1

Dubai International Airport Expansion

July 2010

Contract #TD56

Dubai International Airport Expansion

Contract #TD56 Passenger Loading Bridges

July 2010

8. Maintenance

8.Maintenance

Description

Page

Procedure for the Logical Diagnosis and Correction of Faults77

Initial Checks77

Wiring77

Status Lights79

Input Power80

DC Voltages80

Low Voltage Power Supply Problem80

Converter Faults81

Main Faults82

Troubleshooting Tips86

Troubleshooting Flow Charts90

Parts Replacement103

The Card Rack103

The Inverters103

IGBT Installation104

IGBT Drive Board Installation104

The Output Cable106

Replacing the Output Cable108

1.Procedures for the logical diagnosis and correction of faults

A.Initial Checks

(1)Wiring

Following the initial installation of a Jetpower PWM converter or the replacement of parts, it is always best to inspect and verify that all wiring is correct and secure.

(a)Input/Output Wiring

The incoming three phase 50 or 60 Hertz power is normally brought into the unit through the case and connected to a circuit breaker.

Verify that the wires are connected securely.

Verify that the output cable is connected correctly and check for lug bolt tightness.

(b)Control Wiring

Check the converters start/stop wiring that's connected to TB-6 pins 1 through 6.

Check the output cables E and F safety interlock wiring.

Insure the connector on the IV Sense board is properly seated.

If the converter is mounted on a passenger boarding bridge, use the bridge schematic to check the bridge interlock wiring connected to TB-4.

(c)SCR Wiring

Insure that the three wires coming from the input circuit breakers are securely fastened to the appropriate SCR.

Verify that the connectors on the ends of the wires going from the SCR interface board to the SCR are properly seated.

(d)Transistor Drive Boards

Verify that all the 12 VAC and 9 pin D connectors are properly seated.

Check that the transistor output wire from each transistor terminal C2E1 is properly positioned and that the three transistor board mounting screws are tight.

(e)Card Rack Connectors

On the 24 phase board insure that the cable from P1 to inverters 1 & 2 is connected to the top connector and that the cable from P2 to inverters 3 & 4 is connected to the bottom connector.

These connectors can be installed in the wrong place and the Jetpower will operate, but the output voltages will not be correct.

Carefully check the three (3) connectors plugged into the BITE board.

Carefully check the two (2) connectors plugged into the Logic board.

Carefully check the connector plugged into the Power Supply board.

(2)Status Lights

When first inspecting a Jetpower PWM converter that has been reported as having a problem, always begin by first checking the status of the three lights on the front of the unit.

ColorStatusIndication

RedOffNo Faults Being Reported

The red light off indicates that there are no faults being reported by the converter.

This is the normal operating condition of this light.

RedSteadySystem Fault

When the red light is on steady, a fault condition has occurred.

Check the seven segment displays on the logic board to see what the fault is.

Red FlashingInput Out of Phase

When the red light is flashing, either the input (380/480 volts) is missing one or two phases, or the input voltages are out of tolerance.

YellowOffNo Input Power Applied

The yellow light off indicates that the 380 or 480 input voltage is not being received by the converter.

YellowSteadyInput Power Applied

The yellow light will always be on steady whenever the input circuit breaker is on and input power is being supplied to the converter.

Yellow FlashingAircraft Safety Circuit Bypassed

To enable a Jetpower converter to be operated without an aircraft (no 28 volts on pin F) the bypass switch on the logic board must be turned on.

A flashing yellow light indicates that the bypass switch on the logic board is turned on.

GreenOff400 Hz Power Off

The green light off indicates that the converter is not operating and 400 Hz power is not present at the aircraft plug.

GreenSteady400 Hz Power to the Aircraft Plug

The green light is on steady whenever the converter is turned on and is operating.

Green FlashingNo 28v Received from the Aircraft

Once 28 volts has been supplied to the converter, its removal causes the converter to shut off and the green light to begin flashing.

