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1. lt lt Lower cap bank assy electrical connection nuts Step 2 Soft charge card Figure 7 5 Upper and Lower Capacitor Bank Assemblies VLT is a registered Danfoss trademark 7 8 InputTerminal Mounting Plate Assy Option C Note that weight of disconnect can be up to 35 pounds 16 kg Slide disconnect down to clear fuses and remove The drive has component options that mount to the input mounting plate This results in differing unit configurations These 4 If cooling fan is mounted disconnect fan cable options include input terminal blocks input disconnect RFI filter input fuses and an additional cooling fan These options 5 If RFI filter is mounted disconnect RFI cable may need to be removed from the mounting plate assembly to reduce the weight of the assembly for ease of removal 6 Note that weight of terminal plate without 1 disconnect can be up to 44 pounds 20 kg To remove terminal plate remove 8 retaining nuts 10 mm from terminal plate and lift entire assembly from mounting studs Disconnect input power wiring from terminals L1 L2 13 and ground connector R
2. CBL21 Fm Es BRAKE IGBT CBL23 EXT BRAKE 2E DFe 2 R BRAKE GATE gt TE RES CARD PCAI3 Figure 2 8 Brake Option 2 10 VLT is a registered Danfoss trademark Cooling Fans All drives in this size range are equipped with cooling fans to provide airflow along the heatsink Units in NEMA 1 IP21 and NEMA 12 IP54 enclosures have in addition a fan mounted in the enclosure door to provide additional airflow to the rest of the unit Units in chassis IPOO enclosures have in addition a fan mounted to the top of the unit to provide additional cooling Some drives in this size range have a small 24 VDC fan mounted on the input plate This fan is only mounted on E frame size units equipped with both an RFI filter and mains fuses The fan provides air flow around the main fuses The fan operates anytime the drive is powered All fans are powered by the main line voltage which is stepped down by an autotransformer and then regulated to 200 or 230 VAC by circuitry provide on the power card On off and high low speed control of the fans is provided to reduce overall acoustical noise and extend the life of the fans Regardless of the heatsink temperature the fans are started shortly after main input power is applied to the drive If the heatsink temperature is below 86 F 80 C the fans will turn off after a short inter
3. 10 2 10 3 Block Diagram D1 525 600 690 VAC esses tenente tte trennt tentent tnnt 10 3 10 4 Block Diagram D2 525 600 690 VAC esses eerte rtenten tnter tnt tn tentent nitas 10 4 10 5 Block Diagram E1 380 500 VAC sesenta treten tnnt ntn ttn tenent 10 5 10 6 Block Diagram E1 525 600 690 VAC essent tenente tette trennt tne ntes 10 6 List of Tables Table Title Page Ratings Table 380 500 V rcp tre te dicic cie aene Intro 7 Ratings Table 525 600 525 690 V Intro 9 1 1 VLT 5000 Series Status Definitions sessi nnn 1 3 1 2 VLT 4000 6000 8000 Series Status Definitions sese 1 5 153 Fault Messages eme Ee ERU te di e d 1 7 1 4 Control Terminals and Associated Parameter essent 1 9 3 1 Visual Inspection pom eph optet citet 3 2 5 1 Fan Transformer Resistance s secescscseceseeseseeeeeeseeeeseseseeeeseaeaeeeeeaseeeseaeaeeeeseasaeesaneasenaeaeeneees 5 12 5 2 Scaling Card Resistance Values c cscsssssessesseceeseeseeseeseeseeseenssteesesteseeseeaeeseeseeteasaeeateaseateaees 5 25 9 1 Spare Pails List ooa ce eI RE UR 9 1 vii INTRODUCTI
4. DIGITAL INPUTS MK101 19 20 27 ANALOG I O MK100 DISC FUSE OPTION 42 45 TEST CONNECTOR 3 2 1 INTERFACE CARD PCA2 S201 Za RFVHF SWITCH CURRENT SCALING CARD 4 MK100 SCR GATE DRIVER 919 S 105 104 no 106 NC D MKi05 MK400 R S hoc oc B POWER CARD PCA3 L1 DC INDUCTOR HEATSINK FAN HEATSINK FAN CAPACITOR HEATSINK DOOR FAN TRANSFORMER PRE TEST GATE DRIVE CARD 5 MK750 CBL19 MK104 HF SWITCH Gwe H
5. VOd S Oow Ki ON ON 90 sor alvo 00 DIN vvOd oNnvos 1 HOLIMS 4 2 39VdH31NI 2 3snd osla 00DIN DOWNY oz 1ODIN SANANI e HOLO3NNOO 1581 7031409 HOLIMS vue SNIVW avia OLN INISLVSH LHL OVA 00S 08 6 01 D1 525 600 690 VAC TH1 HEATSINKNTC CN1 DISABLE MAINS RECTIFIER EXTERNAL BRAKE TEMP SWITCH DISPLAY CONTROL PANEL CONTROL CARD PCA1
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7. eseexm ezeoriA zecor zzror A 21917 ped ads uede ds yoo1g zs wi ze wi zorria ___ _____ ____ eseria zoerLia zsevrA aeoesrn uL E EET EE m 59715 157 sueg Block diagram Sparepart opare Parts List E frame Sizes PCAs PCA2 176F8551 Spare Interface PCA CC 5352T5 Interface Card between Control Card and Power Card conformal coated PCA 2 176F8552 Spare Interface PCA CC 5452T5 Interface Card between Control Card and Power Card conformal coated PCA 2 176F8553 Spare Interface PCA CC 5502T5 Interface Card between Control Card and Power Card conformal coated PCA 2 176F8611 Spare Interface PCA CC 5552T5 Interface Card between Control Card and Power Card conformal coated PCA 2 176F8462 Spare Interface PCA CC 5402T7 Interface Card between Control Card and Power Card conformal coated PCA 2 176F8464 Spare Interface PCA CC 5502T7 Interface Card between Control Card and Power Card conformal coated PCA2 176F8465 Spare Interface PCA CC 5602T7 Interface Card between Control Card and Power Card conformal coated PCA3 176F8313 Spare Power PC
8. 2018 Z070 ZANO 1019 Wha idno HOLSIS3H 31VO 00 DIN M M viVOd 584 31V9 3xvug dvo od ZNVEO ANYA dvo od DINVBO NOILdO Siva 189 Divya HOMS 3H BEWHO SNVHL NYS XNISIv3H z zu aft NAO OSDIN Svod 1531 3AIHQ 3459 HOLIMS 2
9. MK101 19 20 27 ANALOG MK100 DISC FUSE OPTION lae a2 45 INTERFACE CARD S201 Za 5 SWITCH MK103 P400 CBL4 RFI OPTION NANNAN CURRENT SCALING CARD PCA4 MK100 SCR GATE DRIVER 91919 S 105 104 108 c ne 100 AUX S 108 R 5 POWER CARD L1 DC INDUCTOR e Cry Xs RFI CARD PCA12 RFI SWITCH RFI SWITCH MK450 PRETEST MK550 GATE DRIVE CARD 5 MK750 MK850 HEATSINK FAN li HEATSINK FAN CAPACITOR DOOR HEATSINKDOOR FA
10. SB Qo a gio UU c cic o o o lt lt lt Warning Voltage High Alarm Voltage High 1109 1109 1109 1109 1109 1130 1130 1130 1130 1130 d d Brake On Voltage Brake On Voltage Full Duty Cycle 1 1 10 10 10 10 10 10 108 0 0 109 0 Ao ajA NIN N a ayo NJO a MPS Start Voltage MPS Stop Voltage LT Out LT Out Overcurrent Warning Overcurrent Alarm 1 5 sec delay ayo ojo Al ceo Cou NIN N ayo NJO ojojo ojo OJO Earth Fault Alarm LT Out Heatsink Over Temperature egrees C oj lt lt lt gio gio ww ww 0 o o o lt lt lt lt Mains Phase Warning 5 sec delay Mains Phase Alarm 25 sec delay C Bus Ripple C Bus Ripple NIN ALO Olay NIN N ajo NJO Ojo ojo Oo egrees egrees egrees Tm D o 4 3 T 9 v i an On High Sped Temperature an Off Temperature an Voltage Low Speed an Voltage High Speed use existing 525 600 V drive o T an VAC an VAC T 2 2 2 2 o NIN ALO ceo Cou NIN N ayo NJO Ojo ojo Oo VLT is a regi
11. o v oc oo S u OPN SOIN TERI 00 IW oNnvos 901 ON soi ge se Ave LXa D e HOLO3NNOO 1531 HOLIMS 3H I4H 1025 IVO 3OVJH3LLNI 37 2 ec NOLLdO 3snd osla 00 DIN SOTVNY 7051405 HOLIMS WNL navsia LI IHL IVA 069 009 ScS E1 380 500 VAC TH1 HEATSINK NTC CN1 DISPLAY CONTROL CARD PCA1 CONTROL PANEL PCA2 TEST CONNECTOR INTERFACE CARD RFI HF SWITCH EXT 24V Ls 36 DISC FUSE OPTION RFI OPTION IOTE F4 AND 26 ONLY INSTALLED WHEN FUSE OR DISCONNECT ARE
12. HF SWITCH VLT is a registered Danfoss trademark 10 1 gt ESS HOLIMS ssojueq e 1A 39HVHO14OS oat NOILdO 3HVHS QVO1 21991 xovdoNoo3 1189 3naow HOMS IH NOILdO 4 AA tOTO sana eano sano 2078 zana zano HOLSIS3H 31VO ano ioa
13. 2 PCA8 HF CARD CBANK1 DC BANK BRAKE GATE RES CARD PCA13 BRAKE OPTION BRAKE IGBT EXT BRAKE RESISTOR Dry V MK100 GATE RESISTOR CARD PCA6 CUP GUPI EUPI 901 ELOI CUP2 GUP2 FUP GLO ELO CUPS GUP3 EUPS GLOS ELOS e 5 NTC z RFI OPTION RFI CARD PCA12 c2 Hey UP 3 LL a hG 4 ECONOPACK MODULE IGBT1 LOAD SHARE OPTION SOFTCHARGE PCA11 BOARD ue HF SWITCH
14. 4 9122 SLIA WOd eoeneiu 99g eeds 91985921 pled JAMO pue PIED 1 2191 201 4 99g ereds G49849214 2 VOd pled 1 pue PIED 1 Z I9LeLOSLIN vod 99g ereds 71985921 2 VOd D ps J l Pb D D 1 PIED pue PED 04000 2129051 VOd OOgezeds 51983941 pled 1 pue LL2S0S LN e2epeiju 008 21883971 2 VOd p189 pue ueewjeg 212 0 1A VOd e2epeiu 998 11985971 1 pue pIe ueewjeg ZOESLTA VOd SOVSYSLNI 29991205 7058941 2 VOd p129 pue ueewjeg 2S82811A VOd 99g ereds 5058941 2 VOd kh e e ep e e 4 PIED pue PED 04000 VOd 3OVvJH31NI OOg ereds 60583941 pled 1 pue ZSISLIA VOd 3OVJ3H3INI 008 eed 108854971 2 VOd DES zoverw seein
15. 20 S 202S L1A S H OSIQ aa 3Hvds 80783911 o o o o peo 0 HOS Z0 S 202S L1A SNNIW ST aa SuVdS 2078392 1 9cag D 2 Js DJ L L snid req HOS sjoeuuo 20 S 202S1L1A SM1d ST aa 3Hvds 50783941 sega Pook L L Jeyje6o 1901 exeiq OM eur sioeuuo 20 S 202S LTA 3uvds 96683971 vega Poe e e e TT T T T eseud Jed euo uej eu e o sng indino Duo Z0 S z026 1 IAHOSN3S T d8 3HVdS 68683971 zegg L eseud eseud 103 1951 0 51090009 Z0 6 2026 L IA A HO1OW G8 3u vds 7858911 Legg Le J e e e M 10 eseud 104 1991 0 09009 5055 0591 1A Wn HOL0W as 3uvds 86849 1 0 88 _ 1991 01 joyoedeo sjoeuuo uoiwpues sng 189 jeddn 20 S 202S L 1A dvO 189l ASSV g8a 3uvds 8228492 1 6cag _ D s Js p e JJ L Nquiesse yompues seq indui 1861 Z0 6 2026 QNI LGOl ASSV 8d 3uivds 2 839 1 Fw i Dw fe o 2 2 Nquiesse eq indu 189 o1 indino 109 1990009 Z0 S 202S LASNNIW NIT 8 45 28683971 2288 _ JD _ p enup jo epis indui 109 sjoeuuo 209 202917
16. e 1A 9 6 asn4 sue pue 1834 4H Jed esnj 1e od ejqeo ewes 3 ueJ esnj ejqeo ereds 51983911 9c 182 198 1 4251 01 14 3 dOTelqeo 3uvads 98684971 abseyoyos sseuJeu Lau OG Buoyos eigeo 3uvds 98683911 92180 sseuieu aM 13 15 Duoyos eiqeo 3uvds 78983911 voldo JojsiseJ 1995 exeJq Sl 3 199 exerg eiqe 3uvds 58683911 12199 pied 101sise go eAup sseuJeu AM eure 3 ere5 1agb5r eiqeo a3uvads 68983911 61 8L 21780 1e Mod ejqeo 3 uid9 L eau eieo ejqeo 3uvds 1898592 9199 101 U09 YOUMS JH JO 18414 14H p129 eAup anM eure L3 u9iMs I3H eigeo 3uvds 08683911 91199 sng eBeyoA 13 AUO 4 5 94583911 t199 HOS 0 sseuJeu eure L3 HOS eigeo 3uvds 92984921 ergo Jed SHUN vSdl LedI uo suej OY eui Je 10 1 2099 79 4 4 45
17. VLT is a registered Danfoss trademark 10 3 HOLIMS 3H ssojueq e 1A 1405 oat i NOLLdO 3HVHS 21991 SINGOW 3nnaow exovdoNoo3 v Ol Quvo NOILdO 149 pps a AAA ANYA dvo od H3ddn OLN 5 3 19 HOLSIS3H 4 iana aano eana
18. S v 291 51 TA 1891 3HVdS 2978492 9 11891 ped jeuueuj pue sejqeo ayeb sjeuejsej 1991 S v CLS L 1A 1891 3HVdS 19785921 9 VOd 11891 S10 9npuoaiuies 2 L xueq pyeo eouejeq xueg L I9L2SES 22 ISL IA VOd eouejeg eeds 92984921 01 6VOd xueq pyeo xueg S v LZ0ES 27 LGL TA vOd eouereg e eds 01984921 01 L L L Yd eBreuoyos ZJ9120 9 zz LSL 1A OO VOd erede 22984921 jexoeiq eaw vod eBieuoyos 2069 22 LGL1A 2O VOd 39uvHOL1JOS eJeds 9088941 uu exe a a ee fouenbei4 ZJo1zses zz LG 1 vod JH ereds 2583971 8 vOd fouenbei uBiH 2069 26 LGLTA Yod e eds 2083921 8 VOd L L L 8 L 21912929 22 15 pue 912069 22 5 1 OY 4 Q OO vOd 9 60583941 S VOd 5 219122 1 9 2708 vod 1ewog uo sieisu vod Bureos uano WYO S8 S vod Purreos r ereds 9298492 v VOd 2191289 pue 1205 1 uo SISU uuo ors vod 5 21283921 Y VOd ue vE p 1 34n 3h 7 4 Gp Wc 1915059 pue 912929 1
19. Table of Contents INTRO DUCTION aa aaa aE Eaa daanan aaa a intro 1 PURPOSE T intro 1 VET PRODUGCT OVERVIEW erc re ngon cett ire titre ir Rc ene Hd intro 1 FOR YOUR SAEETY cere ato i endi came ieiunus ich intro 1 ELECTROSTATIC DISCHARGE ESD sse entente nter tnnt tette niani intro 1 TOOLS REQUIRED rtt ria ete a intro 3 Additional Tools Recommended for Testing seen intro 3 SECTION 1 OPERATOR INTERFACE AND DRIVE CONTROL 1 1 INTRODUCTION ri t enit o et d a t ne d taces 1 1 INOrMallDIS PLAY IT 1 1 OCURRE 1 2 Factory Default Display Settings seien tentent tentata tan 1 2 WARNINGS AND AEARMS tice ta den cena ihe P d oa e nn 1 6 uncensored kn 1 6 m 1 6 SERVICE FUNCTIONS e 1 6 FAULT MESSAGE TABLE lnc dea cac rec dike dares 1 7 DRIVEINPUTS AND OUTPUTS nea reiecta daten 1 8 Input ee Signals tet ELE Control Terminals Control Terminal Functions RRRA 1 9 Grounding Shielded Cables tte ie s 1 11 SECTION
20. 5122 5152 5202 VLT 5252 5302 6152 6172 6222 6272 6352 8152 8202 8252 8302 8352 Normal overload current ratings 1 10 Output current Nominal A 525 550 V MAX 60 sec A 525 550 V Nominal A 551 690 V MAX 60 sec A 551 690 V Nominal kVA 550 V Nominal kVA 575 V Nominal kVA 690 V Typical shaft output kW 550 V HP 575 V kW 690 V High overload torque 160 Output current Nominal A 525 550 V MAX 60 sec A 525 550 V Nominal A 551 690 V MAX 60 sec A 551 690 V Nominal kVA 550 V Nominal kVA 575 V Nominal kVA 690 V Typical shaft output kW 550 V HP 575 kW 690 V Power loss Normal overload W Power loss High overload W Limits and Ranges Warning Voltage Low DC Bus V Alarm Voltage Low DC Bus V Warning Voltage High DC Bus V Alarm Voltage High DC Bus V Brake On Voltage DC Bus V Brake On Voltage Full Duty Cycle DC Bus V SMPS Start Voltage DC Bus V SMPS Stop Voltage DC Bus V Overcurrent Warning VLT Out Overcurrent Alarm 1 5 sec delay VLT Out Earth Fault Ala
21. corel a 2 zszei1 zocei3 zs 1829190140 OF 2229 ezeor zzii esiosa feronra zoo eseon 22 21917 Zorpia 2 eeraa zwi ____ serra zoevinA zszeinA aesisita acest 2 20251 zsisiia 221617 0151 220617 zeosriA zszsi1A zozsiin esisita 221917 OWA 009 56 OWA 069 ScS OWA 087 088 OWA 09t 08 OWA 005 088 Jed sjueuieuinbag yed zeds wedowds 59715 157 sueg Spare Parts List D frame Sizes Requirements Per Drive Requirements Per Drive 380 500 VAC 380 460 VAC 380 480 VAC 525 690 VAC
22. PE PE Min 16mm Equalizing cable PLC etc DANFOSS 1752A165 11 Correct grounding Control cables and cables for serial communication must be fitted with cable clamps at both ends to ensure the best possible electrical connection Incorrect grounding Do not use twisted cable ends pigtails since these increase shield impedance at high frequencies Ground potential protection When the ground potential between the drive and the PLC or other interface device is different electrical noise may occur that can disturb the entire system This can be resolved by fitting an equalizing cable next to the control cable Minimum cable cross section is 8 AWG 50 60 Hz ground loops When using very long control cables 50 60 Hz ground loops may occur that can disturb the entire system This can be resolved by connecting one end of the shield with a 100 nF capacitor and keeping the lead short Serial communication control cables Low frequency noise currents between drives can be eliminated by connecting one end of the shielded cable to drive terminal 61 This terminal connects to ground through an internal RC link It is recommended to use twisted pair cables to reduce the differential mode interference between condutors Figure 1 3 Grounding Shielded Cables VLT is a registered Danfoss trademark 1 11 2 INTERNAL DRIVE OPERATION GENERAL This section is intended
23. edno 101 IANI 9vod HOLSIS3H 31VO o0 M n S3d 31VO ava a ANYA dvo 2 H3MO z NOILdO 534 31V9 3 a HOLIMS 4H MSWHOJSNVM L OOObNISIVSH p t 170 Nr ANISH 1591 aud 1
24. sees 5 23 5 16 Control Card Test Connections sse entente terrent enitn 5 28 6 1 Control Card Cassette esses tentent tenente tte trennt te tentent 6 1 6 2 Interface Card Power Card and Mounting Plate sse 6 2 6 3 Gale Drive Linie int debet uie 6 3 6 4 Soft Charge Card Assyria sid 6 3 6 5 D2 Upper and Lower Capacitor Bank Assemblies 6 4 6 6 D1 Single Capacitor Bank Assembly sssssseseseseeeetn treten tentent tnter enne 6 5 6 7 D2 Soft Charge Resistot o eroe Rete Hd 6 6 6 8 01 Soft Charge Resistor iniiis ieena aiiai 6 7 6 9 Input Terminal Mounting Plate Assy sseeeeeeeennnnennnen nnns 6 10 6 10 D2 SCR Diode Module sesenta tte ttnn tinte tentent 6 11 6 11 D1SCR Diode Module 0 0 estes eesessessssteseeseseeseeseeseeesseesesteseeseeaseneeseesesnssteetentesteatenssnseseetensen 6 15 List of Figures continued Figure Title Page 6 12 Current Sensor cient 6 18 6 13 reote b npa cp cde b annt 6 19 6 14 AC Input Terminals ttt tette tr d ce Ee e tete teras 6 21 6 15 D2 IGBT MOdUleS eee e ei e to e ted eus
25. 176F8588 Spare Insul Terminal Block E1 Frame Motor terminal insulation block 1 per phase 176F8372 Spare Term Insul BRK LD SHR VLT51 22 5303 Brake terminals insulation block 1 per drive 176F8588 Spare nsul Terminal Block E1 Frame Load Share terminal insulation block 2 per drive 176F8589 Spare Label Set Terminal E1 Frame Mains motor load share and brake terminal block label set 176F8590 Spare Insul IGBT Chassis E1 Frame Insulator under IGBT input bus bar assemblies VLT8502 VLT8602 VLT8652 VLT8502 VLT8602 a i f 8 Oo o s J 3s 3 3 3 3 k fs 80 ae es a 5 4 3 E 2 a 2 SS i J 3s 3s 3 3s 3 1 O s 3s 3 3 3 a re eS ees eS ae ee BE i 2 2 2 2 O 2 2 ieee eee Se ee ae ee EE SSS ESS Sa __ 1 a D 1 1 __________ ______________ _______ Bus Bars 176 8595 Spare BB SCR Di Input E1 Frame From input plate to SCR and Diode 1 per phase 3 3 3 _3 3 3 176F8596 Spare BB SCR Di Output E1 Frame Attaches to the SCR and Diode on the DC side
26. eS _ _ Ai Drive Sizes and PCA1 176F1400 SPARE PCA CONTROL VLT5000P Control PCA VLT 5000 Process IPCA1 176F1452 SPARE CTRL CARD ASSY PROC CONF Control PCA VLT 5000 Process Conformal coated _______ 17621405 SPARE PCA CTRL CARD VLT6000 Control PCA VLT 6000 HVAC IPCA1 _____ 17621453 SPARE CTRL CARD AQUA HVAC CONF Control PCA VLT 6000 HVAC Conformal coated 176F5591 SPARE PCA CONTROL VLT4000V Control PCA VLT 4000 IPCA1 176F5592 SPARE PCA CONTROL VLT4000V COAT Control PCA VLT 4000 Conformal coated 17523595 _ SPARE CONTROL FLUX UNIT W SOFTWARE C Control PCA VLT 5000 Flux Conformal coated IPCA1 _____ 17625580 SPARE PCA CONTROL 8000A Control PCA VLT 8000 Aqua IPCA1 176 5581 SPARE CONTROL CARD VLT8000A COATED Control PCA VLT 8000 Aqua Conformal coated LCP1 17920401 SPARE LOCAL CONTROL PANEL PROC LCP Process 17527804 SPARE LOCAL CONTROL PANEL HVAC LCP HVAC Aqua 4000 IPCA1MK100 613X6358 SPARE CC CONNECTOR 12 POS Controll card 12 position terminal block connector IPCA1MK105 _ 613 6360 SPARE CC CONNECTOR 3 POS Controll card 3 position terminal block connector 101 613X6359 SPARE CC CONNECTOR 9 POS Controll card 9 position terminal block connector PCA1 17521158 SPARE CRADLE LCP LCP cradle PCA1 17571064 SPARE CONTROL CARD CASSETTE Control
27. o Hn Onal Dus T aset D T Oe Qus T lh lh aie eae er we m T Bs WOR WO Wr p 00 200 m eg 55 ug 0 cog 00 mug __ ___0000000 _ m 000000 __ 0000000 __ LL 0000000 00 000 00 0 00 0000 000 00 oom 000 00 000 000 00 poo 000 1 a a co CD oo co oo CT oo co o nn SN 7E MK850 MK250 MK350 MK650 MK750 brake MK450 MK550 MK105 MK102 U MK103 V MK104 W brake option Figure 5 13 Gate Drive CardTest Connectors VLT is a registered Danfoss trademark 5 21 11 If using measure pins 1 and 2 of each connector Waveform to IGBTs is a square wave that goes positive to 14 VDC and negative to 9 VDC Average voltage read by DVM should be 2 2 to 2 5 VDC When using an oscilloscope the readings should appear as in Figure 5 14 Input 20 0 15 0 10 0 5 0 00 5 0 10 0 15 0 20 0 2 100 us 50 us Div IGBT Gate Signal measured on the Gate Drive Card 5 volts per division vertical scale 50 microseconds per division time scale Unit running at 30 Hz Figure 5 14 Gate Signal Waveform from Gate Drive Card An incorrect reading of a gate signal indicates the gate drive card is defective or the signal has been lost prior to it arriving at the gate card The gate signals can then be checked with the signal test board to verify t
28. ala A E A A E E NIN o elu 2 o m ooo ojo ojo A Normal overload current ratings 110 96 Nominal A 525 550 V e 4 60 sec 525 550V Nominal A 551 690 V 60 sec 551 690 V Nominal kVA 550 V Nominal kVA 575 V Nominal kVA 690 V kW 650 V HP 575 V kW 690 V Output current N o pical shaft output High overload torque 160 Output current gt o Nominal A 525 550 V 60 sec A 525 550 Nominal A 551 690 V MAX 60 sec A 551 690 V 2 2 2 l s 8 3 5535 ERE gt gt gt lt lt lt NAR ic Output e pe kW 550 V HP 575 V kW 690 V pical shaft output s f Power loss Normal overload W Power loss High overload W 4 go AJo Ooo a a olor 5 4 3 17 14 fa TST INISINI alaja o 1 1 j a Qo a imits and Ranges Warning Voltage Low Alarm Voltage Low lt lt lt lt alo afo e o o Am ojo 0 ojo
29. A 2 Figure 6 8 D1 Soft Charge Resistor 2 of 3 6 8 VLT is a registered Danfoss trademark 6 Remove soft charge resistor by removing two Reassembly POU Soret 1 Clean heatsink surface with mild solvent or alcohol solution 2 Reassemble remaining parts in reverse order of their removal Tighten T25 and 8mm mounting screws to 20 2 25 Nm and T30 10 mm to 35 in Ibs 4 Nm Soft Charge Resistor Mounting screws Step 6 Figure 6 8 D1 Soft Charge Resistor 3 of 3 VLT is a registered Danfoss trademark 6 9 6 10 Input Terminal Mounting Plate Assy 1 Disconnect input power wiring from L1 L2 L3 and ground connection 2 Remove upper most bus bar retaining nuts 13mm from AC power input bus bars L1 L2 and L3 3 Disconnect fan autotransformer cable at in line connector 4 Remove 4 or 5 10mm retaining nuts varies with size from mounting plate ACAUTION Input terminal mounting plate weighs approx 15 60 165 7 27 kg depending on mounted options 5 Remove entire assembly from mounting studs Reinstall in reverse order of this procedure Tighten mounting nuts to 35 in llbs 4Nm Bus bar retaining nuts shown removed Step 2 Input power connector Step 1 Transformer connector Step 3 Retaining nuts Step 4 Figure 6 9 InputTerminal Mounting Plate Assy 6 10 VLT is a registered Danfoss trademark
