Troubleshooting of Rockwell AutoMax DPS

Case 2: Speed fluctuation of SD3000 DC driver

Phenomenon: The motor has unstable speed and periodic shaking at low speeds (<50RPM).

troubleshoot

Entering the AutoMax Executive to monitor the speed feedback values in the UDC task online, it was found that the fluctuations were synchronized with the current feedback.

Check the current loop gain (adaptive gain function) in PMI. The parameter 'Adaptive Gain Enable' has not been enabled.

After enabling adaptive gain, low-speed fluctuations disappear.

Principle: In the low current intermittent region of a DC driver, conventional gain cannot be maintained stably, and adaptive gain needs to be enabled.

Case 3: 567 PowerMax medium voltage drive reports "gate pole fault"

Phenomenon: Sudden tripping during operation, with the fault recorded as' Gate Driver Fault - Phase A '.

troubleshoot

Check the panel LED of the corresponding GDI module: The fiber TX/RX is normal, but the "Gate Fault" LED is on.

Check the gate drive board (GDU) of the power unit and find that the power indicator light of one GDU is not on.

Measuring the input voltage of GDU, it was found that the fuse was blown.

After replacing the GDU and fuse, resume operation.

Attention: After replacing the GDU, the gate pulse width needs to be recalibrated (using PMI software tool).

Preventive maintenance and spare parts list

To ensure the long-term reliable operation of the AutoMax DPS system, it is recommended to maintain it according to the following cycles:

Component cycle content

Clean the end face of the fiber optic connector with anhydrous alcohol every six months and check for scratches

PMI rack fans clean the filter screen annually, measure the speed or replace the bearings

Measure the capacitance and equivalent series resistance (ESR) of the DC bus capacitor every 5 years, and replace it if it decreases by 20%

UDC module battery (if any) is measured for voltage every year and replaced when it falls below 3V (note: UDC uses flash memory and does not require batteries)

The power module heat sink is cleaned of dust with compressed air every quarter

Check the grounding resistance of the shielding layer and measure the insulation resistance of the rotary cable every 2 years

Recommended spare parts list (based on on-site configuration):

UDC module (P/N 57Cxxx)

PMI processor module (applicable to corresponding driver types)

Fiber optic jumper (ST-ST, multiple lengths)

Power module (115VAC input)

Rotary/Drive I/O Module

IGBT or IPM of power module (specific model needs to be confirmed)