(3)Input Power

(a)If the red fault light is flashing, then either the input (380/480 volts) is missing one or two phases or the input voltages are out of tolerance.

(b)Depress first the A IN, then the B IN and finally the C IN push buttons on the key pad.

(c)The input voltages should be displayed on the digital panel meter, visible through the clear Plexiglas window.

(d)If the incoming voltages are not correct, use a hand held digital voltmeter and trace back through the converter to the incoming circuit breaker and then on to the source of the utility power to determine where the problem is.

(4).DC Voltages

(a)Check the +5 VDC and the 15 VDC by observing the three green LED's located on the P/S board.

(b)These LED's should be on and all at about the same intensity.

B.Low Voltage Power Supply Problem

(1)If any of the power supply LED's are not lit or are dim, turn off the main power to the converter, unplug the Power Supply board from the card rack (leaving the cable plugged into the front of the board) and then turn back on the main power to the converter.

(2)If the three LED's are still not properly lit, replace the P/S board.

(3)If the LED's are properly lit with the board unplugged, turn off the main power to the converter and find the source of the problem.

(a)To do this, first place an ohm meter between ground (pins 1,A,22 or Z) on the card racks edge connector and the pin associated with the unlit LED. +15v is pin 2,B. -14v is pin 21,Y. +5v is pin 3,C.

(b)Then remove one circuit board at a time from the card rack until the cause of the problem (usually a short) is eliminated.

(CAUTION:Be extremely careful to not remove or install a circuit board with the main input power on.B.Converter Faults

A steady red light on the front of the converter indicates that a fault signal has been returned to the logic board.

(1)Inverter Alarms

(a)One of the most common causes of a fault (red) light is an inverter alarm.

(b)A number will appear on the top numerical LED located on the edge of the logic board which indicates which inverter is causing the problem.

(2)Main Faults

The bottom LED on the Logic board displays the main faults. The following is a detailed description of these faults:

IndicationFault

1Input Voltage to High.

This fault should only occur when the input voltage is more than 10 % higher than the rated input voltage. For 480 volt rating this would be 528 volts, for 415 it would be 456 volts, for 380 it would be 418 volts. Use the voltage reading obtained on the digital meter on the unit for checking this because this is what the fault circuitry uses. If the voltages are all OK it is worth checking the voltage setting on the Logic Board for an incorrect setting. See Logic Board description for how to set the switches. If this still does not eliminate the fault then the Logic board could be bad. This fault is reset by first pushing the stop button and then by removing and reapplying the input power. This fault will also cause the red lamp on the front panel to blink.

2DC Bus Fault.

This fault is to indicate that a fault has occurred on the DC bus Discharge system. Whenever input power is removed the Discharge board activates and discharges the voltage on the DC bus. Two large resistors mounted on the Discharge bard are used to discharge this voltage. A heat sensor is mounted on the resistors. If the resistors get too hot the heat sensor will trip and a DC Bus fault will occur. This fault could mean that the Discharge board tried to discharge with power applied to the unit. This could happen if the board failed or the cable connected to the board is not plugged in or a wire has come loose going to this connector. There is one green LED on the board. This indicates that the board is receiving 120vac to tell in to NOT discharge. When the 120vac goes away it will discharge.

3Output Voltage Low.

This fault will occur when the output voltage goes below 100 volts for more than 4 seconds. Under normal conditions this should not ever occur. The most common occurrence is when the voltage control pot has been turned down and the Jetpower is started. If the voltage is not adjusted above 100 volts within 4 seconds this fault will occur. This fault is cleared by pushing the stop button.

4Output Voltage Above 180 Volts.

This is another fault that should not ever occur. It is in the unit to shut it down if the voltage ever got this high in order to meet MIL-STD-704. If this fault occurs then something is wrong with the 24 Phase board that makes it put out too high of output voltage. This fault is cleared by pushing the stop button.

5Output Voltage High.