30. ile V77 Figure 7 8 SCR and Diode Modules 1 of 3 VLT is a registered Danfoss trademark 7 7 8 Ifunit is not equipped with load sharing option 9 Remove both positive and negative SCR proceed to step 9 If unit is equipped with load output bus bars by removing 6 connection screws sharing load share minus bus bar must be T50 There are 3 screws per bus bar removed as follows 10 Remove three SCR and Diode input bus bars by a Remove 2 retaining nuts 13 mm removing 6 connection screws T50 There are 2 connecting load share bus bar to the SCR Screws per bus bar output bus bar CONTINUED NEXT PAGE b Remove retaining nut 17 mm connecting load share bus bar to load share terminal on opposite end of bus bar not shown c Remove load share bus bar Tid e go aS amp L 6 c oo F EO e a xt Positive output bus bar i Step 9 C 9 e 90 Load sharing option retaining stud Step 8 d Positive output bus o je bar connecting screw i FT 5 9 gt ae a 5 9 p Q D 2 cl Negative output bus bar DD ua BB42 Step 9 SCR and Diode Negative output bus input bus bar BB41 bar connec
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32. 6 6 6 9 Soft Charge SC Resistors D1 6 7 6 10 Input Terminal Mounting Plate Assy eene tentent nnn 6 10 6 11 SCR Diode Module D2 Units sese 6 11 6 12 SCR Diode Module 01 Units essere tentent tentent 6 15 6 13 C rrent SENSO 6 14 Fan Asserribly merid tief dd di dti Pa c 6 15 AC Input Terminals 6 16 IGBT Modules D2 Units osion ennan 6 22 6 17 IGBT Modules D1 Units nennen tentent nter treten ettet tenis 6 25 SECTION 7 E FRAME SIZES DISASSEMBLY AND ASSEMBLY INSTRUCTIONS 7 1 ELECTROSTATIC DISCHARGE ESD isses tentent tette tnnt tente 7 1 ZO INSTRUGTIONS rt d tete tete cand e e e tl ur ne 7 1 7 1 Control Card Cassette a te tnnt tentata tnn 7 1 1 2 Interface Cari s ree tente ete eaten t rte deni s 7 2 7 3 Powel Gard etie Ru din dela ial aemper aru dA 7 2 7 4 Control Card Power Card Mounting Plate seen tenentes 7 2 7 5 Gale Drive sca EL din aia aie a 7 3 7 6 Soft Gharge Card cst eee e tela Ls abs 7 3 7 7 2n dee Cetero devas td pee cag 7 4 7 7 1 Upper Capacitor Bank i 7 4 7 7 2
33. D FRAME SIZES DISASSEMBLY AND ASSEMBLY INSTRUCTIONS ADANGER Drives contain dangerous voltages when connected to line voltage No disassembly should be attempted with power applied Remove power to drive and wait at least 20 minutes to let 6 0 INSTRUCTIONS 6 1 Control Card Cassette 1 Remove control wiring by unplugging control terminals See Figure 6 1 drive capacitors fully discharge Only a 2 Remove grounding clamps by removing two competent technician should carry out service screws holding each in place Save screws for reassembly ELECTROSTATIC DISCHARGE ESD Many electronic components within the adjustable frequency 3 ForNEMA 12 configurations disconnect cable drive are sensitive to static electricity Voltages so low that between LCP and control card they cannot be felt seen or heard can reduce the life affect performance or completely destroy sensitive electronic 4 Unplugthe two ribbon cables from side of control components card AC AU TIO N 5 Loosen two captive screws to free cassette T20 Torx Use proper electrostatic discharge ESD procedures when servicing drive to prevent 6 Slide cassette down and free from mounting tabs damage to sensitive components 7 Remove and replace control card in accordance NOTE Frame size is used throughout this manual where ever procedures or components differ between drives based upon the unit s physical size Refer to tables in the Introduction Section to determin
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35. s Fue 2 FKS 12 BE FU3 r 7l ew SRL swi L9 A A 777 r TBI 15 n el 0 RFI SWITC e L S mu P CBL9 gt os Ire No RFI relay on 525 690V C8L24 J units E1 units have 2 RFI sim s S cates cards sz gt scr C L 4 T CBL26 SOFTCHARGE BOARD ___ PCAII Elle RI Figure 2 4 Rectifier Circuit VLT is a registered Danfoss trademark 2 5 Intermediate Section Following the rectifier section voltage passes to the intermediate section see Figure 2 5 This rectified voltage is smoothed by an LC filter circuit consisting of the DC bus inductor and the DC bus capacitor bank The DC bus inductor provides series impedance to changing current This aids the filtering process while reducing harmonic distortion to the input AC current waveform normally inherent in rectifier circuits The DC capacitor bank assembly consists of up to eight capacitors arranged in series parallel configuration Higher power units have two capacitor banks assemblies Also contained within the assembly is the bleeder balance circuitry This circuitry maintains equal voltage drops across each capacitor and provides a current path for discharging the capacitors once power has been removed from the drive Also located in the intermediate section is the high frequency HF
36. 1 plus 1 minus 2 2 2 2 2 _ 2 2 176F8597 Spare BB DC Bus Plus Before Coil E1 DC Plus to DC Coils 1 per drive 1 __ 3 1 We ec ed 176F8598 Spare BB DC Bus Minus Before Coil E1 DC Minus to DC Coils 1 per drive T _ u o co ee 176F8599 Spare BB DC Bus After Coil E1 Frame From DC Coil output to IGBT sandwitch 1 plus 1 minus 2 2 2 _ 2 2 2 176F8600 Spare BB Assy IGBT Ind E1 Frame DC Bus Sandwich Connects to the IGBT inputs 1 per drive 1 1 1 1 1 131 1 176F8601 Spare BB Assy IGBT Cap E1 Frame Connects the Capacitor Bank to the IGBT inputs 1 per phase 3 3 3 S3 3 3 353 176F8602 Spare BB IGBT Output E1 Frame From IGBT output between SCR and Diode 1 per phase 3 3 3 3 353 _ 176F8603 Spare BB Over Fan Box E1 Frame Output over the fan box 1 per phase 9 8 8 3 3s 3 176F8604 Spare BB Current Sensor 5352 E1 Goes through the current sensors 1 per phase 3 3 3 176F8605 Spare BB Current Sensor 5452 5502 E1 Goes through the current sensors 1 per phase _ 3 3 3 po com ede o om 176F8606 Spare BB Brake Assy E1 Frame Collection of brake bus bars Does not include terminal bus bars d4 d 44 d w ww o 1 3 l 176F8607 Spare BB Load Share Plus E1 Frame Load Sharing Plus bus bar 1 per drive spi wd Ime
37. 6 11 SCR Diode Module D2 Units 5 Remove screw T30 from terminal 1 of each SCR Diode module by accessing screw through 1 Remove lower DC capacitor bank per instruction access hole in SCR Diode input bus bar Remove SCR input bus bars 2 Remove input terminal plate per instructions 6 Remove each IGBT output bus bar by removing 3 Remove retaining nuts 8mm from SCR input bus nut 18mm from stud Also remove retaining bars screw T40 at other end of IGBT output bus bars not shown 4 Note the color coding for each of three wires attached to retaining studs Ensure that correct CONTINUED NEXT PAGE wire is attached to applicable stud upon reassembling Remove wiring from studs SCR Diode input bus bar retaining nut and stud Steps 3 amp 4 SCR Diode terminal screw Step 5 SCR Diode input bus bar BB21 or BB22 per drive power rating IGBT output bus bar retaining nut Step 6 SCR Diode terminal screw Step 5 IGBT output bus bar BB32 Step 6 Figure 6 10 D2 SCR Diode Module 1 of 4 VLT is a registered Danfoss trademark 6 11 7 Remove twelve T30 screws from output lower side of IGBT modules 8 Remove retaining nut 8mm from each intermediate IGBT output bus bar Remove intermediate IGBT bus bars 9 Remove 4 nuts 10mm two on either side connecting rectifier DC bus bars to main DC bus bars These are located to either side of SCR Diode modules CONTINUED NEXT PAGE
38. IGBT module Retaining nut Step 8 Retaining screws Step 9 Bus bar BB30 Bus bar BB31 TERNS 4 g gt Main DC bus bar 25 Step 9 Bus bar BB27 Bus bar BB26 IGBT output retaining screws Step 7 Retaining screws Step 9 Intermediate IGBT output bus bar BB30 Step 8 Figure 6 10 D2 SCR Diode Module 2 of 4 6 12 VLT is a registered Danfoss trademark 10 Remove rectifier DC bus bars by removing 3 Screws T25 connecting each rectifier DC bus bar to standoffs on SCR Diode modules CONTINUED NEXT PAGE Bus bar BB27 Bus bar BB28 Rectifier DC bus bars BB23 or BB24 per drive power rating Step 10 Di Le 47 Retaining screws Step 10 Figure 6 10 D2 SCR Diode Module 3 of 4 VLT is a registered Danfoss trademark 6 13 Note Note which gate leads are attached to each module to ensure that leads are reconnected to correct modules upon reassembly 11 Remove SCR gate lead connectors from modules 12 Remove two SCR Diode module retaining screws on each module T30 and remove SCR Diode modules SCR Diode module Step 12 REASSEMBLY 1 Toreplace SCR Diode modules follow instructions included with replacement module 2 Reassemble in reverse order Tighten remaining T25 and 8mm screws to 20 in lbs 2 25 Nm and T30 to 35 in Ibs 4 Nm 3 Besureto cross tighten replacement unit per instructions with spare
39. Nominal A 441 500 V MAX 60 sec A 441 500 V Nominal kVA 400 V Nominal KVA 460 V Nominal KVA 500 V Typical shaft output kW 400 V HP 460 V kW 500 V Power loss Normal overload W Power loss High overload W Limits and Ranges Warning Voltage Low DC Bus V Alarm Voltage Low DC Bus V Warning Voltage High DC Bus V Alarm Voltage High DC Bus V Brake On Voltage DC Bus V Brake On Voltage Full Duty Cycle DC Bus V SMPS Start Voltage DC Bus V SMPS Stop Voltage DC Bus V Overcurrent Warning VLT Out Overcurrent Alarm 1 5 sec delay VLT Out Earth Fault Alarm VLT Out Heatsink Over Temperature Degrees C Mains Phase Warning 5 sec delay DC Bus Ripple VAC Mains Phase Alarm 25 sec delay DC Bus Ripple VAC Fan On Low Speed Temperature Degrees C Fan On High Sped Temperature Degrees C Fan Off Temperature Degrees C Fan Voltage Low Speed Fan VAC Fan Voltage High Speed VLT is a registered Danfoss trademark Fan VAC Mains supply 3 x 525 690 V 5000 amp 8000 Series Ratings Table 525 600V 525 690V Mains supply 3 x 525 600 V 4000 amp 6000 Series Model number 4152 4202 4252 4302 VLT 4352
40. SCR and Diode Modules 3 of 3 VLT is a registered Danfoss trademark 79 7 11 Current Sensor 1 Remove input terminal plate in accordance with procedure 2 Remove retaining nut 17 mm connecting current sensor bus bar to motor terminal bus bar 3 Remove retaining nut 17 mm or T50 screw depending on unit type connecting current sensor bus bar to IGBT over fan bus bar 4 Note which cable is attached to current sensor Ensure that correct cable is attached upon reassembly Unplug cable from current sensor being removed 5 Remove the 2 retaining nuts size varies with model from stud on baseplate and remove Sensor Reinstall in reverse order of this procedure Tighten 17 mm retaining nuts or T50 screw to 170 in Ibs 19 2 Nm IGBT terminal bus bar mounting screw Current sensor Step 3 SS Current sensor mounting screws 2 Step 5 Output motor terminal bus bar retaining nut Step 2 Figure 7 9 Current Sensors 7 10 VLT is a registered Danfoss trademark 7 12 Fan Assembly 5 Remove fan assembly by removing 6 retaining nuts 10 mm Note that fan assembly weights 1 Remove input terminal plate in accordance with approximately 25 pounds 11 kg procedure Reinstall in reverse order of this procedure Tighten 10 mm 2 Remove retaining nut 17 mm or T50 Torx screw retaining nuts to 35 in lbs 4 0 Nm and 17 mm connecting depending on unit type conn
41. Spare IGBT Kit 450A 1200V E1 Frame IGBT gate PCA fasteners and thermal pad 1 per phase IGBT1 2 3 PCA 6 7 8 176F8432 Spare Kit 300A 1700V E1 Frame IGBT gate PCA fasteners and thermal pad 1 per phase IGBT1 2 3 PCA 6 7 8 176F8433 Spare IGBT Kit 450A 1700V E1 Frame IGBT gate PCA fasteners and thermal pad 1 per phase IGBT4 5 PCA13 14 176F8316 Spare Kit BRK VLT5122 VLT5302 IGBT gate PCA fasteners and thermal pad 2 per drive SCR1 2 3 176F8558 Spare SCR Kit 500A 1600V E1 Frame SCRs fasteners and thermal pad Note does not include Diode 1 per phase D1 2 3 176F8559 Spare Diode Kit 600A 1600V E1 Frame Diode fasteners and thermal pad Note does not include SCR 1 per phase 176F8434 Spare SCR Kit 430A 2200V E1 Frame SCRs fasteners and thermal pad Note does not include Diode 1 per phase 176F8435 Spare Diode Kit 540A 2200V E1 Frame Diode fasteners and thermal pad Note does not include SCR 1 per phase Resistors 176F8321 SpareThermistor ASSY D Frame Heat sink thermistor includes cable assembly 176F8560 Spare Softcharg Res ASSY 27 Ohm 155W Soft charge resistor includes cable assembly 176F8467 Spare Softcharg Res ASSY 68 Ohm 155W Soft charge resistor includes cable assembly Capacitors C2 3 4 5 6 7 8 9 10 176F8323 Spare CAP IGBT Snubber 1000V 1 5uF IGBT snub
42. The use of the load sharing terminals can take on two different configurations In one method the terminals are used to tie the DC bus circuits of multiple drives together This allows for the possibility of one drive that is in a regenerative mode to share its excess bus voltage with another drive that is in the motoring mode When applied correctly this can reduce the need for external dynamic brake resistors while also saving energy In theory the number of drives that can be connected in this way is infinite however the drives must be of the same voltage rating In addition depending on the size and number of drives it may be necessary to install DC reactors and DC fuses in the DC link connections and AC reactors on the mains Attempting such a configuration requires specific considerations and should not be attempted without first consulting Danfoss Application Engineering In the second method the drive is powered exclusively from a DC source This is a bit more complicated First a DC source is required Second a means to soft charge the DC bus at power up is required Last a line voltage source is required to power the fans within the drive Again such a configuration should not be attempted with out first consulting Danfoss Application Engineering Specific Card Connections Connector FK102 terminals 104 105 and 106 located on the power card provide for the connection of an external temperature switch The input could be
43. VLT is a registered Danfoss trademark 7 1 7 2 Interface Card 6 Remove current scaling card from power card by 1 Disconnect cables from connectors on interface pushing in retaining clips on standoffs KEEP THIS card MK100 MK102 and MK105 If replacing SCALING CARD TO REINSTALL ON ANY interface card disconnect cables from connectors REPLACEMENT POWER CARD Scaling card MK101 and MK103 controls signals operating with this specific VLT drive Scaling card is not part of replacement power card 2 Remove interface card by remove 4 mounting screws 25 from standoffs Reinstall in reverse order of this procedure Tighten mounting screws and interface card standoffs to 20 in Ibs 2 25 Nm 7 4 Control Card Power Card Mounting Plate 1 Remove control card cassette and interface card in accordance with procedures Reinstall in reverse order of this procedure Tighten T25 Screws and interface card standoffs to 20 in Ibs 2 25 Nm Card will initialize in service mode Follow instructions enclosed with the spare interface card to enter data required 7 3 Power Card 2 Disconnect all cabling from power card 1 Remove interface card in accordance with procedure 3 Remove 4 mounting nuts 10mm 2 Disconnect cables from connectors on power 4 Remove wiring from 2 fuse blocks on mounting card MK100 MK102 MK104 MK105 MK106 plate MK107 MK109 MK110 and FK100 5 Remove optional wiring connections as 3 Remove 2 interfac
44. allow the drive to trip This is purposely done so the units operation is not misinterpreted A third method in controlling regenerated energy is with a dynamic brake With this system the optional brake electronics are built into the VLT 5000 drive with an external resistor bank mounted outside of the drive The drive monitors the level of the DC bus Should the level become too high the drive switches the resistor across the DC bus and dissipates the unwanted energy into the resistor bank This will actually increase the rate of deceleration Less often is the case that the overvoltage condition is caused bythe load while it is running at speed In this case the dynamic brake option can be used or the overvoltage control circuit It works with the load in this way As stated earlier regeneration occurs when the speed of the load is greater than the commanded speed Should the load become regenerative while the drive is running at a steady state speed the overvoltage circuit will increase the frequency to match the speed of the load The same restriction on the amount of influence applies The drive will add about 1096 to the base speed before a trip occurs Otherwise the speed could continue to rise to potentially unsafe levels In applications with very high inertia such as a centrifuge it is recommended to use a VLT 5000 Flux drive 4 2 VLT is a registered Danfoss trademark Mains Phase Loss Trips The drive actually monitors phase
45. card to the gates of the IGBTs The series connection of each set of IGBTs is delivered to the output first passing through the current sensors Once a run command and speed reference are present the IGBTs begin switching to create the output waveform as shown in Figure 2 6 Looking at the phase to phase voltage waveform with an oscilloscope it can be seen that the Pulse Width Modulation PWM principal creates a series of pulses which vary in width Basically the pulses are narrower as zero crossing is neared and wider the farther from zero crossing The width is controlled by the pulse duration of applied DC voltage Though the voltage waveform is a consistant amplitude the inductance within the motor windings will serve to average the voltage delivered and so as the pulse width of the waveform varies the average voltage seen by the motor varies as well This then equates to the resultant current waveform which takes on the sine wave shape that we expect to see in an AC system The frequency of the waveform is then determined by the rate at which the pulses occur By employing a sophisticated control scheme the drive is capable of delivering a current waveform that nearly replicates a true AC sine wave This waveform as generated by the Danfoss VVC s PWM principle at the control card provides optimal performance and minimal losses in the motor Hall effect current sensors monitor the output current and deliver proportional signal
46. high frequency EMI VLT is a registered Danfoss trademark 45 EMI Propagation Drive generated EMI is both conducted to the AC line and radiated to nearby conductors See Figures 4 2 and 4 3 for illustrations VFD AC Line Motor Motor cable E _ Stray capacitance _ Stray capacitance D E lt Ground Potential 1 Potential 2 Potential 3 Figure 4 2 Ground Currents Stray capacitance between the motor conductors equipment ground and other nearby conductors results in induced high frequency currents High ground circuit impedance at high frequencies results in an instantaneous voltage at points reputed to be at ground potential This voltage can appear throughout a System as a common mode signal that can interfere with control signals Theoretically these currents will return to the drive s DC bus via the ground circuit and a High Frequency HF bypass network within the drive itself However imperfections in the drive grounding or the equipment ground system can cause some of the currents to travel out to the power network VFD AC Line Motor ae MATT Motor cable T Stray capacitance M 7 Figure 4 3 Signal Unprotected or poorly routed signal conductors located close to or in parallel to motor and AC line conductors are susceptible to EMI 4 6 VLT is a registered Danfoss trademark Signal wiring to BMS Conductor Curre
47. lt lt lt 176 8608 Spare BB Load Share Minus E1 Frame Load Sharing Minus bus bar 1 per drive 1 131 13 14 od 4 176F8410 SPARE BB STAND OFF PKG10 VLT5202 5302 Bus bar mounting standoff Package of 10 7 17628610 SPARE IGBT Output Standoff PKG9 E Frame IGBT output bus bar mounting standoff Package of 9 9 per drive O ooe S afe nz M 0 y Enclosure Fabrications __________ ______________ _______ 176F8430 Spare Cable Clamp 60mm o a l ___ O 1 aje Service Tools _________ ______________ Se 176F8437 SPARE TOOL PWR SIG BOARD VLT5 122 5302 Power PCA signal test board 11 T Y T 176F8439 SPARE TOOL PWR PWR CABLES VLT5122 5302 Power PCA test cables 1 y Td cc 1 je d MI VLT is a registered Danfoss trademark 9 7 D1 380 500 VAC TH1 HEATSINKNTC DISPLAY CONTROL CARD PCA1 CONTROL PANEL DIGITAL INPUTS TEST CONNECTOR DISABLE MAINS RECTIFIER EXTERNAL BRAKE TEMP SWITCH CBL7 2m AUX FAN CBL7 1 2 3 2 1 6 4 31 2 j 5 8 PULSE NTC LEGACY CBL3
48. pack style modules In these units each switch half phase is made up of two or three IGBTs in parallel A Hall effect type current sensor is located on each phase of the output to measure motor current This type of device is used instead of more common current transformer CT devices in order to reduce the amount of frequency and phase distortion that CTs introduce into the signal With Hall sensors the average peak and ground leakage currents can be monitored INVERTER 1 SECTION IGBTs Figure 2 3 Typical Power Section VLT is a registered Danfoss trademark 2 3 SEQUENCE OF OPERATION Rectifier Section When input power is first applied to the drive it enters through the input terminals L1 L2 L3 and on to the disconnect or and RFI option depending on the unit s configuration see Figure 2 4 If equipped with optional fuses these fuses FU1 202 FU3 limit damage caused by a short circuit in the power section The SCRs in the combined SCR Diode modules are not gated so current can travel to the rectifier on the soft charge card In E1 drive models the SCR and diode modules are separate Additional fuses located on the soft charge card provide protection in the event of a short in the soft charge or fan circuits Three phase power is also branched off and sent to the power card It provides the power card with a reference of the main supply voltage and provi
