Rockwell Automation Allen-Bradley SMC-50 Bedienungsanleitung

SMC™-50 Fully Solid-State Smart Motor Controller

Bulletin 150

User Manual

Rockwell Automation Publication 150-UM011A-EN-P - July 2011 213

Chapter

Troubleshooting

Introduction

For safety of maintenance personnel as well as others who might be exposed to

electrical hazards associated with maintenance activities, follow the local safety

related work practices (e.g., NFPA 70E, Part II in the United States).

Maintenance personnel must be trained in the safety practices, procedures, and

requirements that pertain to their respective job assignments.

The following flowchart is provided to aid in quick troubleshooting.

SHOCK HAZARD: Hazardous voltage is present in the motor circuit even

when the SMC-50 is off. To avoid shock hazard, disconnect main power

before working on the controller, motor, and control devices (e.g.,

Start-Stop push buttons). Procedures that require parts of the equipment

to be energized during troubleshooting, testing, etc., must be performed

by properly qualified personne using appropriate local safety work

practices and precautionary measures.

ATTENTION: Disconnect the controller from the motor before measuring

insulation resistance (IR) of the motor windings. Voltages used for

insulation resistance testing can cause SCR failure. Do not make any

measurements on the controller with an IR tester (megger).

NOTE: The time it takes for the motor to come up to speed may be more or less than

the time programmed. This depends upon the motor and load characteristics.

NOTE: Depending upon the application, the braking options (SMB Smart Motor

Braking and Slow Speed) may cause some vibration or noise during the

stopping cycle. To minimize vibration or noise, lower the braking current

adjustment. If this is a concern in your application, please consult the factory

before implementing the braking options.

214 Rockwell Automation Publication 150-UM011A-EN-P - July 2011

Chapter 10 Troubleshooting

Figure 88 - Troubleshooting Flowchart

Define nature

trouble.

YES

See Table 108 See Table 109 See Table 110 See Table 112

See Table 111

Fault Displayed?

Motor rotates but

does not accelerate

to full speed.

Motor stops

while running.

Miscellaneous

situations.

Motor will not start.

There is no output

voltage to the motor.

Table 110 - Fault Display Explanation

Display Fault Code Fault Enabled Possible Causes Possible Solutions

Line Loss

(with phase indication) 1, 2, 3 Prestart &

Running

•High impedance line connection

•Missing supply phase

•Motor not connected properly

•Incoming 3-phase voltage instability

•Check for line and load loose connections.

•Check for open line (e.g., blown fuse).

•Check for open line lead(s).

•Verify power quality.

•Disable this fault/alarm feature.

Shorted SCR

(with phase Indication) 4, 5, 6 In All Modes

•Shorted power module. •Check for shorted SCR, perform a resistance check

(refer to Power Module Check section), or replace

power module if necessary.

Open Gate

(with phase indication) 7, 8, 9 Start or Stop

•Open gate circuitry

•Loose gate lead

•Perform a resistance check (refer to Power Module

Check section), replace power module if necessary.

•Remove control module from the power section and

check gate lead connections (TB5, TB6, and TB 7)

are firmly seated to the control module.

•Disable this fault/alarm feature.

SCR Overtemp or

PTC Power Pole 10 or 60 In All Modes

•Controller ventilation blocked

•Controller duty cycle exceeded

•Fan failure

•Ambient temperature limit exceeded

•Failed thermistor

•Check for proper controller ventilation.

•Check application-appropriate duty cycle.

•Wait for controller to cool or provide external

cooling if ambient temperature is high.

•Check for fan operation. Replace fan, if necessary.

•Replace power module or control module as

needed.

No Load or Open Load

(with Phase Indication)

14,

15,

16,

Prestart Only

•Loss of load side power wiring with

phase indication (15=A, 17=C)

•Start command cycled unexpectedly

with motor rotating

•Check all load side power connections.

•Check motor windings (megger).

Voltage Unbalance or

Current Imbalance 18 or 42 Running

•Power line unbalance is greater than

the programmed value

•The delay time programmed is too

short for the application

•Check the power system and correct if necessary or

change the programmed value.

•Extend the delay time to match the application

requirements.

•Disable this fault/alarm feature.

