Rockwell Automation Allen-Bradley Dialog Plus 1503D - Page 165

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Troubleshooting 10-23

1560D-UM051D-EN-P – February 2005

Figure 10.13 – 6900V Module with Boards and Frame Removed, 180/360 A

Module retaining hardware locations (4)

Line Connection

Load Connection

Module retaining hardware locations (4)

Line Connection

Load Connection

Main Page

Table of Contents3
Preface9
Service Procedure9
1503D - Chassis Mount Retrofit Controller11
1560D - Retrofit Controller11
Description11
Documentation11
Manual Objectives11
Product Overview11
1562D - Combination Controller12
Dialog Plus™ Control Module12
Selectable Kickstart13
Soft Start13
Starting Modes13
Current Limit Start14
Dual Ramp Start15
Full Voltage Start15
Overload16
Protection and Diagnostics16
Stall Protection and Jam Detection18
Line Faults19
Open Gate19
Excessive Starts/Hour20
Metering20
Overtemperature20
Underload20
Communication21
Control Options22
Programming22
Soft Stop Option22
Status Indication22
Application Considerations23
Pump Control Option23
Preset Slow Speed Option25
SMB™ Smart Motor Braking Option25
Slow Speed with Braking Option26
Hardware Description27
Power Module27
Self-Powered Silicon-Controlled Rectifier Gate Driver Board27
Interface Board28
Typical MV Dialog Plus Power System Diagram29
Bulletin 1562D • Basic Control - Soft Stop or Pump Control30
Bulletin 1562D • Basic Control - Standard Module30
Functional Description30
Bulletin 1562D • Scanport Control - Soft Stop or Pump Control31
Bulletin 1562D • Scanport Control - Standard Module31
Bulletin 1560D • Basic Control - Soft Stop or Pump Control32
Bulletin 1560D • Basic Control - Standard Module32
Receiving39
Safety and Codes39
Unpacking and Inspection39
General Precautions40
Transportation and Handling40
Installation Site41
Mounting41
Grounding Practices42
Recommended Torque Values42
Power Connections43
Interlocking46
Power Wiring46
Control Cables47
Fan47
Fiber-Optic Cables47
Ground Bus Bar47
Installation47
Physical Location47
Power and Control Wiring47
Power Factor Correction Capacitors48
Surge Arrestor Protection Devices50
Emergency Bypass51
Motor Overload Protection51
Multi-Motor Protection51
Two-Speed Motors51
Human Interface Module52
Connecting the Human Interface Module to the Controller53
Control Enable55
Communication Modules56
Accessory Requirements57
Wiring57
Converter Modules58
Control Terminal Designations60
Commissioning Procedure61
Preliminary Set-Up61
System Characteristics62
MV Dialog Plus™ Module63
Preliminary Check63
Programming63
Hi-Pot and Megger Test64
Power Supply Tests66
Control Function Tests69
Resistance Checks70
Start-Up70
Keypad Description71
Overview71
Programming Menu71
Password75
Search75
Electrically Erasable Programmable Read-Only Memory (EEPROM)76
Parameter Management76
Random Access Memory (RAM)76
Read-Only Memory (ROM)76
Using Parameter Management77
Current Limit Start78
Parameter Modification78
Soft Start78
Dual Ramp Start80
Full Voltage Start80
Basic Setup81
Advanced Setup82
Example Settings83
Calibration85
Motor Data Entry85
Overview85
Metering87
Overview87
Viewing Metering Data87
Human Interface Module89
Options89
Overview89
Control Wiring for Scanport Control92
Programming Parameters92
Soft Stop Option93
Pump Control Option94
SMB Smart Motor Braking Option95
Preset Slow Speed Option96
Slow Speed with Braking Option97
Control Wiring99
Logic Control Data99
Overview99
Serial Communications99
Control Enable100
Parameter Listing101
Reference/Feedback101
Scale Factor Conversion101
SMC Status Data101
Datalinks/Slc Block Transfers102
Display Unit Equivalents102
Interfacing102
Processing Time102
Remote I/O Examples104
Example #2 - SLC 500 Controller with Block Transfer108
1203-GK5 Communication Module Switch Settings126
Devicenet Examples126
Explicit Messaging131
Example Ladder Logic Program135
Clear Fault137
Fault Display137
Overview137
Fault Buffer138
Fault Codes138
Fault Auxiliary Contact139
Fault Definitions139
General Notes and Warnings143
Troubleshooting143
Fault Identification144
Fault Display Explanation145
Control Module Removal149
Voltage Feedback Circuit Tests150
IGDPS Boards151
IGDPS Board Leds152
Circuit Board Replacement153
Power Circuit Troubleshooting154
Thyristor Testing154
SCR Replacement Procedure155
Snubber and Resistor Circuit Testing169
Snubber Resistor Replacement171
Contamination183
Periodic Inspection183
Safety and Preventative183
Coils184
Terminals184
Vacuum Bottles184
Final Check out185
Overload Maintenance after a Fault Condition185
Solid-State Devices185
Static-Sensitive Items185
Barriers186
Control Components - Electronic186
Fans186
Interlocks186
Keep Good Maintenance Records186
Power Components186
Parameter Information187
Parameter List187
Parameter Text/Display Unit Cross-Reference192
Spare Parts193
Accessories202
Appendix C Accessories202

Rockwell Automation Allen-Bradley Dialog Plus 1503D - Page 165

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