49. test tools provide a safe and sure point for making necessary measurements Test equipment described in this section is available from Danfoss AWARNING Use of test cable allows powering the drive without charging DC bus capacitors Main input power is required and all line powered devices and power supplies are energized at rated voltage Use extreme caution when conducting tests on a powered drive Contact with powered components could result in electrical shock and personal injury Test Cable and SCR Shorting Plug p n 176F8439 SCR shorting plug Cable with connectors Figure 8 1 Test Cable and SCR Shorting Plug This tool provides the ability to power up the Switch Mode Power Supplies SMPS and activate all the control functions ofthe drive without having the DC bus charged It provides protection for troubleshooting gate drive signals and other important control signals within the drive than having the DC bus disabled The cable is connected between the soft charge card and the power card The SCR shorting plug shorts the gates of the SCRs to ensure they do not fire and add a charge to the DC bus Test cables provided after September 2005 are usable on all drives described in this manual Test cables prior to that date are shorter and apply only for D frame size units To install the cable first ensure the drive is powered down and the DC bus is fully discharged 1 For D frame size units follow pro
50. 14 Fan Assembly 1 Remove input terminal mounting plate assembly per instructions Remove 3 IGBT output bus bars by removing 6 retaining nuts 8mm one from each end of IGBT output bus bars Remove bus bars NOTE Omit steps 3 and 4 for D2 units OF Terminal Step 3 L xS 4 52 35 3 Use 4 in 100mm minimum extension and remove terminal 1 of SCR Diode module 4 Note the color coding for each of three wires attached to retaining studs Ensure that correct wire is attached to applicable stud upon reassembling Remove AC power lead to intermediate SCR input bus bar by removing nut 8mm and remove bus bar CONTINUED ON NEXT PAGE Intermediate SCR input bus bar Step 3 Retaining nut Step 4 Retaining nut Step 2 IGBT output bus bar Step 2 Retaining nut Step 2 Figure 6 13 Fan Assembly 1 of 2 VLT is a registered Danfoss trademark 6 19 5 Disconnect in line molex connector 6 Remove fan assy by removing 6 8mm retaining nuts from stud Note that fan assy weighs approx 18 lbs 8 kg Reinstall in reverse order of this procedure Tighten mounting nuts to 20 in lbs 2 25 Nm Inline molex connector Step 6 20 72 27 Qo LS Ea SF 44 OL Retaining nut Step 7 Figure 6 13 Fan Assembly 2 of 2 6 20 VLT is a registered Danfoss trademark 6 15 AC Input Ter
51. 2 1 Ohm Test of Transformer 380 500V For the following tests read the plug end of connector CN2 that is connected to the transformer 1 Measure between CN terminals 1 and 3 Approximately 15 ohms should be read Fan transformer CN2 Fan fuse 2 Measure between CN2 terminals 1 and 2 Approximately 12 ohms should be read 3 Measure between CN terminals 2 and 3 Approximately 4 ohms should be read Incorrect Reading An incorrect reading would indicate a defective fan transformer Replace the fan transformer When finished be sure to reconnect CN2 5 1 9 2 2 Ohm Test of Transformer 525 690V For the following tests read the plug end of connector CN2 Figure 3 6 Fan Transtormerand Fuse Location that is connected to the transformer 1 Measure between CN2 terminals 1 and 3 Approximately 20 ohms should be read 2 Measure between CN2 terminals 1 and 2 Approximately 8 ohms should be read 3 Measure between CN terminals 2 and 3 Approximately 12 ohms should be read VLT is a registered Danfoss trademark 5 11 5 1 10 Fan Continuity Tests E frame Sizes Make all continuity checks using an ohmmeter set to Rx1 Scale A digital or analog ohmmeter can be used Some instability may result when measuring resistance of a transformer with a multimeter This can be reduced by turning off the auto ranging function and setting the measurement manually To aid in making the measurements un
52. 2 INTERNAL DRIVE 2 1 2 1 DESCRIPTION OF OPERBATION 2 er i ior te e ri dee et da 2 1 Logic Sectio ticus LU 2 1 Logic To Power s a o coc reel ea keh eta ta ed tette 2 2 uerum 2 3 SEQUENCE OF OPERATION 1 cr tci d Rte EE ec a i E pn 2 4 Rector Section de ooi e 2 4 Intermediate Section cre ic re dc lem ic ide c ien ta das 2 6 Inverter SOCUON m hate 2 8 Brake Option Cooling Fans Load Sharing Specific Card CONNECHONS 5 2 ta Pete e Rl t nae 2 11 SECTION 3 TROUBLESHOOTING 3 1 TROUBLESHOOTING TIPS di iate d ds 3 1 Exterior Fault Troubleshooting s iuter nte trt tre cerca cea cca ac te dc c 3 1 Fault Symptom Troubleshooting 3 1 Visual 3 2 3 0 FAULT SYMPTOMS cc ied e rame i ite hi a re 3 3 DISPLAY 3 3 3 131 INOIDISPlay ii E ere aiibi inta dd Eh did 3 3 3 1 2 Intermittent DIS Play sez MM 3 3 3 1 3 Display Line 2 Fla
53. 3 x 380 500 V Ratings Table 380 500V Model num ber VLT 4152 VLT 4202 VLT 4252 VLT 4302 VLT 4352 VLT 5122 VLT 5152 VLT 5202 VLT 5252 VLT 5302 VLT 6152 VLT 6172 VLT 6222 VLT 6272 VLT 6352 VLT 8152 VLT 8202 VLT 8252 VLT 8302 VLT 8352 Normal overload current ratings 1 10 96 Nominal 380 440 V MAX 60 sec A 380 440 V Nominal A 441 500 V MAX 60 sec A 441 500 V Nominal kVA 400 V Nominal kVA 460 V Nominal kVA 500 V Typical shaft output kW 400 V HP 460 V kW 500 V High overload torque 160 26 Output current Nominal A 380 440 V MAX 60 sec 380 440 V Nominal A 441 500 V MAX 60 sec A 441 500 V Output Nominal kVA 400 V Nominal kVA 460 V Nominal kVA 500 V Typical shaft output kW 400 V HP 460 V kW 500 V Power loss Normal overload W Power loss High overload W Limits and Ranges Warning Voltage Low DC Bus V Alarm Voltage Low DC Bus V Warning Voltage High DC Bus V Alarm Voltage High DC Bus V Brake On Voltage DC Bus V Brake On Voltage Ful Duty Cycle DC Bus V SMPS Start Voltage DC Bus V SMPS Stop Voltage DC Bus
54. 5352T6 7 1 1 L1 176F8341 SPARE BUS INDUCTOR VLT5302 DC 5302T5 1 L1 176F8536 Spare Bus Inductor 350uH DC 5042 5122T6 7 1 1 1 1 1 1 L1 176F8537 Spare Bus Inductor 250uH DC 5152T6 7 1 L1 176F8538 Spare Bus Inductor 195uH DC 5202 5252T6 7 1 1 L2 3 4 176F8342 SPARE I SENSOR 300 Amp Motor current sensor 300 amp 5122 5252T5 and 5042 5252T6 7 3 3 3 3 3 3 3 3 3 3 3 3 3 3 L2 3 4 176F8343 SPARE I SENSOR 500 Amp Motor current sensor 500 amp 5302T5 and 5352T6 7 3 3 TR1 176F8344 SPARE FAN TRANSFORMER ASSY 500V Fan transfomer T4 5 drives Includes cables and plug 1 1 1 1 1 TR1 176F8535 SPARE Fan Transformer ASSY 690V 400VA Fan transfomer 76 7 drives Includes cables and plug 1 1 1 1 1 1 1 1 1 1 1 Disconnects SW1 176F8345 SPARE DISCONNECT SW 200A 600V D1 Frane Disconnect switch 5122 5152T5 and 5042 5152T6 7 1 1 1 1 1 1 1 1 1 176F8346 SPARE DISCONNECT HANDLE ROD D1 Frame Disconnect switch handle for 200 Amp disconnect 1 1 1 1 1 1 1 1 1 swi 176F8347 SPARE DISCONNECT SW 400A 600V D2 Frame Disconnect switch 1 1 1 1 1 1 1 176F8348 SPARE DISCONNECT HANDLE ROD D2 Frame Disconnect switch handle connection rod for 400 Amp disconnect 1 1 1 1 1 1 1 Cables CBL 1 2 176F8362 SPARE CABLE CONTROL PCA 30PIN VLT5122 5303 Cables between control card and interface card 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 CBL3 176F8360 SPARE CABLE INTF PCA 30PIN VLT5122 5302 Cable between interface card and power card 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CBL4 176F8361 SPARE CABLE INTF PCA 44PIN V
55. 82 1 BRAKE RESISTOR FAULT During the brake test the VLT 5000 has found a short circuit at the brake terminals or the resistance between terminals 81 82 is too low Verify no shorts exist at the terminals and the brake resistor is the proper value for the VLT 5000 2 BRAKE IGBT FAULT The brake transistor is shorted As a result of the shorted transistor substantial power may be transmitted to the brake resistor Disconnect input power to the unit Perform Brake IGBT Test 5 2 11 in Section 5 It may be possible to run the drive with the brake resistor disconnected however the braking function will be inoperative VLT is a registered Danfoss trademark WARNING ALARM 44 ENCODER FAULT Not applicable for the VLT 4000 6000 8000 This message active for VLT 5000 units programmed for Speed Closed Loop operation only The measured feedback differs from the reference by more than 3 x slip RPM The encoder signal is interrupted from terminal 32 or 33 Check the connections of encoder device ALARM 60 EXTERNAL FAULT Parameter 304 has been programmed for Safety Interlock and alogic O is present at terminal 27 Terminal 27 must have a logic 1 for the unit to operate This fault can be manually reset The following Warning Alarms are only applicable to the VLT 4000 6000 8000 series drives WARNING 62 FOUT gt FHIGH Output frequency high The output frequency is higher than the value program
56. DC bus bars from inductor Remove IGBT Ind bus bar Remove 8 retaining screws T25 mounting each Replace IGBT modules in accordance with instructions included with replacement modules Reassemble in reverse order Attaching Hardware Tightening Torque 8 T25 20 in Ibs 2 25 Nm 10 T30 35 in Ibs 4 0Nm 85 in Ibs 9 6 Nm 17 mm T50 170 in Ibs 19 2 Nm n 98 21 22 REASSEMBLY ds 2 13 mm D HD e e e e o nr Figure 7 12 IGBT Modules 4 of 4 VLT is a registered Danfoss trademark Retaining nut Step 17 Retaining nut Step 21 eq High frequency board Retaining screw Step 18 Retaining nut Step 16 Retaining screw Step 15 IGBT Cap bus bar BB47 IGBT board IGBT retaining screw Step 22 SECTION 8 SPECIAL TEST EQUIPMENT TEST EQUIPMENT Test tools have been developed to aid in troubleshooting these products It is highly recommended for repair and servicing this equipment that these tools be available to the technician Without them some troubleshooting procedures described in this manual cannot be carried out Although some test points can be found inside the drive to probe for similar signals the
57. INCLUDED PCA15 DIFF MODE FILTER RFI FAN SOFTCHARGE BOARD PCA12 LOAD SHARE WIRES CURRENT SCALING CARD PCA4 DC INDUCTOR DISABLE MAINS RECTIFIER EXTERNAL BRAKE TEMP SWITCH CBL6 e s aad AUXFAN POWER CARD PCA3 GATE DRIVE CARD PCAS PRE TEST MK450 MK650 MK750 GATE RESISTOR CARD CBANK1 LOWER CBANK2 UPPER DC BANK DC CAP BANK REGEN WIRES HF SWITCH GATE RESISTOR CARD PCA7 HS FAN ASSEMBLY HEATSINK FAN C1 NOTE DIFFERENT CONFIGURATION FU4 TR1 FOR VLT 5352 CBL5 HF SWITCH BRAKE GATE RES CARD BRAKE GATE RES CARD PCA14 GATE RESISTOR CARD PCAB cum oui rur cum mer oue cum aws awo oo noo FII Ef ORF N T HEATSINK FAN CAPACITOR HEATSINK DOOR FAN TRANSFORMER F3 ee ec NOTE F3 NOT INSTALLED ON CHASSIS UNITS BRAKE OPTION BRAKE IGBT EXT BRAKE e RESISTOR VLT is a registered Danfoss trademark 10 5 ssojueq e 1A 9 0L QuvO8 JDYVHILIOS NOLLdO 3933 YO GVOT Quvo ano n 4 4 1891 34 V
58. Lower Capacitor Bank isiin ninini an tentent tenente trennt tette 7 4 7 8 Input Terminal Mounting Plate Assy Option seen 7 5 7 9 Soft Charge nl bett fbr ten 7 6 7 10 SCR and Diode Modules ese eese tenente tate treten tette netten ton 7 7 741 Currerit Sensor c ite et ici d Rd ci 7 10 TA2 Fan ASSembly iei e hp po BO Pod o t net 7 11 7 13 AC Input Motor Load Sharing or Regen Terminals sess 7 12 114 GBTMOGdUles cr nter dern reden Dre 7 13 SECTION 8 SPECIAL TEST EQUIPMENT erret nnne nnn tentem tnnta ttn anainua tantas 8 1 TEST EQUIPMENT e ete o De ER e e b dei de m tide 8 1 Test Cable and SCR Shorting Plug p n 176F8439 sees 8 1 Signal Test Board p n 17628437 sesenta tenente tnnt entente 8 2 Signal Test Board Pin Outs Description and Voltage Levels sse 8 2 vi List of Figures Figure Title Page Exploded View 01 Frame Size sesenta nter tn tnnt tenis Intro 4 Exploded View D2 Frame Size c ssssscsssessessesseseetesteseesteaeeseestetesneeseeteateateatenseasetesnsaneetenses Intro 5 Exploded View E Frame Size sese ee tenter ta tentent Intro 6 Contr
59. Remove 3 snubber capacitors 10 Remove IGBT bus bar assy 11 At bottom end of IGBT module remove 6 retaining screws 2 each for U V and W intermediate IGBT output bus bars 12 Remove retaining nut 8mm from 3 intermediate IGBT output bus bars Remove intermediate IGBT output bus bars 13 Remove IGBT module 14 Clean heatsink surface with mild solvent or alcohol solution Snubber capacitor Step 9 IGBT module SN X E E 0 Retaining nut Step 11 REASSEMBLY 1 Replace IGBT module in accordance with instrucions enclosed with replacement module 2 Tighten remaining T25 and 8mm screws to 20 in lbs 2 25 Nm and T30 and 10 mm to 35 in Ibs 4 Nm 3 Reassemble drive in reverse order of disassembly and tighten attaching hardware in accordance with torque tables IGBT bus bar assembly Step 8 Retaining nut Step 8 W gt Bp Retaining screw Step 9 Intermediate IGBT output bus bar Step 11 Figure 6 16 D1 IGBT Module 2 of 2 6 26 VLT is a registered Danfoss trademark SECTION 7 E FRAME SIZES DISASSEMBLY AND ASSEMBLY INSTRUCTIONS ADANGER Drives contain dangerous voltages when connected to line voltage No disassembly should be attempted with power applied Remove power to drive and wait at least 40 minutes to let drive capacitors fully discharge Only a 7 0 INSTRUCTIONS 7 1 Control Card Cassette 1 Remove control wiring by unp
60. Tests ete bete ete e D edis 5 24 5 2 12 Current Sensors ct de eoe i eee ie ep Peto cde 5 25 5 2 19 Fari iE aatia Dad es 5 26 Table of Contents continued 5 2 14 Input Terminal Signal Tests sse ntn tette treten tette 5 27 5 22 15 Control Test eta enti tete e i d EE ARE e e S uc 5 28 5 3 INITIAL START UP OR AFTER REPAIR DRIVE TESTS sss 5 29 SECTION 6 D FRAME SIZES DISASSEMBLY AND ASSEMBLY INSTRUCTIONS 6 1 ELECTROSTATIC DISCHARGE ESD seien tette tette netten 6 1 6 0 INSTRUCTIONS reb td br de ddnde ce putes eot p e a o t iaa 6 1 6 1 Control Card Cassette ttn tetto tentent entes ttn 6 1 6 2 Interface Card accro ee So dede equ quee onc d 6 2 6 3 Powel 6 2 6 4 Control Card Power Card Mounting Plate essent 6 2 6 5 Gale Drive Card 6 3 6 6 Soft Charge is tania oet e edn tee ete 6 3 6 7 Capacitor Bank s 2 3 eee qe etate iv ee bad 6 4 6 7 1 Upper Capacitor Bank D2 Units essent tentent tentent nn 6 4 6 7 2 Lower Capacitor Bank D2 Units essere tentent tentent tentent 6 4 6 7 3 Single Capacitor Bank D1 Units sese ttn nter 6 5 6 8 Soft Charge SC Resistors D2
61. W phase TP25 TP30 negative Signal per i TEN originates on Control Card 2v div 100us div Run 10Hz 8 6 VLT is a registered Danfoss trademark Spare Parts List General Notes IGBT spare part kits for D1 and D2 380 500 VAC units include the IGBT modules required to replace all modules in the drive along with the gate cables For all other units the IGBT spare part kits have just one IGBT module and gate cables must be ordered separately The IGBT mounting procedure has changed from thermal grease application to use of thermal mounting pads Replacement parts now come with thermal pads Thermal grease is permitted for existing spare parts in inventory For 600 690 VAC units use only the wire harness dated after 18 April 2005 For 380 500 VAC drives either the new or older wire harness may be used The date of the spare is shown on the spare part kit When ordering spare parts for conformal coated drives choose the appropriate conformal coated version of the control card and power card All other spare parts are suitable for conformal coated drives and can be usediin either coated or non conformal coated drives Bus bars used in some units are aluminum Spare part bus bars are always plated copper Plated copper bus bars are useable for all units Common Spares for All Models Block diagram Spare part Spare part name o T Comments __ _ 6 _ 6___ Designator Number 40 characters
62. a switch mode power supply SMPS which provides the unit with 24 VDC 18 VDC 18 VDC and 5 VDC operating voltage The logic and interface circuitry is powered by the SMPS The SMPS is supplied by the DC bus voltage VLT 5000 Series drives can be purchased with an optional secondary SMPS which is powered from a customer supplied 24 VDC source This secondary SMPS provides power to the logic circuitry with main input disconnected It can keep units with communication options live on a network when the drive is not powered from the mains Circuitry for controlling the speed of the cooling fans is also provided on the power card Also located on the power card is a relay for monitoring the status of the drive The relay is Form C meaning it has one normally open contact and one normally closed contact ona single throw The contacts of the relay are rated for a maximum load of 240 VAC at 2 Amps The gate drive signals from the control card to the output transistors IGBTs are isolated and buffered on the gate driver card In units that have the dynamic brake option the driver circuits for the brake transistors are also located on this card Power Section The high voltage power section consists of AC input terminals AC and DC bus bars fusing harnessing AC output and optional components The power section see Figure 2 3 also contains circuitry for the soft charge and SCR Diode modules in the rectifier the DC bus filter circuitry con
63. and other devices See Grounding Shielded Cables in this section for correct methods for terminating shielded control cable Output Signals The drive also produces output signals that are carried through either the RS 485 serial bus or terminals 42 and 45 Output terminals 42 and 45 operate in the same manner as the inputs These terminals can be programmed for either a variable analog signal in mA or a digital signal 0 or 1 in 24 VDC In addition the terminals can provide a pulse reference of O to 32 000 pulses Output analog signals generally indicate the drive frequency current torque and so on to an external controller or system Digital outputs can be control signals used to open or close a damper for example or send a start or stop command to auxiliary equipment Additional terminals are 01 02 and 03 which are a Form C relay output Terminals 04 and 05 are a Form A low voltage relay output Terminals 12 and 13 provide 24 VDC low voltage power often used to supply power to the digital input terminals 16 33 Those terminals must be supplied with power from either terminal 12 or 13 or from a customer supplied external 24 VDC power source Improperly connected control wiring is a common service issue for a motor not operating or the drive not responding to a remote input Control Terminals Control terminals must be programmed Each terminal has specific functions it is capable of performing and a numbered parameter associ
64. are not connected from the gate drive card to the gate resistor board or the gate resistors are defective Connect gate signal wires or if the resistors are defective the entire IGBT module assembly requires replacement Replace the IGBT module in accordance with the disassembly procedures in Section 6 or 7 VLT is a registered Danfoss trademark 5 9 5 1 6 Brake IGBT Test This test can only be carried out on units equipped with a dynamic brake option If a brake resistor is connected to terminals 81 and 82 disconnect it before proceding Use an ohm meter set on diode check or Rx100 scale 5 1 6 1 Brake IGBTTest Part 1 Connect positive meter lead to brake resistor terminal R 82 2 Connect negative meter lead to brake resistor terminal R 81 The reading should indicate infinity The meter may start out at a value and climb toward infinity as capacitance is charged within the drive 5 1 6 2 Brake IGBT Test Part Il 1 Connect positive meter lead to brake resistor terminal R 81 2 Connect negative meter lead to brake resistor terminal R 82 The reading should indicate a diode drop 5 1 6 3 Brake IGBT Test Part III 1 Connect positive meter lead to brake resistor terminal R 81 2 Connect negative meter lead to negative DC bus connector MK105 B on the power card The reading should indicate infinity The meter may start out at a value and climb toward infinity
65. bar by removing nut 10mm from stud Also remove retaining screw T30 at other end of IGBT output bus bars not shown CONTINUED ON NEXT PAGE IGBT output bus bar retaining nut Step 6 7 M NU SCR Diode terminal screw Step 5 SCR Diode input bus bar BB21 or BB22 per drive power rating IGBT output bus bar BB32 Step 6 Figure 6 15 D2 IGBT Modules 1 of 3 6 22 VLT is a registered Danfoss trademark 7 Remove 4 10mm retaining nuts at top of IGBT 11 At bottom end of IGBT module remove 12 bus bar assy retaining screws 4 each for U V and W intermediate IGBT output bus bars 8 Remove 12 retaining screws 6 on each module on upper portion of IGBT modules These screws 12 Remove retaining nut 8mm from 3 intermediate also attach the snubber capacitors to the IGBT IGBT output bus bars Remove intermediate IGBT modules see Figure 6 15 1 of 3 for snubber output bus bars capacitor location Remove the snubber capacitors CONTINUED ON NEXT PAGE 9 Remove 10mm retaining nut from IGBT bus bar assy 10 Remove IGBT bus bar assy IGBT module Retaining screws Step 11 Retaining nut Step 12 Step 12 KES Intermediate IGBT output bus bar BB30 cf 7 IGBT bus bar assembly BB29 Steps 7 amp 10 Retaining nut Step 9 Retaining screws shown removed Step 8 Retaining nut Step 7 IGBT module