Rockwell Automation Publication 150-UM011A-EN-P - July 2011 215

Troubleshooting Chapter 10

Overvoltage 19 Running

•Power line grid voltage is greater

than the programmed value

•Abnormal voltage regulation

•The parameter settings &/or delay

time programmed are not suited for

the application

•Check the power system and correct if necessary.

NOTE: If the power source is a backup generator,

check the stability of the generator voltage

regulator. Replace if necessary.

•Modify the parameter &/or extend the delay time to

match the application requirements.

•Disable this fault/alarm feature.

Undervoltage 20 Running

•Power line grid voltage is less than

the programmed value

•Abnormal voltage regulation

•The parameter settings & or delay

time programmed are not suited for

the application

•Check the power system and correct if necessary.

NOTE: If the power source is a backup generator,

check the stability of the generator voltage

regulator. Replace if necessary.

•Modify the parameter &/or extend the delay time to

match the application requirements.

•Disable this fault/alarm feature.

Overload 21 Running

•Motor overloaded

•Overload parameters are not

matched to the motor

•Check motor overload condition.

•Check programmed values for overload class and

motor FLC; verify current draw of the motor.

•Disable this fault/alarm feature. ➌

Underload 22 Running

•Broken motor shaft, belt, greating,

etc.

•Pump cavitation

•Programmed setting incorrect for

application

•Check machine drive components and loading.

•Check pump system.

•Repair or replace motor.

•Check programmed settings.

•Disable this fault/alarm feature.

Jam 23 Running

•Motor current has exceeded the

user programmed jam level for the

programmed time

•Correct source of jam or excessive loading.

•Check programmed time value.

•Disable this fault/alarm feature.

Stall 24 Running

•The motor did not reach full speed

by the end of the programmed ramp

time

•Incorrect programmed setting

•Check pump system, machine drive components,

and loading; repair or replace motor, if necessary.

•Check programmed settings.

•Disable this fault/alarm feature.

Phase Reversal 25 Prestart Only

•The controller is not detecting

incoming supply voltage in the

expected ABC sequence

•Check power wiring and correct, if necessary.

•Disable this fault/alarm feature.

Exp Removed x026 ➊In All Modes

•Expansion module is loose or

removed

•Expansion module is defective

•Reseat or replace the expansion module connector

to the control module and tighten module screws.

•Replace defective module.

Exp Incompat x027 ➊In All Modes

•Expansion module is inserted into an

incompatible control module port

number

•Controller firmware is not

compatible with the expansion

module

•Expansion module is defective

•Insert the expansion module into a compatible

contorl module port.

•Update the control module firmware

•Replace defective module.

Expansion x028 ➊In All Modes

•Expansion module is loose or

removed

•Expansion module is defective

•Expansion module is inserted into an

incompatible control module port

number

•Controller firmware is not

compatible with the expansion

module

•Reseat and/or replace loose/removed module and

tighten module screws.

•Replace defective expansion module.

•Update control module firmware.

Starts per Hour 29 Starting

•The number of starts within the last

hour has exceeded the programmed

value

•Programmed setting is incorrect for

the application

•Wait for the hour to expire, then restart the motor.

•Reduce the actual number of starts per hour or

increase the programmed start time (if allowed by

the application) and controller thermal limits.

•Turn off this fault/alarm feature.

Table 110 - Fault Display Explanation

Display Fault Code Fault Enabled Possible Causes Possible Solutions

216 Rockwell Automation Publication 150-UM011A-EN-P - July 2011

Chapter 10 Troubleshooting

CT Loss

A, B, or C

30,

31, or

In All Modes

•Loose CT cable connection between

the power section and the control

module

•Phase A (F30), B (F31), or C (F32)

current transformer feedback circuit

has failed

•Option Module 150-SM2 with

external CT operation (Fault Code

7030, 8030)

•Remove the control module from the power section;

verify connectors TB2 (A), TB3 (B), and TB4 (C) are

firmly seated to the control module.

•Replace the control module and/or the power

section.

•Inspect the CT sensor cables for loose connections;

check CTs for damage; repair/replace CTs if

necessary; replace 150-SM2 option module if

necessary.

Hall ID 33 In All Modes

•Loose cables betweeen the

controller and power section.