This fault could occur if the voltage goes above 126 volts for to long. It is a timed fault. The higher the voltage the faster it faults. At 2 volts above the limit the Jetpower will run for 1 second, but at 20 volts above the limit it will run for about .1 seconds. This is according to a curve that MIL-STD-704 specifies. Note that some individual specifications call for different over voltage limits so the level that this fault occurs could vary. This fault is cleared by pushing the stop button.

6Output Overload.

This fault can occur if the Jetpower is operated in an overload condition to long. It is timed so that the higher the load the faster the fault will occur. The maximum load is 200%. At about 210% the fault will occur almost instantly. The fault can be reset by pushing the stop button.

7No 28 Volts on E & F.

This fault occurs if the 28 volt interlock system with the aircraft is not functioning. When the Jetpower is started it produces 400 Hz. But if after 4 seconds the 28v interlock signal is not received on TB F from the aircraft this fault will occur. It will also occur instantly if the 28 volt signal is ever lost after this initial 4 second start up time. The most likely reason this fault would occur is if the output cable is bad or the plug was pulled from the aircraft while hot. The fault can be cleared by pushing the stop button.

8E & F Over-Voltage.

This fault occurs if greater than 60 volts is ever present on the 28 volt aircraft interlock wires. This could occur if the output cable has a short in it that applies one of the output phase wires to the 28 volt wires. The fault can be cleared by pushing the stop button.

9Input Voltage Low.

This fault should only occur when the input voltage is lower than 15 % below the rated input voltage. For 480 volt rating this would be 408 volts, for 415 it would be 353 volts, for 380 it would be 323 volts. Use the voltage reading obtained on the digital meter on the unit for checking this because this is what the fault circuitry uses. If the voltages are all OK it is worth checking the voltage setting on the Logic Board for an incorrect setting. See Logic Board description for how to set the switches. If this still does not eliminate fault the Logic board could be bad. The fault can be cleared by pushing the stop button. This fault will also cause the red lamp on the front panel to blink.

ANo Output Voltage Control.

This fault will occur if the Jetpower does not detect the output voltage. It is to protect the aircraft in the event something failed in the Jetpower. The Jetpower regulates its output voltage by observing what it reads at the output. If it reads 0 volts at the output it would try to make the output voltage go higher until it reads the correct voltage. It no signal was detected but the voltage was actually there then very high voltages could be produced on the output.

This fault could occur if the Jetpower is in Automatic control (toggle switch on 24 Phase board) and the voltage control pot is turned down all the way when the start button is pushed. In this condition no voltage is detected and a fault will occur. To stop this turn the voltage control pot up about 1/3 of the way and then push the start button. The Jetpower should come on and then the voltage can be turned up before an under voltage fault occurs.

This fault can also occur if the plug on the IV Sense board has been removed or is not connected properly.

The fault can be cleared by pushing the stop button.

bSingle Output Line shorted.

This fault monitors if one of the output phases goes above 130 volts but the other two remain low. This should never occur but is there for protection. The fault can be cleared by pushing the stop button.

COutput Frequency out of Tolerance.

This fault should never occur. It detects the output frequency and faults if the frequency is lower than 370 Hz or greater than 430 Hz. The 400 Hz generator is crystal locked so the frequency should never vary. But if the crystal failed and it doubled or halved in frequency (most likely failure) this fault would occur. This is an indication that that 24 Phase board has failed. The fault can be cleared by pushing the stop button.

dnot used

EOver Temperature

This fault can occur if one of the large heatsinks get too warm. There are heatsinks on each power switching transistor bank (or IGBT) and on the main rectifier bank. Each heatsink has a temperature switch. They are all wired in series. If any one the switches opens this fault would occur. When this fault occurs the fans on the Jetpower continue to operate but the Jetpower will not. This allows the Jetpower to cool down. This fault could occur if a fan failed and a moderate load was applied to the Jetpower which would cause an over heat condition. If the Jetpower is not warm it is possible that a connection on one of the temperature switches has come off. The fault can be cleared by pushing the stop button.

FIGBT Alarm.