66. be reduced or drive and resistor must be resized VLT is a registered Danfoss trademark WARNING 27 BRAKE IGBT FAULT Not applicable for the VLT 4000 6000 8000 The brake transistor is shorted As a result of the shorted transistor substantial power may be transmitted to the brake resistor Disconnect main input power to the VLT Perform Brake IGBT Test 5 2 11 in Section 5 ALARM 29 HEAT SINK OVER TEMP The heatsink temperature has exceeded its limit See ratings tables in introduction section of this manual This fault results in a Trip Locked condition The drive will also trip when any of the following conditions occur Ambient temperature is above 140 F 60 C or below 4 F 2090 The drive is not on 24V backup and the power supply voltage is out of range Backup power is not monitored by the drive The enable disable connector FK102 is not installed This connector has a shorting wire and is used for the external brake resistor switch It also disables the SCR front end Possible causes are defective cooling fan blocked heat sink or air flow path defective thermal sensor missing bottom gland plate Check fan operation Check for airflow blockage Check for proper clearance above and below drive see Instruction Manual Check fan filters NEMA 12 units Perform Heatsink Temperature Sensor Test 5 1 6 in Section 5 Install bottom gland plate ALARM 30 MISSING MOT PHASE U The unit
67. cases it may be desirable to have a torque limit set at a lesser value This offers protection for the application in that the drive will limit the torque It may however require higher torque at initial start up Under these circumstances nuisance tripping may occur Parameter 409 Trip Delay Torque works in conjunction with torque limit in the VLT 5000 series This parameter selects the length of time the drive operates in torque limit prior to a trip The factory default value is off This means that the drive will not trip on torque limit but it does not mean it will never trip from an overload condition Built into the drive is an internal inverter thermal protection circuit This circuit monitors the output load on the inverter If the load exceeds 10096 of the continuous rating of the drive a timer is activated If the load remains excessive long enough the drive will trip on inverter time Adjustments cannot be made to alter this circuit Improper parameter settings effecting load current can result in premature trips of this type The timer can be displayed VLT is a registered Danfoss trademark 4 1 Overvoltage Trips This trip occurs when the DC bus voltage reaches its DC bus alarm voltage high see ratings tables in introductory section Prior to the trip the drive will display a high voltage warning Most times an over voltage condition is due to fast deceleration ramps with respect to the inertia of the load Dur
68. change to TRIP RESET and allow for manual digital or serial bus reset Line 2 displays alarm and the associated number while line 3 identifies the alarm in plain language 1 6 VLT is a registered Danfoss trademark Warnings During a warning the drive will remain operational although the warning will flash for as long as the condition exists The drive may however take action to reduce the warning condition For example if the warning displayed were Torque Limit Warning 12 the drive would be reducing speed to compensate for the over current condition In some cases if the condition is not corrected or grows worse an alarm condition would be activated and the drive output to the motor terminated Line 1 identifies the warning in plain language and line 2 identifies the warning number MAINS PHASE LOSS SERVICE FUNCTIONS Service information for the drive can be shown on display lines 3 and 4 Twenty six different items can be accessed Included in the data are counters that tabulate operating hours power ups and trips fault logs that store drive status values present atthe 20 most recent events that stopped the drive and drive nameplate data The service information is accessed by displaying items in the drive s 600s parameter group FREQUENCY VN SETUP at i a 1 604 5 Baas Line 3 Line 4 MENU J Use the and keys on the LCP keypad to scroll through parameters Para
69. defective and must be replaced If the signal is not present the problem is external to the drive The circuitry providing the signal along with its associated wiring must then be checked Programming Problems Difficulty with drive operation can be a result of improper programming of the drive parameters Three areas where programming errors may affect drive and motor operation are motor settings references and limits and I O configuration See Drive Inputs and Outputs in Section 1 The drive must be setup correctly for the motor s connected to it Parameters 102 106 must have data from the motor nameplate entered into the drive This enables the drive processor to match the drive to power characteristics of the motor The most common result of inaccurate motor data is the motor drawing higher than normal amounts of current to perform the task expected of it In such cases setting the correct values to these parameters and performing the automatic motor adaptation AMA function will usually solve the problem Any references or limits set incorrectly will result in less than acceptable drive performance For instance if maximum reference is set too low the motor will be unable to reach full speed These parameters must be set according to the requirements of the particular installation References are set in the 200s parameter group Incorrectly set configuration usually results in the drive not responding to the f
70. is ON 5 Measure with oscilloscope or DVM at terminal 14 Terminal 14 is a logic level 5V signal representing voltage across brake IGBT This should measure 5 1 VDC when brake is OFF and drop to zero when brake is ON Incorrect Reading If the signal on terminal 13 is not correct first check that the drive is correctly programmed for dynamic braking parameters 400 404 If the programming is correct replace the control card in accordance with procedures in Section 6 or 7 If the signal on terminal 13 is correct but the signal on terminal 14 is not the brake IGBT gate signal must be checked to determine whether the fault lies in the IGBT or the gate driver card See Gate Drive Signal Tests 5 2 9 5 2 12 Current Sensors Test The current sensors are Hall effect devices that send a signal proportional to the actual output current waveform to the power card The current scaling card attached to the power card Scales the signals from the current sensors to the proper level for monitoring and processing motor control data A defective current sensor can cause erroneous ground faults and over current trips In such instances the fault will usually only occur at higher loads If the incorrect current scaling card is installed the current signals will be improperly scaled This could cause erroneous over current trips If the current scaling card is not installed the drive will trip A couple of simple checks can be made to determi
71. is not attached to the input terminal plate remove retaining nut 13 mm attaching terminal block insulation Reinstall in reverse order of this procedure Tighten 17 mm connecting nuts to 170 in lbs 19 2 Nm and 13 mm or T40 Torx screw to 85 in lbs 9 6 Nm Retaining nut Step 2 Terminal block insullation Step 4 or 5 e 9 TEM e vm 97 FATE WTA co 9 3 3 329 33 Retaining nuts Step 3 Figure 7 11 Terminal Blocks 7 12 VLT is a registered Danfoss trademark 7 14 IGBT Modules 5 Remove wire retaining nut 8 mm from SCR 1 Remove both DC capacitor banks in accordance output bus bars One from DC bus bar and with procedure one from DC bus bar 2 Remove Input Terminal Plate in accordance with 6 Note color coding for each wire attached to procedure retaining studs Ensure that correct wire is attached to applicable stud upon reassembly 3 Remove wire retaining nut 10 mm from each of Remove wiring from studs 3 SCR input bus bars 7 Remove 4 retaining nuts 13 mm on side of bus 4 Note color coding for each of 3 wires attached to bars 2 on each bus bar retaining studs Ensure that correct wire is attached to applicable stud upon reassembly CONTINUED NEXT PAGE Remove wiring from studs Retaining nuts Step 7 SUY f SA Wire reta
72. locations during reassembly Units with 6B For units with brake option remove bus bars brake option will have brake cabling from MK105 between IGBT bus bar assembly see step 10 in in addition Remove capacitor bank per Figure 6 15 2 of 3 and brake IGBT by removing instructions two T25 retaining screws on brake IGBT not shown and two 8mm retaining nuts on IGBT bus 4 Disconnect gate drive cables at connectors on bar assembly not shown IGBT modules 7 Remove IGBT output bus bars by removing nut 5 Disconnect cable connected to connector MK100 10mm from stud Also remove retaining screw on high frequency card T30 at other end of IGBT output bus bars not shown High frequency card CONTINUED ON NEXT PAGE Retaining screw Step 6 Connector MK100 Step 5 DC input bus bar assembly BB3 Step 6A e S 69 D S X 7 EE 2 n Retaining nut Ay Step 6 SN SR lt P Do not remove 6 2 Step 6 TY 7 e ez X lt Gate drive cable connectors me _ amp Steps 3 amp 4 IGBT module IGBT output bus bar BB9 Step 7 IGBT output bus bar retaining nut Step 7 Figure 6 16 D1 IGBT Module 1 of 2 VLT is a registered Danfoss trademark 6 25 8 Remove 4 10mm retaining nuts top of IGBT bus bar assy 9 Remove 6 retaining screws on upper portion of IGBT modules These screws also attach the snubber capacitors to the IGBT modules
73. make several attempts under these conditions and eventually get the unit to pass 6 INTERRUPTED BY USER The AMA function cannot be completed due to the application of a stop command by the user Repeat AMA procedure 7 INTERNAL FAULT A fault has occurred internal to the VLT Failed Control Card or noise interference Repeat AMA procedure if fault reoccurs replace Control Card 8 LIMIT VALUE FAULT The parameter values programmed for the motor are outside the typical characteristics of the drive s internal motor table This is due to the use of a non standard motor Set p 107 to Enable and restart AMA If this fault reoccurs AMA cannot be performed on this particular motor 9 MOTOR ROTATES The motor shaft rotated during the tuning process due to an overhauling load Ensure the load is not capable of rotating the shaft and restart AMA WARNING ALARM 23 BRAKE TEST FAILED Not applicable for the VLT 4000 6000 8000 When a unit with braking is powered up and a stop command is present a brake test is performed automatically by the unit If the result of this test indicates a fault condition in the brake circuit and parameter 404 is set to warning a warning will be displayed If Trip has been set in 404 an alarm will occur The unit will be able to operate in this condition however the brake function will be inoperative Manual reset is possible Possible causes for this are No bra
74. of 5 VDC and proper line power applied to the drive it would be likely that the control card is defective The inrush signalis also deactivated by the control card anytime an over temperature condition exists but that should be indicated by an Alarm 29 and a different group of troubleshooting procedures would be in order If the control card is suspect replace it in accordance with the disassembly procedures in Section 6 or 7 Should the above tests check correctly proceed to testing the SCR gate signals To view the gate signals an oscilloscope and a current probe are required 8 Run drive while under some degree of load At least a 3096 load may be required to consistently See gate signals produced since SCRs are only gated when DC bus falls below peak of line 9 Connect current probe in turn to each positive SCR gate wire white leads marked R S and T at power card connector MK100 The waveform should appear as in Figure 5 12 Figure 5 12 SCR Gate Signal The current pulse should have a waveform as shown Ai gt 1 1A 2 gt 0 40 1 gt 300 us Given all the other tests above were successful a missing gate signal indicates the power card is defective Replace the power card in accordance with the disassembly procedures in Section 6 or 7 A distorted signal may be due to a defective gate on that particular SCR that is loading down the supply Replace the SCR module which correspond
75. sensor test procedure Current Sensor Faults When a current sensor fails it is indicated sometimes by an overcurrent alarm that cannot be reset even with the motor leads disconnected Most often however the drive will experience frequent false earth fault trips This is due to the DC offset failure mode of the sensors To explain this it is necessary to investigate the internal makeup of a Hall effect type current sensor Included inside the device is an op amp to amplify the signal to usable levels in the receiving circuitry Like any op amp the output at zero input level zero current flow being measured should be zero volts exactly half way between the plus and minus power supply voltages A tolerance of 15mv is acceptable In a three phase system that is operating correctly the sum of the three output currents should always be zero VLT is a registered Danfoss trademark When the sensor becomes defective the output voltage level varies by more than the 15mv allowed The defective current sensor in that phase indicates current flow when there is none This results in the sum of the three output currents being a value other than zero an indication of leakage current flowing If the deviation from zero current amplitude approaches a specific level the drive assumes an earth fault and issues an alarm The simplest method of determining whether a current sensor is defective is to disconnect the motor from the drive then
76. terminals 53 and 54 a DC voltage between O and 10 VDC should be read to match the analog signal being sent to the drive For analog input terminal 60 a reading of 0 9 to 4 8 VDC corresponds to a 4 to 20ma signal Note that a minus sign preceding any reading above indicates areversed polarity In this case reverse the wiring to the analog terminals VLT is a registered Danfoss trademark 5 27 5 2 15 Control Card Test The control card tests checks the operation of the analog and digital inputs the analog digital relay outputs and the 10 V control voltage 5 28 1 2 Cycle power to drive Access parameter 620 Operating Mode and select control card test Remove power to drive Wire control terminals as shown in Figure 5 13 Reapply power to drive Press OK key on drive keypad Control card test will be carried out automatically Display will indicate a pass or fail mode If a failure is indicated replace control card in accordance with procedures in Section 6 If tests pass successfully press OK key and parameter 620 automatically returns to normal operation VLT is a registered Danfoss trademark 16 17 18 19 20 27 29 32 33 2 8 222222208E 04 05 12 13 39 42 45 50 53 54 55 60 LJ L1 LJ LJ LJ LJ LJ LJ2 LJ CJ CJ LJ Figure 5 16 Control Card Test Connections 5 3 INITIAL START UP OR AFTER REPAIR DRIVE TESTS Following any repair to a drive o
77. to the drive Dynamic testing traces signal circuitry to isolate faulty components Both D frame and E frame size drives See Introduction Section are covered here Differences in the procedures are noted as required However the Soft Charge and Rectifier Circuit Test Soft Charge Rectifier Test and Fan Continuity Test sections are independent for D frame and E frame drives Replace any defective component and retest the drive with the new component before applying power to the drive as described in 5 3 nitial Start Up or After Repair Drive Tests TOOLS REQUIRED FOR TESTING Digital volt ohm meter capable of reading real RMS Analog volt meter Oscilloscope Clamp on style ammeter Signal test board p n 176F8437 Test cable p n 176F8439 Signal Test Board The signal test board can be used to test circuitry within the drive and provides easy access to test points The test board plugs into connector MK104 on the interface card Its use is described in the procedures where called out See Section 8 Signal Test Board for detailed pin descriptions SignalTest Board Test Cable The test cable bypasses the main DC bus and supplies DC voltage to the power card from the soft charge card This provides voltage for testing the power card without the drive circuitry being powered The SCR shorting plug ensures that the SCRs do not fire The cable connects between the soft charge connector and the power card connector MK105 Te
78. used to monitor the temperature of an external brake resistor Two input configurations are possible A normally closed switch may be connected between terminals 104 and 106 or a normally open Switch between terminals 104 and 105 Should the input change states the drive would trip on an Alarm 29 Overtemperature The input SCRs would also be disabled to prevent further energy from being supplied to the DC bus If no such input is used or the normally open configuration is selected a jumper must be installed between terminals 104 and 106 Connector FK1093 terminals 100 101 102 and 103 located on the power card provide for the connection of line voltage to allow powering the AC cooling fans from an external source This is required when the drive is used in a load sharing application where no AC power is provided to the main input terminals To make use of this provision the jumpers would is a registered Danfoss trademark 2 11 be removed from terminals 100 and 102 101 and 103 The auxiliary line voltage power supply would be connected to terminals 100 and 101 There are two FK100 terminals one on the interface card and one on the power card The power card FK100 terminals 1 2 and 3 provide access to auxiliary relay 1 This is a form C set of contacts meaning one normally open and one normally closed contact on a single throw The contacts are rated for a maximum of 240 VAC 2 Amps and a minimum of 24VDC 10m
79. when the motor was connected then the load is suspect There could be a faulty connection between the drive and motor or a defect in the motor itself Look for bad connections at any junctions of the output wires including connections made to contactors and over loads Also check for burned or open contacts in such devices 5 2 9 IGBT Gate Drive Signals Test This procedure tests the gate drive signals at the output of the gate driver card just prior to them being delivered to the IGBT s A simple test to check for the presence of the gate signals can be performed with a DVM however to actually check the waveforms an oscilloscope is required ACAUTION Disable DC bus when performing this test with Test Cable p n 176F8437 Failure to do so could result in damage to drive if probe is inadvertently connected to wrong pins Additionally AC mains bus bars are in close proximity to these test points Exercise caution when working close to high voltage components Prior to beginning the tests ensure that power is removed from the unit and that the DC Bus capacitors have been discharged Check for the presence of DC bus voltage by measuring power card connector MK105 A with respect to MK105 B The voltage should be zero 0 before proceeding 1 For D frame size units follow procedure in Section 6 for soft charge card removal and disengage soft charge card far enough to disconnect cable plugged into MK3 For D fram
80. 00 and 101 set the mode in which the drive will operate Parameters 102 through 107 match the drive to the motor and adapt to the motor characteristics Parameters 221 and 409 set the torque control features ofthe drive for the application Parameter 100 Configuration sets the drive for open or closed loop operation or torque mode operation In a closed loop configuration a feedback signal controls the drive speed The settings for the PID controller play a key role for stable operation in closed loop as described in the operator s manual In open loop the drive calculates the torque requirement based on current measurements of the motor Parameter 101 Torque Characteristics for the VLT 5000 series Sets the drive for constant or variable torque operation It is imperative that the correct torque characteristic is selected based on the application If for example the load type is constant torque such as a conveyor and variable torque is Selected the drive may have great difficulty starting the load if started at all Consult the factory if uncertain about the torque characteristics of an application Parameters 102 through 106 configure the drive for the connected motor These are motor power voltage frequency current and rated motor speed Accurate setting of these parameters is very important Enter the motor data required as listed on the motor nameplate For effective and efficient load control the drive relies on thi
81. 02 103 or 105 has been set incorrectly Correct the setting and restart AMA 1 LOW P 105 AMA function was unable to be carried out due to incorrect settings or incorrect results of AMA tests The value entered in parameter 105 is too small for the drive Enter correct the value Note the motor nameplate current and the value entered in parameter 105 must be greater than 3596 of the nominal rating of the drive in order to carry out AMA ALARM 22 continued AUTO MOT ADAPT FAIL 2 ASYMMETRICAL IMPEDANCE AMA has detected asymmetrical impedance in the windings of the motor connected The motor may be defective Check motor and motor connections 3 MOTOR TOO BIG AMA function was unable to be carried out due to incorrect settings or incorrect results of AMA tests The motor is too large for AMA to be carried out or the setting in parameter 102 is incorrect Ensure that the motor is sized correctly Correct the setting and restart AMA 4 MOTOR TOO SMALL AMA function was unable to be carried out due to incorrect settings or incorrect results of AMA tests The motor is too small for AMA to be carried out or the setting in parameter 102 is incorrect Ensure that the motor is sized correctly Correct the setting and restart AMA 5 TIME OUT AMA has failed after attempting to tune for a period in excess of what should be normal It is possible that the signal data being returned is noisy It is possible to
