IQ DP-4000
SECTION 6 - TROUBLESHOOTING AND MAINTENANCE
TD 17548B
39
6.1 LEVEL OF REPAIR
This manual is written assuming you will perform only
unit-level troubleshooting. If you trace the cause of a
malfunction to the IQ DP-4000, replace the unit with a
spare and return the malfunctioning unit to Cutler-
Hammer for factory repairs.
6.2 MAINTENANCE AND CARE
The IQ DP-4000 is designed to be a self-contained and
maintenance-free unit. The printed circuit boards are
calibrated and conformal coated at the factory. They are
intended for service by factory trained personnel only.
Operate the IQ DP-4000 in an environment within the
temperature range of -25
°
C to +70
°
C. The environment
should also be free of excess humidity.
If you have spare units, store them in the original
packing material and container.
6.3 TROUBLESHOOTING
This section divides troubleshooting into two parts:
•
Troubleshooting during initial startup (refer to Table
6.A, p.40)
•
Troubleshooting during operation (refer to Table
6.B, p.41)
WARNING
ALL MAINTENANCE PROCEDURES MUST BE
PERFORMED ONLY BY QUALIFIED PERSONNEL
WHO ARE FAMILIAR WITH THE IQ DP-4000 AND
ITS USES. FAILURE TO OBSERVE THIS WARNING
COULD RESULT IN SERIOUS INJURY, DEATH,
AND/OR EQUIPMENT DAMAGE.
TROUBLESHOOTING PROCEDURES MAY INVOLVE
WORKING ON EQUIPMENT IN AREAS WITH
EXPOSED LIVE PARTS WHERE THE HAZARD OF A
FATAL ELECTRIC SHOCK IS PRESENT.
PERSONNEL MUST EXERCISE EXTREME CAUTION
TO AVOID INJURY OR EVEN DEATH.
ALWAYS DISCONNECT AND LOCK OUT THE
CURRENT SOURCE AND CONTROL POWER
SUPPLY BEFORE TOUCHING THE COMPONENTS
ON THE REAR OF THE IQ DP-4000.
6.4 REPLACEMENT
To replace the IQ DP-4000:
1. Turn off control power at the main disconnect or
isolation switch of the power supply. If the switch is
not located in view of the IQ DP-4000, lock it out to
guard against other personnel accidentally turning
on the switch.
2. Verify that all “foreign” power sources wired to the
IQ DP-4000 are de-energized. These sources may
also be present on the relay and the input/output
terminal block. Temporarily short the current
transformer (CT) inputs at a point prior to the IQ
DP-4000’s terminals before attempting to open the
terminals on the IQ DP-4000.
3. Before disconnecting any wires from the unit, you
must individually identify them to assure that you
can reconnect them properly. Make a sketch to aid
in terminal and wire identification.
4. If an optional ribbon cable connects with the
communication port, carefully disconnect it.
5. If the power module for the unit is in a remote
location, carefully unplug the optional extension
cable from the IQ DP-4000 chassis, not from the
power module. Remove the wires by loosening the
wire connection at the screw terminal.
WARNING
SUPPORT THE IQ DP-4000 FROM THE FRONT SIDE
WHEN THE SCREWS ARE LOOSENED OR
REMOVED IN STEP 6. WITHOUT SUCH SUPPORT,
THE UNIT COULD FALL OR THE PANEL COULD BE
DAMAGED.
6. Remove the mounting screws holding the unit
against the door or panel. The screws are
accessible from the rear of the unit. Carefully lay
the screws aside for later use.
7. Remove the present unit and mount the
replacement unit according to 4.2.2 (p.12). Do not
over-tighten screws.
8. To connect the replacement unit, reverse the
procedure outlined in steps 4 - 7.
9. Use the sketch you made in step 3 to replace each
wire at the correct terminal.
10. Go to Section 4.5 (p.20) and perform initial startup.
Summary of Contents for Cutler-Hammer IQ DP-4000
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