Troubleshooting Guide

CTTG #121

Unidrive Size 5 Power Module Fault Isolation

This document pertains to UNIDRIVE Size 5

UNI POD
CONTROL UNI54PM
MODULE POWER
MODULE

WARNING: ALLOW SUFFICIENT TIME FOR THE DRIVE TO DISCHARGE

Recommended Time is 10 minutes after power down
Measure from DC+ to DC- to ensure the buss voltage has discharged.

Problem: Unidrive Size 5 is tripping

When there are multiple power modules involved a fault may need to be isolated. This
document can also be used for instructions on how to move the Control Pod to another
power module in an effort to isolate a fault condition.

The Unidrive Size 5 is mainly comprised of a control module or POD, one or

more power modules, and interconnecting cables. Many times when a fault occurs the
description will indicate the responsible power module. Other times it may be
necessary to move major elements in order to confirm a control, power, or cable
problem within the individual sections. Some common Unidrive Size 5 trips are listed
below. The “n” indicates the power module number.

OI.AC n Over current in the output stage

OI.dc n DC over current
Ot HS n Heatsink over temperature
Ot inP Input stage over temperature
OU n Over voltage
PS n Internal power supply fault
St GL Hardware fault
UFLt n Unidentified trip

CTTG121.doc V1.0 1 3/11/2008

 The control module/POD and each Power Module have dip switch banks that
are set up to identify each device in the system. The control pod dip switch is set to
the total number of power modules on the system. The power module dip switch bank
is set to identify its’ node in the system.

Interconnect Diagram

Size 5 Power modules with the covers removed.

Size 5 POD Control Module
IN 96 Board

10-pin 10-pin
PL4 PL6 PL4

16-pin
16-pin PL9 PL10
PL9
PL1
26-pin PL1 PL4 26-pin

IN 95 Board

IN 96 Board IN 95 Board

PL4
PL6
PL4
PL9

PL1
CTTG121.doc V1.0 2 3/11/2008 PL10
 For questions call Control Techniques Technical Support-USA
at 716-774-1193
Grand Island, NY 14072

IN 95 DIP SWITCH LOCATION

CONTROL POD SWITCH LOCATION

To PL4 of
To PL1 of the IN96 To PL9 of
the IN95 the IN95

The individual components can be isolated by removing cables and reassigning

the dip switches. This may not be suitable for running the motor under full load but it
can certainly assist in efforts to isolate a trip. You may be able to run the motor
unloaded as long as the magnetizing current does not exceed the rating of the
individual power module.

Page # 4 shows an example where power module #2 is removed from the system.

Page # 5 shows an example where power module #1 is removed from the system.

CTTG121.doc V1.0 3 3/11/2008

Change the dip- Remove the cables
switch in the POD from module 1 to
from 2 to 1 module 2

10-pin 10-Way

16-Way
16-pin

26-pin 26-Way

10-pin

The unit has now been

converted to a single
module system. You may
even be able to run the
motor unloaded. If the 16-pin
trip clears in this state
then the problem was in
power module #2 or the 26-pin
interface cables between
power module #1 and
power module #2.

CTTG121.doc V1.0 4 3/11/2008

 Change the dip- Remove the cables from power module 1 to power module 2.
switch in the POD Move the cables from the control POD over to power module #2
from 2 to 1

10-pin 10-Way

Change
16-Way the dip-
16-pin
switch on
the IN95
26-Way
26-pin from 2 to 1

10-pin

16-pin

26-pin

The unit has now been converted to a

single module system. You may even be
able to run the motor unloaded. If the
trip clears in this state then the problem
was in power module #1 or the interface
cables between power module #1 and
power module #2.

CTTG121.doc V1.0 5 3/11/2008