82. 06 2 Measurements should correspond with measurements called out in the Input Voltage Test 5 2 1 1 An incorrect reading at MK106 with a correct input voltage may indicate a problem in the soft charge card or the connecting cable If the above tests reveal no abnormalities it is further possible that the inrush signal has not been enabled by the control card Using the signal test card verify the inrush signal is present and the SCR disable signal is at the correct voltage level as follows 3 Insert signal test board into interface card connector MK104 4 Check SCR disable signal 5 Using a volt meter connect negative meter lead to terminal 4 common of test board 6 Connect positive meter lead to terminal 19 of signal board Areading of 0 VDC indicates the SCRs have been disabled A reading of 0 6 to 0 8 VDC indicates the SCRs are active and should be gated With a reading of O VDC and proper line power applied to the drive it would be likely that the input at power card terminal FK102 has caused the SCRs to be disabled Given the connection at FK102 has been verified the control card would be suspect Check the inrush signal as follows 7 Connect positive meter lead to terminal 7 of signal board A reading of O VDC indicates the inrush signal is active and the SCRs are being gated A reading of 5 VDC indicates the inrush signal is inactive and the SCRs are not gated With a reading
83. 088 2SrS OMd vs L ueJ esnJj eeds 609834921 vna Jo asn4 Uey q eoxd vr ueJ vodd esnj eieds 07783911 vna Jo eDexoeg asnj suey 94 006 95 4 66983911 eens Jo esn suey duiy004 1ues esnJ e eds 1698592 ee ins 59715 157 sued x20Ig opare Parts List E frame Sizes Requirements Per Drive Requirements Per Drive 380 500 VAC 525 690 VAC VLT5352 VLT5452 VLT5502 VLT5552 VLT5402 VLT5502 VLT5602 ViTsss2r_ vosso VLT4452 VLT4502 VLT4602 VLT4652 VLT4502 VLT4602 VLT4652 VLT6402 VLT6502 VLT6552 VLT6602 VLT6502 VLT6602 VLT6652 VLT8452 VLT8502 VLT8602 VLT8652 VLT8502 VLT8602 VLT8652 Terminals Labels Insulators 176F8587 Spare BB Terminal Block E1 Frame Mains terminal stepped bus bar NOT disconnect 1 per phase 176F8587 Spare BB Terminal Block E1 Frame Motor terminal stepped bus bar 1 per phase 176F8399 Spare BB LS VLT5202 5302 Brake terminal left Includes fasteners 176F8404 Spare BB Load Share 2 VLT5202 5302 Brake terminal right Includes fasteners 176F8587 Spare BB Terminal Block E1 Frame Load Sharing terminal stepped bus bar 2 per drive 176F8588 Spare Insul Terminal Block E1 Frame Mains terminal insulation block NOT disconnect 1 per phase
84. 24 V is present proceed with checking the individual inputs as follows 2 Connect negative meter lead to reference terminal 20 3 Connect positive meter lead to terminals 16 17 18 19 27 29 32 and 33 in turn Presence of a signal at the desired terminal should correspond tothe digital input display reading A reading of 24 VDC indicates the presence of a signal A reading of O VDC indicates no signal is present 5 2 14 2 Analog inputs The value of signals on analog input terminals 53 54 and 60 can also be displayed The voltage on terminals 53 and 54 or the current in milliamps for terminal 60 is shown in line 2 of the display If the desired signal is not present in the display the problem may be either in the external control wiring to the drive or a faulty control card To determine the fault location use a volt meter to test for a signal at the control terminals Verify the reference voltage power supply is correct as follows 1 With a voltmeter measure voltage at control card terminal 50 with respect to terminal 55 Meter should read between 9 2 and 11 2 VDC If the 10 V supply voltage is not present conduct the Control Card Voltage Test earlier in this section If the 10 volts is present proceed with checking the individual inputs as follows 2 Connect negative meter lead to reference terminal 55 3 Connect positive meter lead to desired terminal 53 54 or 60 For analog input
85. 38 W 4 3 4 ECONOPACK MODULE 95 GND GBTI Figure 2 7 Inverter Section VLT is a registered Danfoss trademark 2 9 Brake Option For drives equipped with the dynamic brake option a brake IGBT along with terminals 81 R and 82 R is included for connecting an external brake resistor The function of the brake IGBT see Figure 2 8 is to limit the voltage in the intermediate circuit whenever the maximum voltage limit is exceeded It does this by switching the externally mounted resistor across the DC bus to remove excess DC voltage present on the bus capacitors Excess DC bus voltage is generally a result of an overhauling load causing regenerative energy to be returned to the DC bus This occurs for example when the load drives the motor causing the voltage to return to the DC bus circuit Placing the brake resistor externally has the advantages of Selecting the resistor based on application need dissipating the energy outside of the control panel and protecting the drive from overheating if the brake resistor is overloaded The Brake IGBT gate signal originates on the control card and is delivered to the brake IGBT via the power card and gate drive card Additionally the power and control cards monitor the brake IGBT and brake resistor connection for short circuits and overloads
86. 380 500 5202 4252 6222 8252 3 1 380 500 5252 4302 6272 8302 2 6 380 500 5302 4352 6352 8352 5 1 380 500 5352 4452 6402 8452 380 500 5452 4502 6502 8502 380 500 5502 4602 6552 8602 380 500 5552 4652 6602 8652 525 600 690 5042 8052 525 600 690 5052 8062 525 600 690 5062 8072 525 600 690 525 600 690 525 600 690 525 600 690 525 600 690 525 600 690 525 600 690 525 600 690 525 600 690 525 600 690 525 600 690 5072 4102 6102 8102 5102 4122 6122 8122 5122 4152 6152 8152 5152 4202 6172 8202 5202 4252 6222 8252 5252 4302 6272 8302 5302 4352 6352 8352 5352 4402 6402 8402 5402 4502 6502 8502 5502 4602 6602 8602 5602 4652 6652 8652 VLT is a registered Danfoss trademark 5 25 5 2 13 Fan Tests The fan control circuit is made up of the fan transformer and the control circuitry located on the power card along with control signals for ON OFF and speed control from the control card Since the fans do not necessarily run at all times see the description of cooling fans operation under sequence of operation in Section 2 5 2 13 1 Supply Voltage Supply voltage for the fans is from the soft charge card to power card connector MK106 First verify the supply voltage is present as follows 1 With a voltmeter measure AC phase to phase voltage at R S and T of power card connector MK106 It should equal main supply voltage applied t
87. 500 VAC VLT5452 VLT5502 VLT5552 virsss2F vitsasor_ vitssoor vLT44s2 ViT4so2 ViTa6o2 VLT46s2 E characters Cd venez 8502 IP21 IP54 IP21 IP54 IP21 IP54 IP21 IP54 Requirements Per Drive 525 690 VAC VLT5402 VLT5502 VLT5602 ee _ VLT4502 VLT4602 VLT4652 VLT6502 VLT6602 VLT6652 VLT8502 VLT8602 VLT8652 1 21 54 IP21 IP54 IP21 IP54 IP21 IP54 IP21 IP54 IP21 IP54 ip2i iP54_ iIP21 P54 IP21 IP54 IP21 IP54 VLT is a registered Danfoss trademark 9 5 vSdV Ledl p e pep por m L __ ___ ___ E vSdVicdl O0d aa I pe sel e xi __ ___ a e O E Lo Lo 1 oo e _______ aes o p ZSOBLTA Z09811A Z0S81 1A ZS99171A Z09911A Z0S911A ZS9VLTA ZO9VLTA ZOSV eee EMEN ZOOSLTA ZOSSLTA ZOVSLIA ________ 2 Hitt Hitt Hitt _ 1 _ 9 9 zsovi tA zostra zsevi A azossr A desvsr A csssL A ZOSSLIA 5 zSESLIA ____________ Jod ssojueq
88. 525 600 VAC VLT5122 VLT5152 VLT5202 VLT5252 VLT5302 VLT5042 VLT5052 VLT5062 VLT5072 VLT5102 VLT5122 VLT5152 VLT5202 VLT5252 VLT5302 VLT5352 VLT5122F VLT5152F VLT5202F VLT5252F VLT5302F VLT4152 VLT4202 VLT4252 VLT4302 VLT4352 VLT4102 VLT4122 VLT4152 VLT4202 VLT4252 VLT4302 VLT4352 VLT4402 Block diagram Spare part Spare part name Comments VLT6152 VLT6172 VLT6222 VLT6272 VLT6352 VLT6102 VLT6122 VLT6152 VLT6172 VLT6222 VLT6272 VLT6352 VLT6402 Designator Number 40 characters VLT8152 VLT8202 VLT8252 VLT8302 VLT8352 VLT8052 VLT8062 VLT8072 VLT8102 VLT8122 VLT8152 VLT8202 VLT8252 VLT8302 VLT8352 VLT8402 Fuses FU1 2 3 176F8334 SPARE FUSE SEMI 350Amp Mains fuse Package of 1 3 3 3 3 3 FU1 2 3 176F8335 SPARE FUSE SEMI 630Amp Mains fuse Package of 1 3 3 3 FU1 2 3 176F8540 SPARE Fuse Semi 550Amp Mains fuse Package of 1 3 3 3 3 FU1 2 3 176F8539 SPARE Fuse Semi 200Amp Mains fuse Package of 1 3 3 3 3 FU4 5 176F 8440 SPARE FUSE PWR PCA AND FAN 4A PKG3 D Frame Power PCA and fan fuse Package of 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 PCA11 176F8336 SPARE FUSE SOFTCHG 20A PKG3 D Frame Softcharge fuse Package of 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Inductors and current sensors L1 176F8337 SPARE BUS INDUCTOR VLT5122 DC li 5122T5 1 L1 176F8338 SPARE BUS INDUCTOR VLT5152 DC 5152T5 1 L1 176F8339 SPARE Bus Inductor 136uH DC 5202T5 and 5302T6 7 1 1 L1 176F8340 SPARE Bus Inductor 109uH DC 5252T5 and
89. 55 355 400 400 450 110 132 132 160 160 200 200 250 250 315 315 355 355 400 400 500 500 530 250 300 300 350 350 400 400 500 500 600 600 650 200 250 250 315 315 400 400 500 500 560 560 630 VLT 8000 525 690 VLT 8000 380 480 VAC 525 690 VAC Model VLT 8000 AQUA HP 2575 kW 2690 VLT 8000 AQUA HP 2460 VAC kW 9400 VAC 150 200 250 300 350 450 500 550 600 600 unit can attain 600 hp Intro 2 VLT is a registered Danfoss trademark TOOLS REQUIRED Instruction manual for the VLT series drive Metric socket set 7 19mm Socket extensions 4 in and 6 in 100mm 150mm Torx driver T10 T50 Torque 6 170 in Ibs 0 675 19 Nm Needle nose pliers Magnetic sockets Ratchet standard and Philips Additional Tools Recommended for Testing Digital volt ohm meter must be rated for 1200 VDC for 690 V units Analog volt meter Oscilloscope Clamp on style ammeter Test cable p n 176F8439 Signal test board p n 176F8437 GENERAL TORQUE TIGHTENING VALUES For fastening hardware described in this manual the torque values in the table below are used These values are not intended for SCR diode or IGBT fasteners See the instructions include
90. 5602 4652 7 4 3 6 3 2 4 yes 6652 8652 5 12 VLT is a registered Danfoss trademark Incorrect Reading An incorrect reading would indicate a defective fan transformer Replace the fan transformer When finished reconnect MK107 5 1 10 3 Ohm Test of Fans 1 Measure between terminals 3 and 5 of power card connector MK107 Should read approx value D in Table 5 1 Incorrect Reading For fans without an inductor replace the fan For drives with a fan and inductor isolate the fault between the fan and the inductor as follows a Disconnect CN3 and measure resistance between pins 1 and 2 on fan side of conector Reading should be approx 4 ohms If incorrect replace fan b Disconnect CN4 and CN5 Measure resistance across inductor Reading should be less than 1 ohm If incorrect replace inductor 2 Measure between terminals 11 and 13 of power card connector MK107 For units with one top mounted fan a reading of 400 ohms is expected For units with two door mounted fans a reading of 200 ohms is expected Incorrect Reading For units with one top mounted fan replace the fan For units with two door mounted fans isolate the faulty fan as follows a Disconnect wiring from fan terminals b Read across fan terminals on each fan A reading of 400 ohms is expected Replace any defective fans Fan fuse DC bus fuse Mounting plate Power card Figure 5 7 Fan and DC Bus Fuse Locations 5 2 DYNAMIC TEST PROCE
91. 6 22 6 16 DTIGBT MOGUles inet tetti tnt a etn nd nd re re ret e 6 25 7 1 Control Card Cassette eicere enun nel eee ee nee od 7 1 T 2 Interface Card Power Card and Mounting Plate sss 7 2 7 3 Gate Drive Cardano eet ete ehe nein 7 3 7 4 Soft Charge Card ASSy te ttp ern 7 3 7 5 Upper and Lower Capacitor Bank Assemblies essent tenete 7 4 7 6 Input Terminal Mounting Plate Assy with RFI Option eene 7 5 7 7 Soft Charge Resistor tdg eb e bh dd ien 7 6 7 8 SCR and Diode Modules aaa dareen 7 7 7 9 GUITENLSONSOMS sits cia aia Gian duane inv d e D RU e Fn e e ed Coen ee 7 10 7 10 FanASSembly ceret eee e tte eii e e dod 7 11 7 11 Terminal BlOCKS eret ad deal d ate mee ated e e ees ee dete cet es 7 12 7 12 IGBT MOGUIGS tete onte t nde dado o e dust 7 18 8 1 Test Cable and SCR Shorting Plug ssssssesseeenete rettet tnnt 8 1 8 2 Signal Test Board eee ec e eb d ee HACER Ad ee 8 2 10 1 Block Diagram 01 380 500 VAC 10 1 10 2 Block Diagram 02 380 500 VAC
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95. A CC VLT51 22 5302 Power Card does not include I Scaling Card conformal coated PCA3 176F8524 Spare Power PCA CC VLT5122 5352T6 7 Power Card does not include I Scaling Card conformal coated PCA 4 176F8554 Spare Scaling PCA 4 21 Ohm Current Scaling Card 5353T5 PCA4 176F8311 Spare l Scaling PCA 2 56 Ohm Current Scaling Card 5452 5502T5 5602T7 PCA4 176F8308 Spare I Scaling PCA 4 54 Ohm Current Scaling Card 5402T7 PCA 4 176F8309 Spare l Scaling PCA 3 79 Ohm Current Scaling Card 5502T7 PCA5 176F8305 Spare Gate Drive PCA CC D Frame Gate Drive Card conformal coated PCA9 176F8307 Spare HF PCA VLT5122 5302T 4 5 High Frequency Card PCA9 176F8523 Spare HF PCA VLT5122 5352T6 7 High Frequency Card PCA12 176F8555 Spare Softcharge PCA CC T5 E1 Frame Softcharge Card conformal coated PCA12 176F8466 Spare Softcharge PCA CC T7 E1 Frame Softcharge Card conformal coated PCA10 11 176F8510 Spare Balance PCA VLT5122 5302T4 5 Capacitor Bank balance card included in capacitor bank spare part PCA10 11 176F8526 Spare Balance PCA VLT5122 5352T6 7 Capacitor Bank balance card included in capacitor bank spare part Semiconductors IGBT1 2 3 PCA 6 7 8 176F8556 Spare IGBT Kit 300A 1200V E1 Frame IGBT gate PCA fasteners and thermal pad 1 per phase IGBT1 2 3 PCA 6 7 8 176F8557
96. A or 24 VAC 100mA The relay can be programmed via parameter 323 to indicate drive status The interface card FK100 terminals 35 and 36 accept 24 VDC from an external source if the drive is so equipped This input provides control power to keep the control logic and any installed options powered up and communicating even with the main supply power removed from the drive This is particularly useful for maintaining a bus communications network while some drives are not being powered by the mains Terminal positions on the power card labeled MK4OO MK103 and FK101 are reserved for future use 2 12 VLT is a registered Danfoss trademark SECTION 3 TROUBLESHOOTING TROUBLESHOOTING TIPS Before attempting to repair a drive here are some tips to follow to make the job easier and possibly prevent unnecessary damage to functional components 1 Note all warnings concerning voltages present in the drive Always verify the presence of AC input voltage and DC bus voltage before working on the unit Some points in the drive are referenced to the negative DC bus and are at bus potential even though it may appear on diagrams to be a neutral reference Remember that voltage may be present for as long as 40 minutes on E frame size drives or 20 minutes on D frame size drives after removing power from the unit 2 Never apply power to a unit that is suspected of being faulty Many faulty components within the drive can cause damag
97. AY DESCRIPTION OFF1 Stop command Ramp Down received via serial communication and Fieldbus selected in parameter 512 OFF2 Stop command Coast received via serial communication and Fieldbus selected in parameter 512 OFF3 Stop command Q Stop received via serial communication and Fieldbus selected in parameter 512 OVER VOLTAGE Parameter 400 Overvoltage Control enabled Drive is attempting to CONTROL avoid a trip from overvoltage by extending decel ramp time QUICK Quick discharge function has been completed successfully DISCHARGE OK REM BUS JOG1 Remote control selected and Fieldbus selected in parameter 512 Jog 1 command has been given via serial communication REM BUS JOG2 Remote control selected and Fieldbus selected in parameter 512 Jog 2 command has been given via serial communication REM DC STOP Remote control selected and drive stopped via a DC stop signal ona digital input or serial communication REM LCP STOP Remote control selected and drive is stopped via control panel Coast signal on terminal 27 high Start command via remote digital input or serial communication is overridden REM QSTOP Remote control selected and drive stopped via a quick stop signal on terminal 27 or serial communication REM RAMPING Remote control selected and motor speed and drive output frequency is changing REM RUN JOG Remote control selected and drive is running at a fixed frequency set in parameter 213 J
98. DURES Refer to terminal locations in Figure 5 8 for performing dynamic ADAN G E R test procedures Never disconnect input cabling to drive with power applied due to danger of severe injury or NOTE death Test procedures in this section are numbered for reference only Tests do not need to be AWARNING performed In this order Perform tests only as Take all necessary safety precautions for system necessary start up prior to applying power to drive Main 3 phase AC power to drive DC bus loadsharing connections 3 phase output to motor Brake resistor connection Figure 5 8 Drive Power Terminals D size Frames VLT is a registered Danfoss trademark 5 13 5 2 1 No Display Test A drive with no display can be the result of several causes Verify first that there is no display whatsoever A single character in the display or a dot in the upper corner of the display indicates a communication error and is typically caused by an option card not properly installed Under this condition the green power on LED is illuminated Ifthe LCD display is completely dark and the green power on LED is not lit proceed with the following tests First test for proper input voltage 5 2 1 1 Input Voltage Test 1 Apply power to drive 2 Use DVM to measure input line voltage between drive input terminals in turn L1 to L2 L1 to L3 L2 to L3 For 380 480 V drives all measur
99. Div CONTINUED ON NEXT PAGE Figure 5 10 AC Input Current Waveform with Diode Bridge VLT is a registered Danfoss trademark 5 17 With a phase loss the current waveform of the remaining phases would take on the appearance shown in Figure 5 11 Input B 0 0 ms 5 ms Div Figure 5 11 Input Current Waveform with Phase Loss Always verify the condition of the input voltage waveform before forming a conclusion The current waveform will follow the voltage waveform If the voltage waveform is incorrect proceed to investigate the reason for the AC supply problem If the voltage waveform on all three phases is correct but the current waveform is not then the input rectifier circuit in the drive is suspect Perform the static soft charge and rectifier tests and also the dynamic SCR Diode module test 5 18 VLT is a registered Danfoss trademark 5 2 7 Input SCR Test The SCR can be disabled by the drive for various reasons Check the following before making more complicated tests The SCRs can be disabled as a result of an input or lack of input at power card connector FK102 the external brake temperature switch Unless used as an input a jumper must be placed between terminals 104 and 106 of FK102 The SCRs are gated in sequence with the main supply Verify that the voltage reference signal is correct as follows 1 Using a volt meter measure phase to phase AC line voltage at Terminals R S and T of power card connector MK1
100. E INPUTS AND OUTPUTS The drive operates by receiving control input signals The drive can also output status data or control auxiliary devices Control input is connected to the drive in three possible ways One way for drive control is through the keypad on the front of the drive when operating in local hand mode These inputs include start stop reset and speed reference Another control source is through serial communication from a serial bus A serial communication protocol supplies commands and references to the drive can program the drive and reads status data from the drive The serial bus connects to the drive through the RS 485 serial port or through a communication option card The third way is through signal wiring connected to the drive control terminals see Figure 1 1 The drive control terminals are located below the drive keypad Improperly connected control wiring can be the cause of a motor not operating or the drive not responding to a remote input 2020202 o Oo Oo 2 16 17 18 19 20 27 29 32 35 EjgnagamuEiuuPmiuumektE DIN DIN COM DIN DIN DIN DIN COM D IN RS485 RS485 RS485 61 68 69 ooooo o oo oo o o 15 39 42 45 50 53 54 55 60 04 05 12 BE BE OUT A OUT 10 COM RELAY 24N A OUT OUT IN OUT Figure 1 1 Control Terminals 1 8 VLT is a registered Danfoss trademark Input Signals The drive can recei
