Guide to Troubleshooting PowerFlex 520-Series Drives

Introduction

Welcome to our user-friendly guide on troubleshooting the PowerFlex 520-Series Drive. Whether you're a seasoned technician or new to this technology, our aim is to make understanding and resolving common drive issues as straightforward as possible.

Fault Types and Troubleshooting Steps

1. Auxiliary Input (F002)

   • Symptom: External trip input activated.
   • Solution: Check remote wiring and verify communications programming.
     
     

2. Power Loss (F003)

   • Symptom: Single-phase operation with excessive load.
   • Solution: Monitor the AC line for low voltage or interruptions, check input fuses, and reduce load.
     
     

3. UnderVoltage (F004)

   • Symptom: DC bus voltage below minimum value.
   • Solution: Monitor the AC line for low voltage or interruptions.
     
     

4. OverVoltage (F005)

   • Symptom: DC bus voltage exceeds maximum value.
   • Solution: Monitor the AC line for high voltage, adjust deceleration time, or install a dynamic brake option.
     
     

5. Motor Stalled (F006)

   • Symptom: Difficulty in accelerating or decelerating the motor.
   • Solution: Increase acceleration time or reduce load to avoid current overload.
     
     

6. Motor Overload (F007)

   • Symptom: Internal electronic overload trip.
   • Solution: Reduce load to prevent drive output current from exceeding the limit set by parameter P033 [Motor OL Current]. Verify A530 [Boost Select] setting.
     
     

7. Heatsink OverTemperature (F008)

   • Symptom: Heatsink/Power Module temperature too high.
   • Solution: Check for blocked or dirty heatsink fins, ensure ambient temperature is within limits, and check the fan.
     
     

8. Control Module OverTemperature (F009)

   • Symptom: Control module temperature exceeds predefined value.
   • Solution: Check ambient temperature, ensure no airflow obstruction, clean dirt or debris, and check the fan.
     
     

9. Hardware OverCurrent (F012)

   • Symptom: Drive output current exceeds hardware current limit.
   • Solution: Check programming, load, A530 [Boost Select] setting, and DC brake volts.
     
     

10. Ground Fault (F013)

    • Symptom: Current path to earth ground detected at drive output terminals.
    • Solution: Check motor and external wiring for a grounded condition.
      
      

11. Load Loss (F015)

    • Symptom: Output torque current below programmed level.
    • Solution: Verify connections between motor and load, and check level and time requirements.
      
      

12. Output Phase Loss (F021)

    • Symptom: Output Phase Loss detected.
    • Solution: Configure with A557 [Out Phase Loss En], verify motor wiring and motor condition.
      
      

13. Analog Input Loss (F029)

    • Symptom: Loss of an analog input signal.
    • Solution: Configure with t094 [Analog In V Loss] or t097 [Analog In mA Loss], check connections at inputs, and verify parameters.
      
      

14. Auto Restart Tries (F033)

    • Symptom: Unsuccessful attempts to reset a fault and resume running.
    • Solution: Correct the cause of the fault and manually clear it.
      
      

15. Phase to Ground Fault (F038, F039, F040)

    • Symptom: Phase to ground fault detected.
    • Solution: Check wiring between drive and motor, check motor for grounded phase, and replace drive if necessary.

Common Symptoms and Corrective Actions

• Motor Not Starting?

  • Step 1: Check the power supply and connections.
  • Step 2: Look at the motor and ensure it's properly connected.
  • Step 3: Adjust the boost settings if needed.

FAQ Section:

• Q: What if the fault light is flashing?
• A: This usually means the drive is faulted. Try stopping the drive, cycling the power, or resetting the fault.
  

Conclusion

Troubleshooting doesn't have to be daunting. With this guide, we hope you feel more confident tackling common issues with your PowerFlex 520-Series Drive. Remember, understanding the problem is half the battle won!