•Incompatible power section

installed with the controller

•Remove the control module from the power section;

verify connectors TB2 (A), TB3 (B), and TB4 (C) are

firmly seated to the control module.

•Check the power section and replace, if necessary.

NVS Error 34 In All Modes

•Controller memory corrupted

•Option module error (Fault Code

7034, 8034, or 9034)

•Modify a parameter or load parameter defaults

(preferred) and reload the customer-specific

parameters.

•Check the option module sensor cables.

•Replace the option module.

Future Use 35 NA NA NA

V24 Loss 36 In All Modes

•Loose connection at Control

Terminals 1 (+L1) and 2 (-L2)

•Excessive load on internal 24V

supply

•Low line voltage condition

•Check the control power and verify it is within the

specification; check the line connections and

grounding to the SMC-50 control terminals.

•Replace the control module.

V Control Loss 37 In All Modes

•Loose connection at Control

Terminals 1 (+L1) and 2 (-L2)

•Low line voltage condition

•Check the control power and verify it is within the

specification; check the connections and grounding

to the SMC-50 control terminals.

•Replace the control module.

TB Input

1, 2, 3 & 4

38,

39,

40, &

In All Modes

•The condition to generate the TB

Input fault is satisfied

•Terminal wiring configuration or

fault N.O./N.C. configuration of

input is incorrect

•Clear the fault condition.

•Rewire and/or reconfigure the input.

Und Pwr Real ➋43 Running

•Abnormally reduced real (MW)

power draw by the motor possibly

due to broken mechanical

connection (belt, gears, etc.)

between motor and load

•Pump cavitation

•Programmed setting is incorrect for

the application

•Repair/replace the condition causing the reduced

real power load.

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

Ovr Pwr Real ➋44 Running

•Abnormally high real (KW) power

draw by the motor

•Programmed setting is incorrect for

the application

•Repair/replace the condition causing the high KW

power draw.

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

Un Pwr Reac+ ➋45 Running

•Abnormally reduced reactive

(+MVAR) power produced by the

motor

•Programmed setting is incorrect for

the application

•Repair/replace the condition causing the reduced

+MVAR power draw.

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

Ov Pwr Reac+ ➋46 Running

•Abnormally high reactive (+MVAR)

power produced by the motor

•Programmed settings are incorrect

for the application

•Repair/replace the condition causing the high

+MVAR power draw.

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

Table 110 - Fault Display Explanation

Display Fault Code Fault Enabled Possible Causes Possible Solutions

Rockwell Automation Publication 150-UM011A-EN-P - July 2011 217

Troubleshooting Chapter 10

Und Pwr App ➋47 Running

•Abnormally reduced apparent (MVA)

power draw by the motor

•Programmed settings are incorrect

for the application

•Repair/replace the condition causing the reduced

+MVA power draw.

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

Ovr Pwr App ➋48 Running

•Abnormally high apparent (MVA)

power draw by the motor

•Programmed settings are incorrect

for the application

•Repair/replace the condition causing the high

+MVA power draw.

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

Frequency 49 Running

•Speed control regulation system of

the generator prime mover (e.g.,

diesel engine) is unable to adjust to

current load conditions or is

defective

•Abnormal power grid connections;

power generation source is

operating outside its normal

frequency limits or range

•Reduce the generator load, increase grenerator

output, replace the speed control system, or

generator.

NOTE: For a diesel generator system, Rockwell

Automation recommends it be oversized by a

factor of three for Soft Start applications.

•Contact the power company for additional

information.

•Modify the programmed fault/alarm parameters to

better suit the application.

PM Hours 50 In All Modes

•The number of hours programmed in

the PM Hours Parameter has been

reached

•Perform required maintenance and reset the PM

Hours parameter.

•Disable this fault/alarm feature.

PM Starts 51 Pre-Start

•The number of Starts programmed in

the PM Start Parameter has been

reached

•Perform required maintenance and reset the PM

Hours parameter.

•Disable this fault/alarm feature.

Power Quality

A, B, or C

52,

53, or

Start or Stop

•Incoming 3-phase voltage instability

or distortion

•High impedence line or load

connection

•Check supply voltage for capability to start/stop the

motor; check for loose connections on the line side

or motor side of the power wires.

•Verify and correct the input power quality issue

•Disable this fault/alarm feature.