101. HS VOT usg 11891 maon owonoo3 aaow owonooa om w LL P IM NOLO 140 3513 2510 2 4H 2 DINVED 6024 Domani YVO HOLSIS3u 31v9 538 avd dived OSDIW OSW alo sis Sni JAC 3499 3938 HOLIMS 3H 134 i ui 1055 s SLINN SISSVHD NO GITIISNI LON 4 310N TANWd 7081402 3DV3U31NI 4 vV2d uv V2d p v oo vi TOHINOD AV SIG ANIA MNOLDVAVONYA 2 NV NISLY3H HOLINS dV iin i38 sNIVW 378510 2INDNISIViH LHL XI8W3SSV SH IVA 069 009 SCS L3 Danfoss Drives Division of Danfoss Inc Danfoss can accept no responsibility for possible errors in catalogs brochures and other printed materials Danfoss reserves the right to alter its products 4401 North Bell School Road without notice This also applies to products already on order provided that Loves Park Illinios 61111 such alterations can be made without subsequentia
102. LT5122 5302 Cable between interface card and power card 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CBL5 176F8349 SPARE CABLE I SENSE D2 Frame Wire harness from power card to current sensors 1 1 1 1 1 1 1 CBL5 176F8541 SPARE Cable Sense D1 Frame Wire harness from power card to current sensors 1 1 1 1 1 1 1 1 1 CBL8 176F8359 SPARE CABLE HS FAN D2 Frame Wire harness from power card to fan transformer 1 1 1 1 1 1 1 CBL8 176F8542 SPARE Cable HS Fan D1 Frame Wire harness from power card to fan transformer 1 1 1 1 1 1 1 1 1 CBL9 176F8354 SPARE CABLE SOFTCHG RST PRIME D Frame AC voltage from softcharge to power card 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CBL12 176F8358 SPARE CABLE DOOR FAN D Frame Wire harness to door top fan 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CBL13 176F8357 SPARE CABLE SCR D2 Frame Wire harness from power card to SCR 1 1 1 1 1 1 1 CBL13 176F8544 SPARE Cable SCR D1 Frame Wire harness from power card to SCR 1 1 1 1 1 1 1 1 1 CBL14 176F8356 SPARE CABLE UDC LINK D Frame Voltage from DC Bus to power card 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CBL16 176F8350 SPARE CABLE GATE DRIVE D2 Frame Ribbon cable from power card to gate drive card 1 1 1 1 1 1 1 CBL16 176F8363 SPARE CABLE GATE DRIVE D1 Frame Ribbon cable from power card to gate drive card 1 1 1 1 1 1 1 1 1 CBL17 18 19 176F8351 SPARE CABLE IBGT GATE D2 Frame Wire harness from gate drive card to IGBT gate resistor card One per phase 3 3 3 3 3 3 3 CBL17 18 19 176F8364 SPARE CABLE GATE RES D1 Frame Wire harness from gate drive c
103. N TRANSFORMER CBL19 MK104 GVP GWP BRK 2 1 2 5 5 PCA8 HF CARD CBANK1 DC CAP BANK BRAKE GATE RES CARD PCA13 HF SWITCH BRAKE OPTION BRAKE IGBT EXT BRAKE RESISTOR V MK100 GATE RESISTOR CARD PCA6 CUPI GUPI EU 9101 ELOI CUP2 GUP2 EUP2 0102 ELO2 CUPS GUP3 EUPS GLO3 ELOS a 5 N MODULE IGBT1 4 SOFTCHARGE BOARD PCA11 LOAD SHARE OPTION
104. O SISOH ejoN ped pue si1euejsej YIS 082 IG HOS ads 0598911 EZ LHS pembei ejoN ped pue 1 HOS Ao0zz 091 IM IG HOS 91215 62683941 EZ THOS Ayuenb eyoN ped pue 5809 A009 LIM Id H2S 3uVdS 0228492 1 2 21805 ped ewy pue sieuejsej 5809 A009 YSZ 1 LIM Id H9S 3uVdS 81 83971 821455 Ajguenb ejoN ped jeureu pue vog 1851 20 S L1A Z2 ISL TAME YM L89l38vdS 918 911 vi EL vod v 189I ped pue sieuejsej 9126 1901 sepnpoul AOL vOSt 1M 199191205 82984921 1 9 VOd 21189 L p nb ejoN ped pue sieuejsej 9126 1901 sepnpoul A00Z L VO0 1 19919215 22983921 L 9 VOd 21189 ped jeuueu pue sejqeo 5 15 5 51890 sepniou S v LGO S L TA LIM 1891 3HvdS 75783941 4 9 vVOd 21189 ped jeuueu pue sejgeo sjeuejse syOd ereD 19901 S v 12929 20291 1 1891 3HvdS 5578941 1 9 VOd 211991 ped pue sejqeo ereD 5 5 1851 5
105. ON PURPOSE The purpose of this manual is to provide detailed technical information and instructions that will enable a qualified technician to identify faults and perform repairs on VLT series adjustable frequency drives of 125 150 hp to 550 600 hp It provides the reader with a general view of the unit s main assemblies and a description of the internal processing With this information technicians should have a better understanding of the drive s operation to assist in troubleshooting and repair This manual provides instructions for the drive models and voltage ranges described in the tables on the following page VLT PRODUCT OVERVIEW VLT 4000 series drives are designed primarily for the industrial market segment This series of drives is capable of operating only in variable torque mode and are normally found in controlling fans and pumps in industrial process environments VLT 5000 series drives are fully programmable for either constant torque or variable torque industrial applications They are full featured drives capable of operating a myriad of applications and incorporating a wide variety of control and communication options VLT 6000 series drives are designed for the HVAC markets They operate only in variable torque mode and include special features and options well suited for fan and pump applications within the HVAC market The VLT 8000 series drives are designed for water and waste water markets They can operate i
106. T is a registered Danfoss trademark 3 1 Visual Inspection The table below lists a variety of conditions that should be inspected for visually as part of any initial troubleshooting procedure Table 3 1 Visual Inspection Inspect For Description Auxiliary Look for auxiliary equipment switches disconnects or input fuses circuit equipment breakers that may reside on input power side of drive or output side to motor Examine operation and condition of these items as possible causes for operational faults Check function and installation of pressure sensors or encoders etc used for feedback to drive Cable routing Avoid routing motor wiring AC line wiring and signal wiring in parallel If parallel routing is unavoidable try to maintain a separation of 6 8 inches 150 200 mm between the cables or separate them with a grounded conductive partition Avoid routing cables through free air Control wiring Check for broken or damaged wires and connections Check the voltage source of the signals Though not always necessary depending on the installation conditions the use of shielded cable or a twisted pair is recommended Ensure the shield is terminated correctly Refer to the section on grounding shielded cables in Section 1 Drive cooling Check operational status of all cooling fans Check door filters on NEMA 12 IP54 units Check for blockage or constrained air passages Verify bottom gland plate
107. V Overcurrent Warning VLT Out Overcurrent Alarm 1 5 sec delay VLT Out Earth Fault Alarm VLT Out Heatsink Over Temperature Degrees C Mains Phase Warning 5 sec delay DC Bus Ripple VAC Mains Phase Alarm 25 sec delay DC Bus Ripple VAC Fan On Low Speed Temperature Degrees C Fan On High Sped Temperature Degrees C Fan Off Te mperature Degrees C Fan Voltage Low Speed Fan VAC Fan Voltage High Speed Fan VAC VLT is a registered Danfoss trademark Intro 7 Mains supply 3 x 380 500 V Ratings Table 380 500V Model number VLT 4452 VLT 4502 VLT 4602 VLT 4652 VLT 5352 VLT 5452 VLT 5502 VLT 5552 VLT 6402 VLT 6502 VLT 6552 VLT 6602 VLT 8452 VLT 8502 VLT 8602 VLT 8652 Normal overload current ratings 110 96 Intro 8 Output current Nominal A 380 440 V 745 MAX 60 sec A 380 440 V 820 Nominal A 441 500 V 678 MAX 60 sec A 441 500 V 746 Nominal kVA 400 V 516 Nominal KVA 460 V 540 Nominal kVA 500 V 587 Typical shaft output kW 400 V 400 HP 460 V 550 600 kW 500 V 500 High overload torque 160 96 Output current Nominal A 380 440 V MAX 60 sec A 380 440 V
108. VDC 262 VDC 525 690 V 1VDC 373 VDC OV switch must be off 24 VDC regulated supply 23 to 25 VDC 5 0 VDC regulated supply 4 75 to 5 25 VDC Schematic Function Description Reading Using a Digital Acronym Volt Meter 25 GUP T IGBT gate 2 2 2 5 VDC signal buffered Equal on all phases U phase e 4 25 positive Signal originates on Control Card j 2v div 100us div Run 10Hz GUN T IGBT gate 2 2 2 5 VDC signal buffered x Equal on all phases U phase 25 negative Signal gt ones a SEED TRE originates on Control Card 2v div 100us div Run 10Hz 27 GVP_T IGBT gate 2 2 2 5 VDC signal buffered SA Equal on all phases V phase TP25 TP30 positive Signal x originates Av 05 4 ME on Control Card 2v div 100us div Run 10Hz 28 GVN_T IGBT gate 2 2 2 5 VDC signal buffered x Equal all phases V phase neg TP25 TP30 ative Signal urag E originates x on Control Card 2v div 100us div Run 10Hz VLT is a registered Danfoss trademark 8 5 Pin Schematic Function Description Reading Using a Digital No Acronym Volt Meter 29 GWP T IGBT gate 2 2 2 5 VDC signal buffered Equal on all phases W phase 25 positive Signal E originates on Control Card 2v div 100us div Run 10Hz GWN T IGBT gate 2 2 2 5 VDC signal buffered Equal on all phases
109. ainted surface will not create an effective ground connection In addition running a separate ground conductor directly between the drive and the driven motor is recommended Cable routing Avoid routing motor wiring AC line wiring and signal wiring in parallel If parallel routing is unavoidable try to maintain a separation of 6 8 inches between the cables or separate them with a grounded conductive partition Avoid routing cables through free air Signal cable selection Single conductor 600 volt rated wires provide the least protection from EMI Twisted pair and shielded twist pair cables are available which are specifically designed to minimize the effects of EMI While unshielded twisted pair cables are often adequate shielded twisted pair cables provide another degree of protection The signal cable s shield should be terminated in a manner that is appropriate for the connected equipment Avoid terminating the shield through a pigtail connection as this increases the HF impedance and spoils the effectiveness ofthe shield Refer to Section 1 Grounding Shielded Cables A simple alternative is to twist the existing single conductors to provide a balanced capacitive and inductive coupling thus canceling out differential mode interference While not as effective as true twisted pair cable it can be implemented in the field using the materials on hand VLT is a registered Danfoss trademark 4 7 Motor cable selection The
110. al Test in Section 5 Run OK 0 Hz This indicates that a run command has been given to the drive but the reference speed command is zero or missing Check control wiring to ensure that the proper reference signal is present at the drive input terminals and that the unit is properly programmed to accept the signal provided Refer to the Input Terminal Signal Test in Section 5 3 4 VLT is a registered Danfoss trademark Off 1 2 or 3 This indicates that bit 1 or 2 or 3 in the control word is logic O This will only occur when the drive is being controlled via the serial communication bus A correct control word must be transmitted to the drive over the communication bus to correct this STOP VLT 5000 only One of the digital input terminals 16 17 27 29 32 or 33 parameters 300 301 304 305 306 or 307 is programmed for Stop Inverse and the corresponding terminal is low logic 07 Ensure that above parameters programmed correctly and that any digital input programmed for Stop Inverse is high logic 1 Display Indication That the Unit is Functioning but No Output Check that parameter 620 is not set to Run With Inverter Disabled If the unit is equipped with external 24VDC option check that the main power is applied to the drive Note In this case the display will alternately flash Warning 8 3 2 2 Incorrect Motor Operation Occasionally a fault can occur where
111. al overload W Power loss High overload W Limits and Ranges Warning Voltage Low DC Bus V Alarm Voltage Low DC Bus V Warning Voltage High DC Bus V Alarm Voltage High DC Bus V Brake On Voltage DC Bus V Brake On Voltage Full Duty Cycle DC Bus V SMPS Start Voltage DC Bus V SMPS Stop Voltage DC Bus V Overcurrent Warning VLT Out Overcurrent Alarm 1 5 sec delay VLT Out Earth Fault Alarm VLT Out Heatsink Over Temperature Degrees C Mains Phase Warning 5 sec dela DC Bus Ripple VAC Mains Phase Alarm 25 sec delay DC Bus Ripple VAC Fan On Low Speed Temperature Degrees C Fan On High Sped Temperature Degrees C Fan Off Temperature Degrees C Fan Voltage Low Speed Fan VAC Fan Voltage High Speed Fan VAC Intro 10 VLT is a registered Danfoss trademark Ratings Table 525 600V 525 690V Mains supply 3 x 525 600 V 4000 amp 6000 Series 2 em o o a x a Ds a o lt a go o o ayo oD on 5 N N p mi z Rau NA NA _ Vit 5042 VLT 5052 NA pee VLT 8062 5062 VLT 8072 LT 410 LT 507 LT 610 LT 810 LT 412 LT 510 LT 612 LT 812 Model number 805 lt lt ro lt
112. all in reverse order of this procedure Tighten mounting screws to 20 in lbs 2 25 Nm 6 6 Soft Charge Card 1 4 5 Remove control card power card mounting plate in accordance with procedure Remove 2 retaining nuts from soft charge card assembly 10mm Slide assembly part way out to access cable connectors on card Disconnect MK1 MK2 MKS and Remove soft charge card assembly Reinstall by aligning soft charge card with fastening clips on the side of the chassis Reattach connectors Slide into place and tighten mounting screws to 35 in Ibs 4 Nm MK101 RFI filter MK106 int CAE E mmo gm N MK105 MK102 U MK103 V MK104 W brake option Figure 6 3 Gate Drive Card Mounting screw Step 2 MK1 Figure 6 4 Soft Charge Card Assy VLT is a registered Danfoss trademark 63 6 7 Capacitor Bank s NOTE D2 size units have 2 capacitor bank assemblies mounted one above the other Separate disassembly instructions are given for upper and lower capacitor banks For D1 units with one capacitor bank assembly only disassemble in accordance with instructions for single capacitor bank units 6 7 3 6 7 1 Uppe
113. apacitor bank by pulling free from mounting studs connection nuts 10 mm to 35 in Ibs 4 0 Nm Upper capacitor bank assy Upper cap bank assy electrical connection nuts Step 2 Lower cap bank assy electrical connection nuts Step 2 Lower cap bank assy retaining nut Step 3 Lower capacitor bank assy 7 4 Control card cassette mounting bracket nut Step 3 7 7 2 Lower Capacitor Bank 1 Remove soft charge card in accordance with procedures Capacitor bank connection to DC bus bars can be seen recessed in gap between upper and lower capacitor banks Minimum 6 inch 150 mm extension is required Remove 6 electrical connection nuts 8 mm for lower capacitor bank from DC bus bars Remove 4 retaining nuts 10 mm from capacitor bank Note that the weight of the capacitor bank is approximately 20 pounds 9 kg Remove capacitor bank by pulling free from mounting studs Reinstall in reverse order of this procedure Tighten electrical connection nuts 8 mm to 20 in Ibs 2 3 Nm and mechanical connection nuts 10 mm to 35 in Ibs 4 0 Nm Upper cap bank assy retaining nut Step 4 Gate drive card Upper cap bank assy electrical connection nuts Step 2 l
114. ard Power Card Mounting Plate 1 Remove control card cassette and interface card in accordance with procedures 6 3 Power Card 1 Removeinterface card in accordance with 2 Remove 4 mounting nuts 10mm procedure 3 Disconnect all cabling from power card 2 Disconnect cables from connectors on power card MK100 MK102 MK104 MK105 MK106 4 Remove optional wiring connections as MK107 MK109 MK110 and FK100 necessary to free mounting plate 3 Remove 2 interface card standoffs 8mm 5 Lift plate free from chassis 4 Remove power card by removing 5 mounting Reinstall in reverse order of this procedure Torque T25 screws T25 Torx from standoffs mounting screws to 20 in lbs 2 25 Nm MK100 Interface card PCA2 MK101 Interface card mounting screw MK105 MK102 Current scaling card PCA4 MK103 Power card MK102 PCA3 Power card mounting screw Interface card standoff 2 7 A y gt 6 Fy cO 7 OY A 7 Y EN LORD MK105 Mounting plate standoff MK106 _ 103 MK107 MK100 Figure 6 2 Interface Card Power Card and Mounting Plate 6 2 is a registered Danfoss trademark 6 5 Gate Drive Card 1 Disconnect cables from connectors on gate drive card MK102 MK103 MK104 MK106 and if unit has extended brake option MK105 and for 380 500 V units with an RFI filter MK101 Remove gate driver card by removing 6 mounting screws T25 Torx from standoffs Reinst
115. ard to IGBT gate resistor card One per phase 3 3 3 3 3 3 3 3 3 CBL20 176F8352 SPARE CABLE IBGT TEMP VLT5122 5302 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 CBL21 176F8365 SPARE CABLE BRAKE IGBT D1 Frame Wire harness from gate drive card to brake IGBT gate resistor 1 1 1 1 1 1 1 1 1 CBL21 176F8368 SPARE CABLE BRAKE IGBT D2 Frame Wire harness from gate drive card to brake IGBT gate resistor 1 1 1 1 1 1 1 CBL22 176F8366 SPARE CABLE BRAKE POWER PLUS D1 Frame Cable from brake IGBT to brake terminal 1 1 1 1 1 1 1 1 1 CBL22 176F8369 SPARE CABLE BRAKE POWER PLUS D2 Frame Cable from brake IGBT to brake terminal 1 1 1 1 1 1 1 CBL23 176F8367 SPARE CABLE BRAKE POWER MINUS D1 Frame Cable from brake IGBT to brake terminal 1 1 1 1 1 1 1 1 CBL23 176F8370 SPARE CABLE BRAKE POWER MINUS D2 Frame Cable from brake IGBT to brake terminal 1 1 1 1 1 1 1 CBL 24 176F8353 SPARE CABLE SOFTCHG RST D2 Frame voltage from softcharge to power card 1 1 1 1 1 1 1 CBL 24 176F8543 SPARE Cable Softchg RST D1 Frame Wire harness from input power to softcharge assembly 1 1 1 1 1 1 1 1 1 CBL25 176F8355 SPARE CABLE SOFTCHG DC LINK D Frame Wire harness from softcharge to DC bus 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Terminals Labels Insulators TB1 2 176F8371 SPARE TERMINAL INSUL MAINS MOTOR VLT5122 5302 Mains and motor terminals insulation block Includes fasteners 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 TB3 4 176F8372 SPARE TERMINAL INSUL BRK LD SHR VLT5122 5303 Load share terminals insulation block Includes fa
116. as capacitance is charged within the drive Incorrect Reading An incorrect reading on any of the above tests indicates that the brake IGBT is defective Replace the brake IGBT in accordance with the disassembly procedures in Section 6 or 7 The failure of any IGBT may also lead to a failure of the gate drive circuit supplying that device Following the replacement of an IGBT always ensure the gate drive signals are tested in accordance with the procedures in the dynamic test section 5 1 7 Intermediate Section Tests The intermediate section of the drive is made up of the DC bus capacitors the DC coils and the balance circuit for the capacitors 1 Test for short circuits with ohmmeter set on Rx100 scale or for a digital meter select diode 5 10 VLT is a registered Danfoss trademark 2 Measure across positive DC terminal A and negative DC terminal B on connector MK105 on power card Observe meter polarity 3 Meter will start out with low ohms and then move towards infinity as meter charges capacitors 4 Reverse meter leads on connector MK105 on power card 5 Meter will peg at zero while capacitors are discharged by meter Meter then begins moving slowly toward two diode drops as meter charges capacitors in reverse direction Although test does not ensure capacitors are fully functional it ensures no short circuits exist in intermediate circuit Incorrect Reading A short circuit could be caused by a sh
117. asure phase to phase checking U to V then U to W and then V to W All three readings should be within 8 VAC of each other The actual value of the voltage depends on the speed the drive is running at The volts hertz ratio is relatively linear except in VT mode so at 60Hz the voltage should be approximately equal to the line voltage applied At 30 Hz it is about half of that and so on for any other speed selected The exact voltage reading is less important than balance between phases 5 20 VLT is a registered Danfoss trademark 2 Next monitor three output phases at drive motor terminals 96 U 97 V and 98 W with clamp on ammeter Analog device is preferred To achieve accurate reading run drive above 40Hz as this is normally the frequency limitation of Such meters The output current should be balanced from phase to phase and no phase should be more than 2 to 396 different from another If the above tests are successful the drive is operating normally 3 greater imbalance exists than described above disconnect motor leads and repeat voltage balance test Since the current will follow the voltage it is necessary to isolate between a load problem and a drive problem Should a voltage imbalance in the output be detected with the motor disconnected it is necessary to test the gate drive circuits for proper firing Proceed to the gate drive signals test 5 2 9 If the voltage was balanced but the current imbalanced
118. ate drive card can remain attached to cap bank cover plate 4 Remove 4 retaining nuts 10mm from cap bank re cover plate and remove plate 5 Note that weight of cap bank is approx 20 lbs 9 kg Remove cap bank by pulling free from 2i mounting studs KOy Reinstall in reverse order of this procedure Tighten mounting screws to 35 in Ibs 4 Nm LA Gate drive card Step 3 Retaining nuts Step 4 Figure 6 6 D1 Single Capacitor Bank Assembly VLT is a registered Danfoss trademark 6 5 6 8 Soft Charge SC Resistors 02 Units 1 Remove capacitor bank assembly in accordance with procedure NOTE On D2 units only upper cap bank assembly is removed 2 connector on soft charge card must be disconnected Disengage soft charge card far enough to access see Figure 6 4 in accordance with steps 1 3 in soft charge card disassembly procedure 3 Note that soft charge resistor is located under bus bars and held in place by 2 retaining nuts Bus bars do not need to be removed Loosen right most retaining nut 8mm 4 Remove left most 8mm retaining nut 5 Lift left side of SC resistor and remove resistor by sliding to left and out from under bus bars Reinstall in reverse order of this procedure Tighten 8mm mounting nuts to 20 in Ibs 2 25 Nm Tighten 10mm mounting nuts to 35 in Ibs 4 Nm ft ch ist Bus bars BB27 do not remove Soft charge resistor Retaining nut
