage is missing, replace the gate drive board. |
Control board |
Replace the gate drive board |
| No diagnostic lights on the local display are lit but the power output display is lit |
Control board |
Check for 24VDC between TP23(+) and TP31(-) on the control board when the board is powered up. If this voltage is missing, replace the control board. |
| “888” appears on the remote operator panel |
No serial communications |
Ensure that the local panel has power to it. Ensure that the cable between the local and remote panel is seated properly. Verify all wiring, including the serial cable is connected properly. |
| “PIL” flashes on the operator panel |
Hour meter indicates it is time for maintenance |
Refer to owner’s manual for recommended maintenance and the procedure for resetting this alarm. |
| “Alarm Fault” lit …LTI alarm active |
. |
There is only one condition that turns off the LTI alarm: When the power supply is ON and running within 5% of the desired power level. Refer to other faults shown on the operator panel first because the LTI alarm is most likely going off for a good reason. |
Bad load match |
See section on “Impedance Matching” in the installation section of the Owner’s Manual. |
Bad LED on the display |
The control board has its own bank of LED’s with an abbreviated name next to each LED, i.e. “IT” means current trip, “PC” means power control. Look at these LED’s and compare them against the display. |