Power Quality

THD V 55 Running

•The current mix of loads on the

power line contributing to the THD V

has exceeded the programmed THD

V level &/or time

•Check the mix of loads (what was added, what was

changed); modify the load mix if necessary.

•Change the programmed THD V level &/or delay

time.

•Disable this fault/alarm feature.

Power Quality

THD I 56 Running

•The current mix of loads on the

power line contributing to the THD I

has exceeded the programmed THD

I level &/or time

•Check the mix of loads (what was added, what was

changed); modify the load mix if necessary.

•Change the programmed THD I level &/or delay

time.

•Disable this fault/alarm feature.

Config Change 57 In All Modes •A controller parameter has been

modified

•Disable this fault/alarm feature.

Ground Fault X058 ➊Running

•The ground fault current level has

exceeded the programmed value

•The delay time is too short for the

application

NOTE: An optional 150-SM2

Ground Fault PTC Module is

required for this fault.

•Check the power system and motor; correct if

necessary.

•Check the programmed ground fault levels to match

application requirements; modify if necessary.

•Extend the delay time to match the application

requirements.

•Disable this fault/alarm feature.

Motor PTC X059 ➊In All Modes

•Motor ventilation is blocked.

•Motor duty cycle is exceeded

•PTC open or shorted

NOTE: An optional 150-SM2

Ground Fault PTC Module is

required for this fault.

•Check for proper ventilation.

•Check application duty cycle.

•Wait for motor to cool or provide external cooling,

then check resistance of PTC.

•Disable this fault/alarm feature.

Table 110 - Fault Display Explanation

Display Fault Code Fault Enabled Possible Causes Possible Solutions

218 Rockwell Automation Publication 150-UM011A-EN-P - July 2011

Chapter 10 Troubleshooting

I/O Config 61 Pre-Start

•The configuration of the control I/O

does not meet the system rules as

defined in Chapter 4, Configuration

Functions on page 120

•Modify the control I/O configuration to meet the

established rules.

Test Fault 62 In All Modes

•The SMC-50’s Push to Reset/Hold to

Test push button was pressed for

more than three seconds, but less

than ten

•The SMC-50’s Push to Reset/Hold to

Test push button is stuck or

damaged

•To reset the Test fault, press the Push to Reset/Hold

to Test push button for less than two seconds.

NOTE: Only use the Push to Reset push button

when absolutely necessary.

•Attempt to dislodge the push button or replace the

control module if necessary.

Und PF Lag 63 In All Modes

•A lagging PF is abnormally under the

typical value; less inductance or

more capacitance has been

introduced to the power line

•A programmed setting or time value

is incorrect for the application

•Determine the cause of the reduced Lagging PF.

•Modify the porgrammed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

Und PF Lead 64 Running

•A leading PF is abnormally under the

typical value; less inductance or

more capacitance has been

introduced to the power line

•A programmed setting or time value

is incorrect for the application

•Determine the cause of the reduced Leading PF

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

Ovr PF Lag 65 Running

•A lagging PF is abnormally over the

typical value; more inductance or

less capacitance has been

introduced to the power line

•A programmed setting or time value

is incorrect for the application

•Determine the cause of the Over PF Lagging

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

Ovr PF Lead 66 Running

•A leading PF is abnormally under the

typical value; less inductance or

more capacitance has been

introduced to the power line

•A programmed setting or time value

is incorrect for the application

•Determine the cause of the Over PF Leading.

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

-MVAR Over ➋67 Running

•Abnormally high reactive (-MVAR)

power consumed by the motor

•Programmed settings are incorrect

for the application

•Repair/replace the condition causing the high

-MVAR.

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

-MVAR Under ➋68 Running

•Abnormally reduced reactive

(-MVAR) power consumed by the

motor

•Programmed settings are incorrect

for the application

•Repair/replace the condition causing the reduced

-MVAR.

•Modify the programmed fault/alarm parameters to

better suit the application.

•Disable the fault/alarm feature.

RTC Battery Low 69 Pre-Start

•Battery reading is below the

acceptable level to potentially

maintain the real time clock and

calendar

•Replace battery (CR2032) as soon as possible.