119. ated with it See Table 1 4 below The setting selected in the parameter enables the function of the terminal It is important to confirm that the control terminal is programmed for the correct function Parameter settings are displayed by pressing the MENU key on the LCP keypad MENU Use the and keys on the LCP keypad to Scroll through parameters The 300s parameter group is used to set control terminal values See the operator s manual for details on changing parameters and the functions available for each control terminal In addition the input terminal must be receiving a signal Confirm that the control and power sources are wired to the terminal Then check the signal Signals can be checked in two ways Digital Input can be selected for display by pressing DISPLAY MODE key as discussed previously or a voltmeter may be used to check for voltage at the control terminal See procedure details at Input Terminal Test in Section 5 In summary for proper drive functioning the drive input control terminals must be 1 wired properly 2 powered 3 programmed correctly for the intended function 4 receiving a signal Control Terminal Functions The following describes the functions of the control terminals Many of these terminals have multiple functions determined by parameter settings See Figure 1 2 Control Terminals Electrical Diagram Terminal No Function 01 02 O3 Form C relay output Maxi
120. ation cable Check PLC WARNING 35 OUT OF FREQ RANGE Not applicable for the VLT 4000 6000 8000 This warning will only be displayed when operating in Process Closed Loop and the output frequency of the drive is above or below the limits programmed in parameters 201 and 202 Parameter 455 can be programmed to disable this warning This warning could indicate a loss of feedback or an undesired condition in the regulation process Check connections in feedback circuit Check process operation Note Some applications may be designed to operate normally in this mode No action is necessary in this case WARNING ALARM 36 MAINS FAILURE Not applicable for the VLT 4000 6000 8000 The mains failure function has been activated in parameter 407 A choice of actions is available including whether or not to trip A trip can be manually reset This is due to a loss of AC mains voltage Check AC mains voltage ALARM 37 INVERTER FAULT Indicates an IGBT is defective This fault results in a Trip Locked condition NOTE Do not reset and reattempt to start the drive without taking corrective action Further damage may result Faulty IGBT Measure gate to emitter resistance on all IGBTs WARNING 39 CHECK Parameter 104 106 AMA function has detected an error in calculating motor data The settings in parameter 102 104 or 106 are possibly set incorrectly Check the setting and choose Continue or Stop If stop is sel
121. ault detected EARTH FAULT X X 15 Switch mode power fault SWITCH MODE FAULT X X 16 Short circuit CURR SHORT CIRCUIT X X 17 Serial communication timeout STD BUSTIMEOUT X X 18 HP field bus timeout HPFB TIMEOUT X X 19 Fault in EEPROM on power card EE ERROR POWER X 20 Fault in EEPROM on control card EE ERROR CONTROL X 22 Auto motor adaptation fault AMA FAULT X 29 Heat sink temperature high HEAT SINK OVERTEMP X X 30 Motor phase U missing MISSING MOT PHASE U X 31 Motor phase V missing MISSING MOT PHASE V X 32 Motor phase W missing MISSING MOT PHASE W X 34 HPFB communication fault HPFB COMM FAULT X X 35 Out of frequency range OUT FREQ RNG ROT LIM X 37 Inverter fault GATE DRIVE FAULT X X 39 Check parameters 104 and 106 CHECK P 104 amp P 106 X 40 Check parameters 103 and 105 CHECK P 103 amp P 106 X 41 Motor too large MOTOR TOO BIG X 42 Motor too small MOTOR TOO SMALL X 60 Safety stop EXTERNAL FAULT X 61 Output frequency low FOUT FLOW X 82 Output frequency high FOUT FHIGH X 63 Output current low I MOTOR I LOW X X 64 Output current high I MOTOR gt I HIGH X 65 Feedback low FEEDBACK lt FDB LOW X 66 Feedback high FEEDBACK gt FDB HIGH X 67 Reference low REF lt REF LOW X 68 Reference high REF gt REF HIGH X 69 Temperature auto derate TEMP AUTO DERATE X 99 Unknown fault UNKNOWN ALARM X X is a registered Danfoss trademark 1 7 DRIV
122. ber caps mount on IGBT Modules 3 per IGBT module C2 3 4 5 6 7 8 9 10 176F8534 Spare CAP IGBT Snubber 1250V 1uF IGBT snubber caps mount on IGBT Modules 3 per IGBT module CBANK1 or 2 PCA10 and 11 176F8561 Bank 6Cap T5 Capacitor bank includes Balance PCA CBANK1 or 2 PCA10 and 11 176F8562 Spare CAP Bank 8Cap 15 Capacitor bank includes Balance PCA CBANK1 or 2 PCA10 and 11 176F8468 Spare CAP Bank 8Cap T7 Capacitor bank includes Balance PCA Fans F1 C1 176F8578 Spare HS Fan Assy 5352T5 Heat sink fan assembly Includes fan fan box capacitor gasket cables 1 per drive F1 C1 176F8579 Spare HS Fan Assy 5452 5502 Heat sink fan assembly Includes fan fan box capacitor gasket cables 1 per drive F2 176F8330 Spare Door Fan Kit D Frame Door fan kit Includes fan grills support fasteners 2 per drive 176F8331 Spare Door Vent Kit D Frame Door fan vent kit Includes grill support fasterners 2 per drive 176F8332 Spare Door Fan Filter PKG 10 D Frame Door fan filters Package of 10 176F8333 Spare Door Top Fan D Frame Door fan fan only 2 per drive 176F8333 Spare Door Top Fan D Frame Top fan fan only 1 per drive 176F8612 Spare Fuse Fan Input Plate E Frame Input fuse fan for units with RFI Filter and Mains Fuse VLT5352 Requirements Per Drive 380
123. card cassette VLT is a registered Danfoss trademark 9 1 ssojueg pagsipa e 5 2 6 L L L 8 i sepniou do 10 1004 4 dOL HOOQ 3HVdS 55585911 23 vSdl vSdl vSdl 0 Jo Sayy 100q ewel4 Q 0L 431714 HOOQ 3HvdS 66 849 1 vs rzdi vs rzdi vS ledi uoddns u6 1ue 100q 14 LIM ILNSA HOOQ 3uVdS 15585911 vs tedt vs teal vs redr vs redr verear vs teal vS Iedl tS 9 vS ted vS Iedl sjeuejsej uoddns siub in Ue 9ure14 HOO Q 3HVdS O 839 1 Zd 9 ue Ue 4 Q ASSV SH 3HVds 6284971 11199 19 13 424 amol
124. cedure in Section 6 for soft charge card removal and disengage soft charge card far enough to disconnect cable plugged into MK3 2 For all frame sizes disconnect cable from MK3 connector on soft charge card and connect one end of test cable into MK3 3 For D frame size units reinstall soft charge card 4 For all frame sizes disconnect connectors MK100 and MK105 on power card 5 For all frame sizes connect free end of test cable into MK105 6 For all frame sizes connect SCR gate shorting plug included with test cable 176F8437 into cable that was removed from MK100 When reapplying main input power to the drive the soft charge rectifier provides DC power to the power card Testing with the use of the gate signal board and the signal test board can now be carried out without the presence of DC bus voltage VLT is a registered Danfoss trademark 8 1 Signal Test Board 176F8437 Figure 8 2 SignalTest Board The Signal Test Board provides access to a variety of signals that can be helpful in troubleshooting the drive The signal test board is plugged into interface card connector MK104 Points on the signal test board can be monitored with or without the DC bus disabled In some cases the drive will need the DC bus enabled and operating a load to verify some test signals Following is a description of the signals available on the signal test board Section 5 of this manual describes when these tes
125. connectors from Control Card If message remains replace Control Card See Switch Mode Power Supply Test 5 2 2 in Section 5 ALARM 16 CURR SHORT CIRCUIT This indicates that the instantaneous output current has exceeded the maximum level for that drive This fault results in a Trip Locked condition Refer to over current section in the application section This is due to a phase to phase short circuit in motor or motor wiring Check motor and cabling for shorts WARNING ALARM 17 STD BUS TIMEOUT Indicates the serial communication with the drive has failed and the time out function has been activated The delay time programmed determines how long the warning will be present before a trip provided stop and trip has been selected Manual reset is possible Loss of serial communication signal due to faulty wiring or communication equipment PC PLC RS232 485 Adaptor etc Check connections on serial communication cable Check operation of communication equipment WARNING ALARM 18 HPFB BUS TIMEOUT Indicates the communication between a high performance field bus option such as DeviceNet and the drive has failed and the time out function has been activated in parameter 804 The delay time programmed in parameter 803 determines how long the warning will be present before a trip provided stop and trip has been selected in parameter 804 Manual reset is possible Faulty connection in communication wiring or fault
126. ctricity Voltages so low that they cannot be felt seen or heard can reduce the life affect performance or completely destroy sensitive electronic components VLT is a registered Danfoss trademark Intro 1 VLT 4000 and VLT 6000 525 600 VAC Frame size is used throughout this manual 525 600 VAC where ever procedures or components differ Model between drives based upon the unit s physical size Refer to these tables to determine D1 D2 and E1 frame size definitions VLT 4000 VLT 6000 HVAC 4102 6102 4122 6122 4152 6152 VLT 4000 and VLT 6000 380 460 VAC 4202 6172 4252 6222 4302 6272 4352 6352 4402 6402 4502 6502 4602 6602 4652 6652 380 460 VAC Model VLT 4000 VLT 6000 HVAC 4152 6152 150 4202 6172 200 4252 6222 250 4302 6272 300 4352 6352 350 4452 6402 450 4502 6502 500 4602 6552 550 600 4652 6602 600 unit can attain 600 hp VLT 5000 525 690 VAC 525 690 VAC Power High overload Normal Model VLT 5000 P 40 50 37 45 50 60 45 55 60 75 55 75 75 100 75 90 100 125 90 110 125 150 110 132 150 200 132 160 200 250 160 200 VLT 5000 380 500 380 500 VAC Power Model High Overload Normal VLT 5000 P VLT 5000 FLUX HP 2460 kW 2400 kW 2500 VAC 125 150 150 200 200 250 250 300 300 350 350 450 450 500 500 600 550 600 90 110 110 132 132 160 160 200 200 250 250 315 315 3
127. d The power card and fuse require replacement If the fuse checks good there may be a problem with the soft charge circuitry Proceed to the static checks of the soft charge and rectifier circuits earlier in this section VLT is a registered Danfoss trademark 5 15 5 2 4 DC Under Voltage Test The initial charge of the DC bus is accomplished by the soft charge circuit If the DC bus voltage is below normal it would indicate that either the line voltage is out of tolerance or the soft charge circuit is restricting the DC bus from charging Conduct the input voltage test 5 2 1 1 to ensure the line voltage is correct If excessive input power cycling has occurred the PTC resistors on the soft charge card may be restricting the bus from charging If this is the case expect to read a DC bus voltage in the area of 50 VDC 1 Check DC bus voltage by reading power card connector MK105 A with respect to MK105 B If verified remove power from drive and allow it to cool for approximately 20 minutes 2 Reapply power to drive after 20 minutes and recheck DC bus voltage If voltage remains a Short circuit may exist within the intermediate circuit preventing it from charging Proceed to static checks 5 1 earlier in this section 5 16 VLT is a registered Danfoss trademark 5 2 5 Input Phase Imbalance Test Theoretically the current drawn on all three input phases should be equal Some imbalance may be seen however due to va
128. d in Section 6 Do not remove the soft charge card completely or unplug any connectors not called out Doing so will break the continuity path of these measurements and may result in a false interpretation of a failure 1 Extract soft charge card far enough to access connectors 2 Disconnect DC cable at connector MK3 Since the rectifier test requires the soft charge resistor to be in the circuit verify the resistor is good before proceeding 3 Measure resistance between pins A and B of connector MK4 on soft charge card It should read 27 ohms 10 for 380 500V drives and 68 ohms 1096 for 525 690V A reading outside this range indicates a defective soft charge resistor Replace resistor in accordance with disassembly procedures in Section 6 Continue tests Should the resistor be defective and a replacement not readily available the remainder of the tests can be carried out by disconnecting the cable at connector MK4 on the soft charge card and placing a temporary jumper across pins A and B This provides a path for continuity for the remaining tests Ensure any temporary jumpers are removed at the conclusion of the tests For the following tests set the meter to diode check or Rx100 Scale 4 Connect negative meter lead to positive A DC output to DC bus and connect positive meter lead to MK1 terminals R S and T in turn Each reading should show a diode drop An incorrect reading here in
129. d with those replacement parts for correct values Torque Values Table Shaft Size Driver Size Torque Torque Torx Hex in Ibs Nm M4 T 20 7 mm 10 1 0 M5 T 25 8 mm 20 2 3 M6 30 10 mm 35 4 0 M8 T 40 18 mm 85 9 6 M10 T 50 17 mm 170 19 2 VLT is a registered Danfoss trademark Intro 3 Control card cassette Interface card PCA2 Control card PCA1 Power card PCA3 N 5 a Control input terminals ow 3 Capacitor bank assembly CBANK1 PCA9 Capacitor bank cover plate Soft charge fuses Soft charge card PCA 11 IGBT gate driver card PCA5 DC inductor Fan fuse L1 yk BOY FU4 Input terminal mounting plate assembly AC input bus bar Main AC power input terminals TB1 Soft charge module R1 CBL26 TR1 IGBT module IGBT 1 Fan assembly F1 C1 CBL11 SCR Diode module SCR 1 2 3 IGBT output bus bar Current sensor L2 L3 L4 Output motor terminals TB2 Exploded View D1 Frame Size Intro 4 VLT is a registered Danfoss trademark Interface card Control card cassette Control card PCA1 Power card PCA3 Control input terminals Upper capacitor bank cover plate Capacitor bank assembly CBANK2 PCA10 Lower capacitor bank cover plate Soft charge card PCA11 Soft charge fuses IGBT gate driver card PA 5 Sa f DC i
130. des a supply voltage for the cooling fans During the charging process the top diodes of the soft charge rectifier conduct and rectify during the positive half cycle The diodes in the main rectifier conduct during the negative half cycle The DC voltage is applied to the bus capacitors through the soft charge resistor The purpose of charging the DC bus through this resistor is to limit the high inrush current that would otherwise be present Positive temperature coefficient PTC resistors located on the soft charge card are in series with the soft charge resistor Frequent cycling of the input power or the DC bus charging over an extended time can cause the PTC resistors to heat up due to the current flow Resistance of the PTC device increases with temperature eventually adding enough resistance to the circuit to prevent significant current flow This protects the soft charge resistor from damage along with any other components that could be damaged by continuous attempts to charge the DC bus The low voltage power supplies are activated when the DC bus reaches approximately 50 VDC less than the alarm voltage low for the DC bus see ratings tables in the introductory section of this manual The value for the low voltage alarm can be found in the ratings tables in the introductory section of this manual After a short delay an inrush enable signal is sent from the control card to the power card SCR gating circuit The SCRs are automatica
131. dicates the soft charge rectifier is shorted The rectifier is not serviced as a component Replace the entire soft charge card in accordance with the disassembly procedures in Section 6 5 Reverse meter leads with positive meter lead to positive MK3 A Connect negative lead to MK1 terminals R S and T in turn Each reading should show open 6 Connect positive meter lead to negative C Connect negative meter lead to MK1 terminals R S and T in turn Each reading should show a diode arop An incorrect reading here indicates the soft charge rectifier is shorted The rectifier is not serviced as a component Replace the entire soft charge card in accordance with the disassembly procedures in Section 6 7 Reverse meter leads with negative meter lead to negative MK3 C Connect positive meter lead to MK1 terminals R S and T in turn Each reading should show open If all tests indicate correctly while isolating between the SCR Diode modules and the soft charge card the SCR Diode modules are suspect Before reconnecting the cable at MK3 return to the Main Rectifier tests and repeat those tests Put the power card temporarily back in place to retest the main rectifier Replace any defective assemblies in accordance with the disassembly procedures in Section 6 MK1 Figure 5 3 Soft Charge Card Connectors VLT is a registered Danfoss trademark 5 1 3 Soft Charg
132. dl 2069 20291 1 301 O0dl av4 3uvds 95783971 O0dl O0dl 2069 2028 1 1 3dIS H3AOO 00dl 8v4 3uvds 8278392 1 209 202917 5 1H SISSvHO av4 auvds 91783911 L L L 20 S 202SLIA ACIS LT SISSYHO AY4JHYdS 91785921 ZS LS ZZLSLTA dOL HA O0dl av4 3uvds 65783911 2919 22 LG L 1A LOS O0dl av4 3uvds 9278392 1 2919 221 41 1A 3dIS H3AOO O0dl av4 3uvds 12783911 2818 22 LG L1N3GIS 1H SISSVHO av4 3uvds 21783971 2818 22 LG L1A 3dIS LTSISSVHO av4 3uvds 61783911 verear verear verear verear verear 20 S 22 IA 31 V Id NV19 av 3uvdS 0278492 ZOES ZZ LS L 1A vSdl 901 TON3 avA 3uvds 2178392 20 S 221S L 1A 401 TON3 av4 auvds 91785921 0 S 22 LS L A vSdl LOS TON3 av4 3uvds 61785921 0 S 22 LS LT LOS IONS av4 3uvds 81783971 ZO S Z2 LG L TA LI dOL H3AOO avs 3HvdS 6285921 suogne3uqe J eunso 5u3 OL Jo obeyed yopueis seq sng 20 S 202S L1A 0LO d J4O GNVLS 88 3HvdS 01785921 c es Pe ayeid ndu uo 2069 202911 L 1 HOS 8a 3uvds 90785921 se if tft Sli a uo 20 9 202911 1 051 89 39 95 60785921 d ejeid Indu uo
133. e frame size definitions See Section 7 for E frame sizes disassembly and assembly instructions Control card cassette LCP cable connector Step 3 Control card Control terminals Step 1 Captive screws Step 5 Grounding clamps Step 2 with instructions included with replacement card Reinstall in reverse order of this procedure Ensure that two ribbon cables are not crossed Tighten control card mounting screws to 8 in Ib 1 Nm Ribbon cables Step 4 Figure 6 1 Control Card Cassette VLT is a registered Danfoss trademark 6 1 6 2 Interface Card 5 Remove current scaling card from power card by 1 Disconnect cables from connectors on interface pushing in retaining clips on standoffs KEEP THIS card MK100 MK102 and MK105 Disconnect SCALING CARD TO REINSTALL ON ANY cables from connectors MK101 and MK103 only if REPLACEMENT POWER CARD Scaling card replacing interface card controls signals operating with this specific VLT drive Scaling card is not part of replacement 2 Removeinterface card by remove 4 mounting power card screws 25 Torx from standoffs Reinstall in reverse order of this procedure Tighten mounting Reinstall in reverse order of this procedure Tighten T25 screws interface card standoffs to 20 in lbs 2 25 Nm screws and interface card standoffs to 20 in Ibs 2 25 Nm Card will initialize in service mode Follow instructions to enter data required 6 4 Control C
134. e resistance readings based on drive power and voltage rating Note that values listed are values at the current scaling card When measuring with signal test board actual reading may be higher due to meter lead resistance Absence of resistance indicates a missing scaling card 4 1 Reapply power to drive 4 2 Using a DVM connect negative meter lead to terminal 4 common of signal test board 13 Run drive with a zero speed reference 14 In turn measure AC voltage at terminals 1 2 and 3 of signal test board These terminals correspond with current sensor outputs U V and W respectively Expect a reading near zero volts but no greater than 15mv If the control card parameters are setup to provide holding torque while at zero speed the current displayed will be greater than expected To make this test disable such parameters The current sensor feedback signal at this point in the circuit will read approximately 400mv at 100 drive load so any reading above 15mv while the drive is at zero speed has a negative effect on the way the drive interprets the feedback signal A reading of greater than 15mv suggests that the corresponding current sensor be replaced See the disassembly instructions in Section 6 or 7 Table 5 2 Scaling Card Resistance Values Voltage VAC Drive Model Number Resistance Ohms 380 500 5122 4152 6152 8152 4 5 380 500 5152 4202 6172 8202 3 8
135. e DC bus is disabled a simple test can be made to determine if the IGBTs are actually turning on Before proceeding verify that the DC bus is in fact disabled 1 Disconnect cable from connector MK105 on power card With a volt meter measure between white lead of cable disconnected from MK105 and output terminals U V and W in turn Switch between AC and DC scales Voltage should read nearly zero 2 Measure between black lead of same cable and the output terminals U V and W in turn Voltage should read nearly zero With DC bus disabled proceed using a DVM set on diode Scale 1 With drive in a stop mode connect positive meter lead to black lead of MK105 cable disconnected from power card 2 In turn connect negative meter lead to drive output terminals U V and W Meter should indicate a diode drop 3 Leaving positive meter lead connected to cable MK105 run drive at 30 Hz 4 In turn again connect negative meter lead to drive output terminals U V and W Meter should indicate effectively a short circuit or around a 0 035 diode drop which indicates lower IGBTs are turned on and shorting meter to negative bus NOTE Some voltage leakage within unit may cause meter to indicate a small negative voltage drop 5 Repeat test for positive or upper IGBTs 6 With drive in a stop mode connect negative meter lead to white lead of MK105 cable disconnected from power card 7 In turn connect pos
