SYMPTOM PROBABLE CHECK

CAUSE
Phase
Incorrect
Interchange
sequence phase
two incoming
L.E.D.
sequence power lines.
does not No power Measure
lite with
to control input at L1,
power
L2, L3
applied
Blown
All fuses
power or
control
fuses
Jumpers
Filter board
missing or
not
connected
on Filter
Board
Filter board Check output
faulty
of filter
board with
scope at
TB2-1, TB22, TB2-3 *
Control
With scope,
board
check for 5.0
faulty
Volts from
anodes of
D7, D8, D9
Control
SCR's and Check SCR's
blows line power
and Diodes,
fuses with diodes
MOV's
power
Faulty
Motor field
applied
Motor
and
armature
(megger if
breakdown is
suspected
after
disconnectin
g from o
Phase
No supply +5.0 volts

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sequence voltages
from TB1-1
L.E.D. lit
+12.0 volts
no output
from TB2-4
from
(filter board)
control
-12.0 volts
with speed
from TB2-5
adjust full
(filter board)
C.W.
No
+5.0 volts
reference from TB1-13
voltage
Current
Adjust
limit set full current limit
C.C.W.
pot for 3.0
volts from
TB1-12
No run
+5.0 volts
enable
from TB1-7
signal
external
enable
contacts
No ramped +5.0 volts
output
from TB1-10
Open
Connection
Jumper
diagram
"M"
Contacts
contacts
faulty
power or
aux.
Gating &
Check pulse
Isol. Board train with
scope *
Phase
Open
+5.0 volts
sequence interlock or from TB1-2
L.E.D. lit, heatsink
fault
thermostat
L.E.D. lit, open
no output Overcurren Excessive
from
t trip
load
control
(I.O.T.)
condition,
short circuit
in motor or

filter board

Other Application
Factors
Measuring Machine
Torque
Mechanical Formulas
ABB Drive
information
ABB DCE 400 plus DC
External
Drive (pdf)
speed
Obsolete - No Longer
adjust
Available
Control
ABB DCS 400 DC Drive
ABB DCS 500 DC Drive
Board
ABB DCS 500B DC
Drive (pdf)
ABB DTC AC Drive
(pdf)
External
ABB ACS 600 AC Drive
enable
contacts or ABB ACS 800 AC Drive
ABB ACS 800 AC Drive
control
(pdf)
board
ABB ACS 1000 AC Drive
Control
(pdf)
Board
ABB Medium Voltage
Jumper
Softstarters
SIMOREG 6RA24
Siemens DC Drive
"M"

Contactor or SIMOREG 6RA70

"run" relay. Siemens DC Drive
VFD Case Studies
ABB drives & motors
help RNLI
Gating & Paperboard mill
Isol. Board
benefits from DC
drives
Interlock or ABB drive cuts water
Thermostat bill
Process saves energy
with ABB
Drives cut costs at
MINI plant
Check
Film maker slashes
machine &
costs
processes
Drives cuts cost for
Check
toy company
motor.
Close pump doubles

Motor runs
at base
speed or
higher
with low
reference
voltage
applied.

Control
starts but
will not
reach
max.
speed with
speed
adjust full
C.W.

motor leads Replace

intermittent SCRs with
short in
low, megger
motor, SCR readings.
breakover,

megger SCRs
(out of

circuit).
Jumper
Jumper A to Reconnect

missing or T for arm.

or install
in wrong
feedback.
jumper

mode in
Jumper T to
control
T for tach
board.
feedback.
Defective
Tach output Tachometer
tachometer
or coupling
or coupling
Defective
+2.25 volts Isolation &
feedback
from
gating
isolator
terminal A on board
control bd. at
500 volts
output
Defective
TP-10 control Control
control
bd. for +4.0 Board
board
volts
Max. speed Adjust max. Control
set too low speed
Board
Current
Adjust
Control
limit set too current limit Board
low
Reference +5.0 from
Control
voltage
TB1-13
board,
Power
Supplies
(Filter
board)
Jumper in Jumper 1 to Jumper for
wrong
2 for 500
correct arm.
mode on
volts
voltage
iso. &
Jumper 2 to
gating
3 for 240
board
volts

efficiency
ABB energy appraisal
saves $
Staggering energy
savings
Soft starters save
costs
Model 1681
Instruction Manual
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Control
will not
regulate
speed with
load

Control
Unstable

Current
Adjust
limit set too current limit
low
setting +3.0
volts TB1-12
Incorrect
Shunt
ammeter
shunt
Current
Load current
isolator
TB2-1 for
defective
1.25 volts @
100% load.
Line
Line voltage
voltage
when load is
drooping
applied,
with load
voltage
should not
droop more
than 10%
Overload
Load current
condition
Stability or Control
forcing not Board
properly
adjusted

Ammeter
shunt
signal leads
reversed
Defective
tachometer
or coupling
Motor or
load
binding up
Speed
amplifier
Voltage
isolator
defective

Check lead
polarity

Control
Board

Install
correct
shunt
Isolation &
gating
board
Check AC
supply for
adeqacy
and/or
loose
connections
.
Correct
cause of
overload
Adjust
"stability"
and
"forcing".
Replace
board
Connect
leads
correctly

Tachometer Tachometer
and coupling or coupling
Load

Correct load
condition

Control bd.,
IC25, IC27
Voltage
isolator 2.25
volts from

Control
board
Isolation &
gating
board

Relief
Efforts
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experienced the
devastation
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terminal A on
control board
@ rated arm.
voltage
Reference TB1-13 for
Control bd.
voltage
stable volt. or external
unstable
level
po
Current
Current limit Correct
limit set too setting
current limit
low
(speed wil
setting
rise as soon
as it is
turned to
higher
current set.
Wrong
Ammeter
Install
ammeter
shunt
correct
shunt
shunt
Control bd. Control bd. Replace
defective
(substitue
control
spare board) board
* See
schematic for
waveforms.

POWER MODULE BENCH TEST

The purpose of this test is to determine whether
the power module being tested has a defective
thyristor, or thermal sensing switch.
Remove the module from the base panel and lay
on its side. At this point it will be helpful to refer
to the "Exposed View of the DC Motor Controller"
at end of manual. The upper portion of the picture
shows in detail the parts of the SCR/SCR power
module.
Use a Simpson type 270 Multimeter or equivalent
and set the meter to ohms Rx 1 or RxIO.

Thyristor Check
Connect (+) of ohmmeter to SCR cathode test
jack, (-) of ohmmeter to SCR anode test
jack. Meter should read open. Reverse the
ohmmeter leads. Ohmmeter should again read
open.

Now place (+) ohmmeter lead on gate test jack,

(-) lead on anode test jack. Ohmmeter
should read open. Reversing leads should again
give an open reading. Connect (+) of ohmmeter
to gate test jack, (-) of ohmmeter to cathode test
jack. Ohmmeter should read between Ion
and 300n. Reverse ohmmeter leads. Meter should
now read between 20n and soon.

Thermal Sensor Check

Connect leads of ohmmeter to the two terminal
tabs located on the thermal sensor.
The ohmmeter should read zero ohms.
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