This fault occurs when a power IGBT has failed to turn on when it was supposed to. It can occur if the transistor is bad or when an extreme load was applied that was not caught by the overload fault.. The top display on the Logic board will identify which IGBT failed. Sometimes it is obvious that a IGBT (or IGBT) has failed. Physical damage can be seen around the IGBT where it has destroyed itself. If no physical damage is observed then push the stop button, remove and reapply the input power and push the start button again. If no fault occurs it was probably some kind of short on the output that is no longer there. If a fault occurs again then the IGBT that is identified on the top display is bad.

Always replace both the IGBT and the Drive board that is mounted on top of it. After replacing a IGBT put the Logic board into test mode to test the IGBTs before operating normally.

D.Troubleshooting Tips

To simplify troubleshooting, remember that the Jetpower PWM ground power unit consists of only four (4) basic parts.

(1)The Silicon Controlled Rectifiers (SCR's)

(a)This section receives the incoming volts AC and changes it to DC.

(b)This DC voltage is then changed to 400Hz square waves by the inverters. The square waves are then combined by the output transformers to form the three output waveforms.

(c)Therefore, if your problem is something that affects all three of the output voltages the same then the problem is most likely with the rectifier section.

(d)The rectifier is designed to provide the DC bus voltage necessary to produce up to 140 kVA of 3 Phase 400 Hz power.

It contains three (3) high current dual SCRs which are used as a switched rectifier to put the DC on the bus.

This type of rectification is commonly called a six (6) step rectifier.

(NOTE:FMC Jetway Systems does provide a twelve (12) step rectifier as an option.

(e)The SCR control signal that turns the SCRs on and off is generated on the Logic board.

The Logic board knows when to turn the SCRs on and off for proper operation.

When the start button is pushed the Logic board sends the control signal to turn the SCRs on.

When either the stop button is pushed or a fault occurs the Logic board removes the control signal.

When the start switch is pushed the SCRs are turned on and the voltage on the DC bus will ramp up slowly until the SCRs are completely on.

A small pot located on the front of the SCR Ramp board can be used in testing. This pot is a manual adjustment of the DC voltage on the bus. When turned fully counter clockwise no voltage will be present on the bus. As the pot is turned clockwise the voltage will increase. Normal operation is the pot fully clockwise.

(f)Bus Fuse.

This is a fuse that is installed in the main bus directly above the SCRs. If a transistor has destroyed itself or some other major fault this fuse could be blown. If everything appears OK but no voltage is on the output, it is worth checking this fuse with an ohm meter.

(3)The Inverters (IGBTs)

(a)The inverter section consists of the 24 phase board that sends out the inverter drive signals to the four (4) inverters.

(b)The inverters receive the DC voltage from the SCR section. Through the use of large power IGBTs, they change this DC voltage to a string of square waves.

(c)Each of the four (4) inverters are made up of three sections. Each section contains a IGBT drive board and a power IGBT.

(d)Therefore, if your problem is affecting one phase different than another phase then the problem will most likely be with one section of an inverter.

(3)The Transformer Section

(a)The output transformers receive the pulses from the inverter sections and combine them to form the output waveforms.

(b)Therefore, gross irregularities in the output voltages will usually be caused by a problem in the transformer section or an inverter.

(c)When troubleshooting the transformer section always check first for discolored or loose connections.

(d)Then carefully inspect the transformers input and output wires to insure that they are not shorted to the case or to one of the transformer lugs.

(e)When operated with a load the transformer primaries should all have approximately the same current.

(4)The Control Section

This section consists of the Logic board, the stop/start push buttons and the IV sense board.

(a)Logic Board

The Logic board provides the control logic that stops and starts the converter.

This board also receives the 28 volts that comes from the aircraft and provides the logic that controls the operation of the three indicator lights on the front of the converter.

Therefore, if you have a problem with the 28 volt return system or in the operation of the start/stop controls, the problem may be with the Logic board.

(b)The Stop/Start Push Buttons

The stop/start push buttons can be checked using the installation drawings and an ohm meter.

