Checking of I/R module

Condition 1: No Indication on the I/R Module

1) Disconnect the DC Link bus bar and the ribbon cable (X351) which is linking
to the NCU MSD-FDD module.
2) Dont remove the incoming Supply which given to the IR module.
3) Remove all the terminals before removing note down the wire details of each
respective connectors.
4) Plug X181 connector were 1U1, 2U1, 1V1, 2V1, 1W1, 2W1 to be shorted for
electronics voltage.
5) Plug the X171 connector were NS1, NS2 to be shorted for enabling the
internal line contractor.
6) Plug X161 connector were 9,48,112 to shorted for enabling the contactor
energization start, Setup operation terminal, Enable voltage.
7) Plug X121 were pulse enable 63 to be shorted with Enable voltage 9 and
similarly Drive enable 64 to be shorted with 9 enable voltage.
8) After plugging in the connector X181,X171,X161,X121 switch on machine. In
the I/R module indication will be displayed Yellow this indicates healthy sign
of the module and DC link is available (600 VDC)
9) If no indication is displayed on the I/R module it indicates the problem present
in it.

Note: If Burnt out smell is already observed in the module above steps are not
recommended to carry out.
Condition 2: Drive not getting ready

1) Yellow and Green LED are indicating on the I/R module machine is not
getting switch ON.
2) Check the connection of X111 Drive ready that is NO and NC Relay contact
signals.
3) Check the connections of NO and NC contacts wired through the external
relay and how it given to X111 connector.
4) From external relay 24v supply is given to the X111 input (73.1 or 73.2) and
output 24vdc ( 74 NC point and 72 NO point) should come if the output is not
coming then there is internal relay problem.
5) For checking purpose input supply 24vdc can be shorted with the output for
healthy sign in the module.

Note: Keeping permanently short will damage the module.

 I/R Module Troubleshooting

Warning! Dangerous voltages are present! It must be assured that power is

removed and the DC Bus has drained to a safe level before any connections are
removed or checked! Wait at least 5 minutes for the DC Bus to discharge to a
safe level after power off.

When the I/R Module is enabled and functioning properly, there should be 600 VDC across the DC
Bus terminals P600, M600 and only the yellow LED(middle on the right) should be lit.

The incoming voltage at terminal U1, V1 and W1(drive side of 3-Phase inductor) will increase
significantly when the I/R Module is enabled. This is a result of the PWM switching through the 3-
Phase inductor and should be considered normal. The line voltage should be 3-Phase 400 V +/- 10%
at the line side of the 3-Phase inductor.

I/R Faults Possible Cause

Module Dead Check that the incoming line voltage at terminals U1,V1,W1 are 3-Phase
No LEDs or 400 V +/- 10%. For the 80 and 120 KW, Check that line voltage across
Aux. Voltages L1 and L2 is 1-Phase 400V +/- 10%. L1 must be in phase with U1
and L2 must be in phase with V1. Check that terminal block X181 is
plugged in and the jumpers between 1U1, 2U1, etc. are connected
correctly.
If problem found - Repair and re check
If input voltage and X181 are OK - ReplaceI/R module

Unit Enable See Module Dead.

LED not Lit Check that terminal block X171 is installed and that jumpers between
NS1 and NS2 are installed. Check that terminal 48 is +24V with reference to
terminal 19.

15 V, 5V fault Power down and wait for DC Bus to drain to a safe level. Disconnect Ribbon
LED cable(X151) and terminal blocks X121, X141, X161, X171. Power up.
If Fault is gone - There is a short in the interface. Plug in one terminal block at a
time to determine where the short is. If in the interface, trace & repair. If
in the ribbon cable circuit, plug the ribbon cable into one module at a time
to find which module is dragging down the voltage. When that module is
found, pull the controller PCB out of the backplane, if problem is gone,
Power section is bad, if problem still exists, controller PCB is bad. Caution!
Power down before plugging or unplugging the ribbon cable or controller PCBs.
Faults still present - ReplaceI/R Module.

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Supply Fault Determine if the fault appears on power up or enable.
LED If on power up - One phase missing from terminals U1, V1, W1, X181 or bad power
connection. Check power connections and line voltage level (see dead module).
If problem found - Repair and re-check
If input voltage and X181 are OK - ReplaceI/R module

If on enable(48 and 63) - Bad power connection, short in DC Bus, line voltage too
low, line matching transformer KVA too low or impedance too high. Power
down and wait for DC Bus to drain to a safe level. Disconnect bus bars from
P600 and M600 and re-check.
If problem found - Repair and re-check
If OK with DC Bus Bars open - There is a short in the DC Bus of one of the modules.
If all OK - ReplaceI/R module

DC Bus Overvolts Determine if the fault appears on power up or motor deceleration.

LED If on power up - Line volts too high. (360 to 440 VAC)

If on motor decel - Check setting of Dip Switch bit 3, line regeneration mode. For line
regeneration, bit 3 = off. If line voltage is above 424 VAC, set Dip Switch Bit 1
(on = DC Bus 625 VDC). Re-check.
If problem still exists - Replace I/R.

Ext. Enable Check terminals 63, 64, 48 with reference to terminal 19.
LED Lit If all are not +24 Volts, check ground connection to terminal 19, and/or
interface.
If all OK but fault still exists - Check tightness of screw terminals.
If all OK but fault still exists - Replace I/R Module.

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Checking the Power Module/ LT(FDD/MSD)

1) Disconnect the DC link bus bar and tighten back the screw.
2) Remove the Power section cable below the FDD/MSD module (A1, A2)
disconnect the u,v,w
3) Keep the multi meter in diode mode range.
4) Keep Red probe on P600(top bus bar screw)and Black probe on U,V,W on
the multi meter it displays high resistance (OL) forward basis characteristic
5) If it shows Short / uneven value then module is having problem.
6) Keep the Red probe on M600(bottom bus bar screw) and black probe on
U,V,W on the multi meter it displays resistance same value on U,V,W reverse
basis characteristic
7) If it shows short /uneven value then the module is having the problem.
8) Similarly keep the Black probe on P600(top bus bar screw) and Red probe on
U,V,W on the multi meter it displays resistance value same on U,V,W reverse
basis characteristic.
9) If it shows Short / uneven value then module is having problem.
10) Keep the Black probe on M600 (bottom bus bar screw) and Red probe on
U,V,W on the multi meter it will display high resistance (OL) forward basis
characteristic.
11) If it shows Short / uneven value then module is having problem.