Locked Rotor 70 In All Modes

•Motor has stalled; rotor is not

turning

•Check motor and load for binding or jammed

conditions

•Parameters are not adequately configured for the

application. Review and adjust.

•Disable the fault/alarm feature.

Start 71 Starting •A start event (command) has

occurred. This is not a fault. •NA

Slow Speed 72 Slow Speed •A slow speed event (command) has

occurred. This is not a fault. •NA

Table 110 - Fault Display Explanation

Display Fault Code Fault Enabled Possible Causes Possible Solutions

Rockwell Automation Publication 150-UM011A-EN-P - July 2011 219

Troubleshooting Chapter 10

Stop Option 73 Stop Option •A stop option event (command) has

occurred. This is not a fault. •NA

Coast 74 Coast •A coast-to-stop event (command)

has occurred. This is not a fault. •NA

Clear Fault 75 Faulted

•A clear fault event (command) has

occured. This does not generate a

fault.

•NA

Fault 76 Faulted •A fault event (command) has

occured. This is not a fault.

•NA

Param Change 77 Stopped

•A change to one of the controller

parameters has occured. This is not

a fault.

•NA

Reserved 78-99 NA NA NA

System Faults 100-199 In All Modes

•There is an issue with the control

module wiring

•The control module is defective

•Review the control module wiring. Ensure the

ground terminal is secure and connected to the

system’s earth ground. Ensure an RC

snubber/suppressor is connected to all inductive

loads in the control circuit. Refer to input wiring.

•Replace the control module.

➊"X" indicates a port number in which the expansion module resides in the SMC-50.

➋ The Real, Reactive, and Apparent Power faults/alarms are best suited to provide indication of an abnormal running operation of the motor or system which

another parameter (e.g., Underload, Overload, Jam, Stall, etc.) does not provide. To understand what is an abnormal running operation, a "normal" or "typical"

value, usually established during system startup, needs to be determined by the user.

➌If controller based motor overload is disabled, external motor overload protection should be used.

Table 110 - Fault Display Explanation

Display Fault Code Fault Enabled Possible Causes Possible Solutions

220 Rockwell Automation Publication 150-UM011A-EN-P - July 2011

Chapter 10 Troubleshooting

Table 111 - Motor Will Not Start — No Output Voltage to the Motor

Table 112 - Motor Rotates but Does Not Accelerate to Full Speed

Display Possible Cause Possible Solutions

Fault displayed •See fault description •See Table 110 addressing fault

conditions

HIM display is blank •Failed HIM

•Control voltage is absent

•Failed control module

•HIM connection is loose

•Replace HIM

•Check control wiring and correct

if necessary

•Replace control module

•Cycle control power

•Check HIM connection

Stopped

0.0 Amps

•Pilot devices

•SMC Enable input is open at

terminal 9

•Configured or wired input

terminals are not wired

correctly

•Start-Stop control has not

been enabled for the human

interface module

•Control voltage

•Failed control module

•Check wiring

•Check wiring; follow the

instructions on page 193 to

enable control capability.

•Check control voltage

•Replace control module

Starting •One or more power phases are

missing

•Isolation contactor (if used) is

not picking up

•Check power system

•Check that the SMC-50 Aux.

relay output controlling the

Isolation Contactor is configured

to "Normal".

•Check the Isolation Contactor for

proper operation

Display Possible Cause Possible Solutions

Fault displayed •See fault description •See Table 110 addressing fault

conditions

Starting •Mechanical problems

Inadequate Current Limit

setting

•Failed control module

•Check for binding or external loading

and correct

•Check motor

•Adjust the Current Limit Level to a

higher setting

•Replace control module

Rockwell Automation Publication 150-UM011A-EN-P - July 2011 221

Troubleshooting Chapter 10

Table 113 - Motor Stops While Running

Display Possible Cause Possible Solutions

Fault displayed •See fault description •See addressing fault conditions

HIM display is blank •Failed HIM

•Control voltage is absent

•Failed control module

•HIM connection is loose

•Replace HIM

•Check control wiring and correct

if necessary

•Replace control module

•Check HIM connection

Stopped

0.0 Amps

•Pilot devices

•Failed control module

•Check control wiring and correct

if necessary

•Replace control module

Starting •One or more power phases are

missing

•Failed control module

•Check power system

•Replace control module

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