(c)IV Sense Board

The IV Sense board monitors the output voltages and currents and sends samples back to the 24 Phase board and the BITE board.

Therefore, if your problem is output voltage regulation the cause may be either the IV Sense board or the 24 Phase board.

If the problem is with the digital panel meter the cause may be with either the key pad assembly, the IV Sense board, the BITE board or the meter itself.

(5)The Output Cable

(a)Most problems with the output cable will be either shorts between the conductors or open conductors.

(b)Always disconnect the cable from the converter prior to ohming it out.

This will insure you do not get erroneous readings by reading back through the output transformer windings.

(c)Problems occurring immediately after an output cable installation most likely will be caused by the output phase rotation being connected incorrectly.

2.Troubleshooting Flow Charts

3.Parts Replacement

The most common part necessary to replace will be a circuit board.

(CAUTION:Always remember to turn off the main circuit breaker on the unit and use extra care when removing or installing a circuit board.

A.The Card Rack

(1)The circuit boards in the card rack are designed using a common bus. This means that they can plugged into any one of the six (6) slots in the card rack.

(2)Each circuit board edge connector is off set so that the board cannot be installed up-side down.

(3)Use the plastic levers mounted on the front corners of each board to assist in the removal of the circuit board.

B.The Inverters

(1)Circuit Board Removal

(a)To replace the inverter assembly you must first disconnect the 9 pin D connector and the two power supply connectors from the IGBT drive board.

(b)Remove the three large screws from the center of the IGBT drive board and remove the IGBT drive board.

(2)Power IGBT Removal

Remove the four screws holding the power IGBT in place and by carefully prying the + and - bus bars away, slide the IGBT off to the side and out.

(3)IGBT Installation

(a)First ensure that the mounting surface on the heatsink is clean and free of all dirt and grit.

(b)Next wipe off the bottom of the new IGBT.

(c)Remove the paper backing from the heat transfer pad and place it between the IGBT and the heatsink.

(d)Mount the IGBT using the four corner mounting screws. The screws must be tightened gradually to insure the IGBT is seated properly.

(e)Use a torque wrench and insure each screw is torqued to 26 inch/pounds.

(4)IGBT Drive Board Installation

(a)First install insulator sheet on to IGBT Drive Board then install a IGBT drive board, carefully place the drive board assembly against the power IGBT insuring that the small spade connectors on the board are properly mated to the IGBT.

(b)Insure the output cable going to summing transformers is placed in its proper position between the feedback board and the C2E1 (left) terminal of the IGBT.

(c)Screw the drive board assembly onto the power IGBT using the three large screws. Use a torque wrench and insure each screw is torqued to 26 inch/pounds.

(d)To complete the installation, reconnect the power supply connectors and the 9 pin D connector.

(5)In some cases the power IGBT package may actually explode and in so doing cause physical damage to other components within the Jetpower converter.

If you suspect additional damage may have been done, use the following procedure after replacing the IGBT.

(a)Insure the input power to the converter is off.

(b)Unplug connector on SCR Ramp Board.

(c)Turn the auto/manual switch on the bottom of the Logic board to the MANUAL (down) position.

(d)Turn the output voltage adjust potentiometer all the way counterclockwise.

(e)Turn the bypass switch on the front of the logic board to the bypass ON (up) position.

(f)Turn the input power circuit breaker on.

(g)Verify that all three (3) LED's on the power supply board are on.

(CAUTION:Be extremely careful to not remove or install a circuit board with the main input power on.

(h)With the input power applied, verify that none of the green LED's on the IGBT drive boards are on.

If one or more of the green IGBT drive board LED's are on, remove the 9 pin "D" connector from the edge of the board and swap it with a cable from a board who's LED is not on.

If the problem (the green LED on with no input signal) remains with the board, replace both the drive board and the IGBT.

If the problem follows the cable, remove the hood (backshell) from the 9 pin "D" connector and check for loose or broken wires.

If no problem is found with the cable, replace the 24 phase board.

(i)Press the start push button and verify that all the green LED's on the IGBT drive boards are on steady.

