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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) Don’t 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 connector’s.
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.


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.
Profibus connector checking

Please remove all cables before this check.


Terminating resistance switched off
¾ Terminal A1 & A2 should show short.
¾ Terminal B1 & B2 should show short.
¾ Terminal A1 & B1 should show open.
Terminating resistance switched on
¾ Terminal A1 & A2 should show open.
¾ Terminal B1 & B2 should show open.
¾ Terminal A1 & B1 should show 220 ohms. This value should not change even if the
switch is operated a couple of times.
Other checks
¾ There should not be any short between any terminal and body / shield.
¾ With termination switch on pin # 3 & 6 should show 390 ohms. With termination switch off
these should show open.
¾ With termination switch on pin # 5 & 8 should show 390 ohms. With termination switch off
these should show open.
Data Loading in 840D Using WINPCIN / PCIN