If one or more of the green IGBT drive board LED's are not on, remove the 9 pin "D" connector from the edge of the board and swap it with a cable from a board who's LED is on.

If the problem (the green LED is not on) remains with the board, replace both the drive board and the IGBT.

If the problem follows the cable, remove the hood (backshell) from the 9 pin "D" connector and check for loose or broken wires.

If no problem is found with the cable, replace the 24 phase board.

(j)Depress the stop push button and turn off the input power circuit breaker.

(k)Plug in cable to SCR Ramp Board.

(l)Turn the input power circuit breaker back on.

(m)Return the auto/manual switch on the top of the voltage control board to the auto (up) position.

(n)Set the output voltage adjust potentiometer to approximately it's mid range.

(o)Depress the start push button.

(p)Adjust the output voltage adjust potentiometer until the output voltage reads approximately 115 volts on the digital panel meter.

C.The Output Cable

(1)Checking the Output Cable

Problems with a 400Hz output cable can be of several types and are usually caused by the miss-use of the cable.

(a)Shorted Conductors

To check for a shorted output cable, first turn the output voltage control potentiometer all the way counter clockwise and then switch the converter to MANUAL output voltage control using the toggle switch located on the bottom of the 24 Phase board. Now start the unit and bring the output voltage up slowly while monitoring the output current. A rapid rise in output current with no load applied to the unit indicates a shorted output cable.

(b)Open Conductors

An open conductor will result in the absence of one or more of the output phases at the aircraft plug.

First, insure that the converter is operating correctly by measuring all three phases at the output terminal block in the converter.

Now measure the voltages at the end of the cable to verify that one or more line is open.

(c)The 28v Return Lines (E & F)

If the cable head is inadvertently left lying on the apron, it may be run over by a vehicle.

A common result is to have the E or F lines be either broken or shorted to one the 400Hz phases resulting in further damage to the converter.

(2)Replacing the Output Cable

(a)Ordering a New Cable

New cables or replacement heads may be ordered directly from FMC Jetway Systems.

The cables come complete with an aircraft plug on one end and 3/8 inch terminal lugs on the other end with the individual wires marked Phase A, Phase B, Phase C, neutral, E and F.

(b)Installation

Insure that the connections made to the converters output terminal block are tight and that the correct phase rotation has been observed.

This page has been left blank intentionally for future expansion and comments.

This page has been left blank intentionally for future expansion and comments.

Page 108

Volume 5 - Jetpower PWMRev 2

Section 8 - MaintenanceVolume 5 - Jetpower PWM

Page 88Section 8 - Maintenance

Rev 0

_980225926.doc

Check wiring from LV MOV board

to Power Supply board:

LV MOV Brd

PWR Supply Brd

J4-1 to J1-6

J4-2 to J1-7

J4-3 to J1-8

J4-4 to J1-9

Yes

Find wiring

problem?

Check voltage on Mother

board connectors P2-P7

pin 17, 18, 19 to ground.

They should have similar

voltage readings as were

measured on LV MOV

board

No

Voltages within

tolerance?

Correct wiring

problem

Yes

Replace BITE

Board

Yes

Replace Power

Supply board

Red Flashing

Light

Jetpower PWM Troubleshooting Chart

Remove all boards except Power

supply from card rack. Remeasure

voltages on P2-P7 pin 17, 18, 19.

Voltages within

tolerance?

Replace Mother

board

No

Plug in Logic board with plugs on front of

board not connected.

Check voltages on pin 17, 18, 19 again.

Voltages within

tolerance?

Replace Logic

board

Yes

No

Check voltages

on pin 17, 18, 19

again

Voltages within

tolerance?

Finished

Remove Logic board and plug in BITE

board with plugs unplugged. Check

voltages on pin 17, 18, 19 again.

Voltages within

tolerance?

Yes

Replace BITE

board

No

Plug boards back in and

start over

Yes

Yes

No

No

Faults 1 and 9

2912364

Rev NC

Page 3 of 13

_980227200.doc

Turn input CB off.

Put Logic board in normal

mode.

While watching LEDs on Bus

Charge board turn on the main

CB.

Do two green

LEDs come on?

Do two yellow

LEDs come on?

Yes

Replace Bus

Charge board

No

Does

bus fault occur

after 20

seconds?

Yes

Go back to

beginning

Yes

Turn off main CB,

replace Logic board

No

Set Logic board in

normal mode

Push stop and then

start

Operate ok?

No

Finished

Go back to

beginning

No

Yes

Yes

Jetpower PWM Troubleshooting Chart

Fault 2 - DC Bus

Fault

Return auto/manual and bypass

switches to their normal positions

2912364

Rev NC

Page 5 of 13

_980228162.doc

Fault F - IGBT

This sheet is for use when

the Jetpower has a Bus

Charge board installed

Examine the IGBT that

is identifed on the top

fault display

Is there evidence

of damage?

Examine other IGBTs

for evidence of

damage

Is there evidence

of damage?

No

Replace the IGBT and

drive board

Yes

Replace the IGBTs and

drive boards

Yes

Use ohm meter and check the

DC bus fuse (if there is one

installed). Replace if bad.

No

Put Logic board into test mode

(see manual) and turn on input

power.

Do any drive

boards LEDs come

on?

Push stop and then

start button

Do any drive

board LEDs come

on?

No

Replace all boards and

IGBTs that have have

LEDs on

Yes

Replace 24 Phase

Board

No

Yes

Jetpower PWM Troubleshooting Chart

2912364

Rev NC

Page 12 of 13

_980225755.doc

This drawing and any associated information or amendments are proprietary and confidential to

Jetway Systems. The drawing and information may only be used for the specified contract under

which it is delivered and only by the purchaser. Acceptance of the drawing and information

constitutes agreement not to reproduce it in whole or in part and not to disclose it to any other

party and not to use it for any purpose beyond the limited license granted herein without prior

written consent.

Jetway Systems

a division of FMC

Description

INSTR JETPOWER PWM TROUBLSHOOTING CHARTS

Code 54077

Drawing

2912364

Rev.

NC

Sheet 1 of 13

Date

Appd.

Date

08Feb99

By

MLFullmer

The following pages are troubleshooting charts for the Jetpower PWM units.

Not all faults are contained here. Only the ones that are considered more prevelant

The faults displayed on the lower display on the 24 Phase board are:

0 - No fault

1 - Input Voltage to high

2 - DC bus fault

3 - Output voltage to low

4 - Output voltage > 180v

5 - Output voltage > 130v

6 - Output overload

7 - No 28v on EF

8 - EF overvoltage

9 - Input Voltage to low

A - Output Voltage not detected

b - Single output line shorted

C - Output frequency fault

E - Overtemperature

F - IGBT fault

_980224056.doc

Do all

of the Drive board LEDs

come on?

Swap 24 Phase cable

plugs from a Drive

board where no LEDs

come on to one where

the LEDs come on.

Do LEDs

now light on the no LED

board?

Replace the drive

board and IGBT where

LEDs will not light

Replace 24 Phase

board

No

No

Yes

Push stop, remove

input power, plug in

SCR RAMP board

plug. Reapply input

power. Push start.

Slowly turn pot on SCR

RAMP board clockwise

untill fully clockwise.

Turn output voltage

control pot until there is

30-40 volts on the

output. Check all three

output voltages using

the panel meter.

Are they all within 1

volt of each other?

Turn the voltage

control pot up until

output is 100v. Let run

for 1-2 minutes.

Push stop. Toggle

auto/manual switch to

auto. Push start. Adjust

voltage to 115.

If load bank is available

apply load. If not then

repair is done.

Check that all of the

drive boards got

attatched correctly to

the IGBTs.

No

Yes

Yes

Fault F - IGBT

Jetpower PWM Troubleshooting Chart

This chart is for Jetpowers

that have SCR RAMP

boards installed

2912364

Rev NC

Page 11 of 13