136. e a program to a repaired unit The LCP is removable during operation to prevent undesired program changes With the addition of a remote mounting kit the LCP can be mounted in a remote location of up to ten feet away Control terminals with programmable functions are provided for input commands such as run stop forward reverse and speed reference Additional output terminals are provided to supply signals to run peripheral devices or for monitoring and reporting status The control card logic is capable of communicating via serial link with outside devices such as personal computers or programmable logic controllers PLC The control card also provides two voltage supplies for use from the control terminals The 24 VDC is used for switching functions such as start stop and forward reverse The 24 VDC supply is also capable of supplying 200ma of power part of which may be used to power external encoders or other devices A 10 VDC supply rated at 17 is also available for use with speed reference circuitry The analog and digital output signals are powered through an internal drive supply The three power supplies are isolated from one another to eliminate ground loop conditions in the control input circuitry A single pole low voltage relay on the control card activates external devices based on the status of the drive The contacts of the control card relay are rated for 50 VAC at 1 Amp However in UL applications the ratin
137. e and Rectifier Circuits Test E frame Sizes For E frame size drives the rectifier and soft charge circuits are tested separately The soft charge circuit is made up of the soft charge rectifier fuses and the soft charge resistor The rectifier circuit is made up of the SCR and diode modules The soft charge resistor limits the inrush current when power is applied to the drive The soft charge circuit card also provides snubbing for the SCRs It is important to pay close attention to the polarity of the meter leads to ensure identification of a faulty component should an incorrect reading appear Prior to making the test it is necessary to ensure the soft charge fuses F1 F2 and F3 located on the soft charge card are good An open fuse could indicate a problem in the soft charge curcuit Continue test procedures Figure 5 4 shows the soft charge card and the location of the fuses It is for reference only It is not necessary to remove the card to perform the tests Disconnect MK3 from the soft charge card and leave disconected until completion of soft charge and rectifier tests 5 1 3 1 Soft Charge FuseTest Use a digital ohmmeter to test continuity on rectifier fuses F1 F2 and F3 on the soft chanrge card 1 Measure F1 across fuse Open reading indicates open blown fuse 2 Measure F2 across fuse Open reading indicates open blown fuse 3 Measure F3 across fuse Open reading indicates open blown fuse A measure
138. e card standoffs 8mm necessary to free mounting plate 4 Remove power card by removing 4 mounting 6 Lift plate free from chassis screws T25 and one locking stud from standoff Reinstall in reverse order of this procedure Torque 10mm 5 Disconnect ground lug from ground connector mounting nuts to 35 105 4 0 Nm MK100 Interface card PCA2 MK101 Interface card mounting screw MK105 MK102 Current scaling card PCA4 Power card PCA3 MK103 Ground connector Locking stud s Dm 2 Z 27 e 2 y 4 105 Mounting plate standoff MK109 MK100 MK106 FK103 MK107 Figure 7 2 Interface Card Power Card and Mounting Plate 7 2 VLT is a registered Danfoss trademark 7 5 1 ate Drive Card MK101 RFI filter MK106 Disconnect cables from connectors on gate drive card MK102 MK103 MK104 MK106 and if unit has brake option MK105 and for 380 500 V 2 T units with an RFI filter MK101 of Sais Oen Orns Deli 2 Remove gate driver card by removing 6 mounting sie pingere tri rri rin screws T25 Torx from standoffs X M ae ea ae a ee AE MU C ne 00 200 OO OO 09 00 OO Reinstall in reverse order of
139. e of performing and a numbered parameter associated with it The setting selected in the parameter enables the function of the terminal See the Operator s Manual for details VLT is a registered Danfoss trademark Terminal No Function 55 61 68 69 1 10 Common for analog inputs This common is isolated from the common of all other power supplies If for example the drive s 24 VDC power supply is used to power an external transducer which provides an analog input signal terminal 55 must be wired to terminal 39 Programmable O to 20 mA or 4 to 20 mA analog current input Resistance approx 200 Q Used for reference or feedback Signals RS 485 common RS 485 interface and serial communication DANFOSS 17524081 14 24Nd c max 200mA 10Vd c max 17mA 0 4 20mA Located on power card Int 24Vd c SN on Tx Rx Tx Rx 1617 15 9 20 27 Ext 24Vd c SWA off un 24Vd c Figure 1 2 Control Terminals Electrical Diagram VLT is a registered Danfoss trademark Grounding Shielded Cables It is recommended that shielded control cables be connected with cable clamps at both ends to the metal cabnet of the drive Figure 1 3 shows ground cabling for optimal results PLU etc VLT PLC etc PLC etc VLT
140. e size units reinstall soft charge Disconnect connectors MK100 and MK105 on power card Connect free end of Test Cable into MK105 Connect SCR gate shorting plug included with test cable 176F8437 into cable that was removed from MK100 Located on the gate drive card near each gate signal lead is a 3 pin test connector These are labeled MK250 MK350 MK450 550 MK650 MK750 and if the drive is equipped with a brake option MK850 For the sake of clarity refer to the 3 pins as one two and three reading left to right Pins 1 and 2 of each connector are in parallel with the gate drive signal sent to the IGBTs Pin 1 is the signal and pin 2 is common 7 Reconnect AC power to drive 8 In stop mode apply power to drive 9 Measure pins 1 and 2 of each test connector Each reading should be approximately 9 VDC indicating all IGBTs are tuned off 10 Apply run command to drive and 30 Hz reference 2 Disconnect cable from connector on soft charge card and connect one end of test cable 9 CONTINUED ON NEXT PAGE into MK3 E a O TT 9 00 D pid Do 0 oo 0 0 0 00 n Dno n nsn
141. e to other components when power is applied Always perform the procedure for testing the unit after repair as described in Section 5 Test Procedures 3 Never attempt to defeat any fault protection circuitry within the drive That will result in unnecessary component damage and may cause personal injury 4 Always use factory approved replacement parts The drive has been designed to operate within certain specifications Incorrect parts may affect tolerances and result in further damage to the unit 5 Read the instruction and service manuals A thorough understanding of the unit is the best approach If ever in doubt consult the factory or authorized repair center for assistance Exterior Fault Troubleshooting There may be slight differences of servicing a drive that has been operational for some extended period of time compared to a new installation With good troubleshooting techniques however it is not safe to make many assumptions To assume a motor is wired properly because the drive has been in service for some time may overlook loose connections improper programming or added equipment for example It is best to develop a detailed approach beginning with a physical inspection of the system See Table 3 1 Visual Inspection for items to examine Fault Symptom Troubleshooting This troubleshooting section is divided into sections based on the symptom being experienced To start Table 3 1 provides a visual inspection ch
142. ead connectors from modules not shown If unit is equipped with brake option remove two bus bars attaching brake IGBT module to IGBT bus assy Remove SCR Diode mounting screws SCR Diode module Mounting screws Step 8 REASSEMBLY 1 Toreplace SCR Diode modules follow instructions included with replacement module 2 Reinstall module and mounting screws Tighten remaining T25 and 8mm screws to 20 in lbs 2 25 Nm and T30 and 10 mm to 35 in Ibs 4 Nm 3 Reassemble remaining parts in reverse order of their removal Figure 6 11 D1 SCR Diode Module 3 of 3 VLT is a registered Danfoss trademark 6 17 6 13 Current Sensor 1 Remove motor cabling as required 2 Remove input terminal mounting plate assembly per instructions 3 Remove terminals U V and W by removing 3 mounting screws Terminal slides out from under current sensor 4 Disconnect current sensor cable from current sensor 5 Note which cables attach to which sensor for reasembly Remove 2 8mm retaining nuts from stud on chassis baseplate and remove sensor Reinstall in reverse order of this procedure Tighten 8mm mounting nuts to 20 in Ibs 2 25 Nm Current sensor Terminal Ay Figure 6 12 Current Sensors 6 18 is a registered Danfoss trademark Terminal mounting screw Current sensor mounting screws 2 Terminal mounting screws 2 Output motor cable connection screws 2 6
143. eateseeateneensesseeasen 5 9 5 1 6 Brake IGBT Test teet i neca d eC 5 10 5 1 7 Intermediate Section Tests seis esset ttnn tatnen 5 10 5 1 8 Heatsink Temperature Sensor Test sese nter nttntenn 5 10 5 1 9 Fan Continuity Tests D frame Size sese nter ntes 5 11 5 1 10 Fan Continuity Tests E frame Sizes sse tenentes 5 12 5 2 DYNAMIC TEST PROCEDURES ttnt anten tnt tanta aeae ieai 5 13 S2 No Display Test iit ed e t e tiers 5 14 5 2 1 1 Input Voltage Test 5 14 5 2 1 2 Basic Control Card Voltage Test sess tnnt 5 14 5 2 2 Switch Mode Power Supply SMPS Test sese 5 15 5 2 3 Zero DC Bus Voltage Test ssssessssseseeee tenente treten te tnnt 5 15 5 2 4 DC Under Voltage Test 5 16 5 2 5 Input Phase Imbalance Test seen tnnt tenete 5 16 5 2 6 Input Test ERO dupli 5 17 5 2 7 Input SCR Test iia aet dt i e e abc ed edat 5 19 5 2 8 Output Phase Imbalance Test esses trennt tnnt tnnt tenis 5 20 5 2 9 IGBT Gate Drive Signals Test sesenta 5 21 5 210 4 GBTSwitiching T6sl tette 5 24 5 2 11 Brake TGBT
144. eck list Many times the root cause of the problem may be due to the way the drive has been installed or wired The check list provides guidance through a variety of items to inspect during any drive service process Next symptoms are approached as the technician most commonly discovers them reading an unrecognized drive display problems with motor operation or a warning or alarm displayed by the drive Remember the drive processor monitors inputs and outputs as well as internal drive functions so an alarm or warning does not necessary indicate a problem within the drive itself Each incident has further descriptions on how to troubleshoot that particular symptom When necessary further referrals are made to other parts of the manual for additional procedures Section 4 Drive and Motor Applications presents detailed discussions on areas of drive and system troubleshooting that an experienced repair technician should understand for effective analysis Finally a list of tests called After Repair Tests is provided These tests should always be performed when first starting a drive when approaching a drive that is suspected of being faulty or anytime following a repair to the drive 3 0 Fault Symptoms 3 1 Display 3 1 1 No Display 3 1 2 Intermittent Display 3 1 3 Display Line 2 Flashing 3 1 4 WRONG Displayed 3 2 Motor 3 2 1 Motor Will Not Run 3 2 2 Incorrect Motor Operation 3 3 Warnings and Alarms 3 4 After Repair Tests VL
145. ected AMA will have to be started over WARNING 40 CHECK Parameter 103 105 AMA function has detected an error in calculating motor data The settings in parameter 102 103 or 105 are possibly set incorrectly Check the setting and choose Continue or Stop If stop is selected AMA will have to be started over WARNING 41 MOTORTOO BIG AMA function has detected an error in calculating motor data The motor is too large for the VLT or the setting of parameter 102 is incorrect Check the motor and setting and choose Continue or Stop If stop is selected AMA will have to be started over WARNING 42 MOTORTOO SMALL AMA function has detected an error in calculating motor data The motor is too small for the VLT or the setting of parameter 102 is incorrect Check the motor and setting and choose Continue or Stop If stop is selected AMA will have to be started over ALARM 43 BRAKE FAULT Not applicable for the VLT 4000 6000 8000 A test of the brake function has failed The possible causes as shown in the display are listed below The numbers in brackets will be logged as the value in parameter 617 These failures result in a Trip Locked condition Make corrections as needed 0 BRAKE CHECK FAILED During power up the brake test failed to find a resistor connected or the resistance between terminals 81 82 is too high Verify that the brake resistor is properly connected to terminals 81
146. ecting each of 3 IGBT nuts or 50 screw to 170 in lbs 19 2 Nm over fan bus bars to 3 current sensor bus bars 3 Remove retaining nut 17 mm connecting each of three IGBT over fan bus bars to three IGBT output bus bars 4 Disconnectin line Molex connector in fan wiring Cut tie wrap to free wiring from frame Retaining nut Step 5 Retaining nut Step 3 Fan housing Molex connector T 4 TOR IGBT output bus bar BB49 Retaining nut Step 2 96 IS aes Tr 194 1 459 D WNS Oeren Figure 7 10 Fan Assembly VLT is a registered Danfoss trademark 7 11 7 13 AC Input Motor Load Sharing or Regen Terminals 1 Remove external wiring from terminals as required 2 Remove retaining nut 17 mm connecting terminal bus bar to other bus bar assemblies 3 Remove 2 retaining nuts 13 mm attaching terminal bus bar to terminal block insulation Slide terminal bus bar out 4 If terminal block is attached to input terminal plate not shown remove retaining screw T40 attaching terminal block insulation otherwise go to step 5 5 If terminal block
147. ee Figure 2 1 REC IHIEL INTETIMIEDIATE CIRCUIT 1 1 d INVERTER SECTION IGBTs TI joc 1 T2 Beer Ts ppm 11 SPT CHARGT CIRC Hv Power Section Logic to Power Interface Control Logic Figure 2 1 Control Card Logic To provide an overview the main drive components will be grouped into three categories consisting of the control logic section logic to power interface and power section In the sequence of operation description these three sections will be covered in greater detail while describing how power and control signals move throughout the drive Logic Section The control card contains most of the logic section see Figure 2 2 The primary logic element of the control card is a microprocessor which supervises and controls all functions of drive operation In addition separate PROMs contain the parameters to provide the user with programmable options These parameters are programmed to enable the drive to meet specific application requirements This data is then stored in an EEPROM which provides security during power down and also allows the flexibility to change the operational characteristics of the drive A custom integrated circuit generates a pulse width modulation PWM waveform which is then sent to the interface circui
148. egistered Danfoss trademark 1 1 Status Display The status line of the display line 4 reports inputs commanding drive operations The VLT 5000 series drives have a slightly different status display format than the VLT 4000 6000 8000 series drives FREQUENCY ey amm SETUP EE a RUHHIHG LOCAL 1 For the VLT 4000 6000 8000 the first status display indicates where the start command comes from automatic or hand start In auto start the drive looks for a remote start signal In hand start the drive receives a local input through the HAND START key 2 Thesecond status display indicates where the speed command comes from remote or local Local responds to the and keys on the keypad Remote looks for an external reference Signal The third display shows the operational status of the drive running stopped stand by ramping and so on For the VLT 5000 series the status display on line 4 is not segmented It shows the operational status of the drive with the local or remote indication as part of the display title Tables 1 1 and 1 2 list the displays shown in the status line and define their meaning Because the VLT 5000 series and VLT 4000 6000 8000 series have different display status indications the definitions appear in separate tables Familiarity with the status display provides information regarding the operational mode of the drive The status line d
149. ements must be within the range of 342 to 528 VAC or 342 to 550 VAC for VLT 5000 Readings of less than 342 VAC indicate problems with the input AC line voltage For 525 690 V drives all measurements must be within the range of 446 to 759 VAC or 446 to 660 VAC for VLT 6000 Readings of less than 446 VAC indicate problems with the input AC line voltage In addition to the actual voltage reading the balance of the voltage between the phases is also important The drive can operate within specifications as long as the phase imbalance is not more than 3 Danfoss calculates line imbalance per an IEC specification Imbalance 0 67 X Vmax Vmin Vavg For example if three phase readings were taken and the results were 500 VAC 478 5 VAC and 478 5 VAC then 500 VAC is Vmax 478 5 VAC is Vmin and 485 7 VAC is Vavg resulting in an imbalance of 3 Although the drive can operate at higher line imbalances the lifetime of components such as DC bus capacitors will be shortened 5 14 VLT is a registered Danfoss trademark Incorrect Reading An incorrect reading here requires that the main supply be investigated further Typical items to check would be Open blown input fuses or tripped circuit breakers Open disconnects or line side contactors Problems with the power distribution system ACAUTION Open blown input fuses or tripped circuit breakers usually indicate a more serious problem Prior to replacing fuses or reset
150. emove upper most bus bar retaining nut 17 mm from each of three terminals Reinstall in reverse order of this procedure Tighten 10 mm mounting nuts to 35 in Ibs 4 0 Nm 17 mm connection nuts i Use ones rt Shown S mounted remove to 170 in llbs 19 2 Nm and T40 mounting screws to 85 in Ibs disconnect from terminal plate assembly to 9 6 Nm reduce weight of terminal plate as follows a Loosen connection nut 17 mm between fuse and disconnect b Remove 4 mounting screws T40 from disconnect Fuse RFI filter assembly Retaining nut Step 2 Connection nut Step 3a Input terminals Step 1 S PA 4 S 12 Cooling fan Step 4 nput terminal mounting plate Figure 7 6 Input Terminal Mounting Plate Assy with option VLT is a registered Danfoss trademark 7 5 7 9 Soft Charge Resistor 1 Remove input terminal plate assembly in accordance with procedure 2 Disconnect MK4 connector on soft charge card 3 Loosen top retaining nut 8 mm on soft charge resistor 4 Remove bottom retaining nut 8 mm on soft charge resistor 5 Lift bottom of soft charge resistor and remove resistor by sliding down Reinstall in reverse order of this procedure Tighten 8 mm retaining nuts to 20 in Ibs 2 3 Nm MK4 connector Step 2 Soft charge card Top retaining nut Step 3 Soft charge resistor Bottom retaining nut Step 4 Figure 7 7 Soft Charge Re
151. f this manual The drive is still operational Ramp Down time too short Parameter 208 or 210 for VLT 5000 207 for VLT 4000 6000 8000 WARNING 6 DC LINK VOLTAGE LOW The intermediate circuit voltage DC is below the lower warning limit See ratings tables in introduction section of this manual The drive is still operational AC line voltage too low Check AC input line voltage WARNING ALARM 7 DC LINK OVERVOLT The intermediate circuit voltage DC is above the overvoltage limit See ratings tables in introduction section of this manual It may be necessary to use dynamic braking As an alternative in the VLT 5000 the Over Voltage Control OVC scheme can be activated in parameter 400 For the VLT 4000 6000 8000 the OVC function is always active and the setting of parameters 400 and 410 have no effect on this alarm The voltage level detected will be displayed Manual reset is possible Warns for 5 sec trips after 25 sec Ramp Down time Parameter 208 or 210 for VLT 5000 207 for VLT 4000 6000 8000 significantly too short See Overvoltage Trips in Section 4 for more details WARNING ALARM 8 DC LINK UNDERVOLT The intermediate circuit voltage DC is below the under voltage limit See ratings tables in introduction section of this manual The unit will trip after a set period of time On the VLT 5000 extended units with an external 24VDC supply this message will be displayed as long as input power is rem
152. filter card It contains a high frequency filter circuit to reduce naturally occurring currents in the HF range to prevent interference with other sensitive equipment in the area The circuit as with other filter circuitry can be sensitive to unbalanced phase to ground voltages in the three phase AC input line This can occasionally result in nuisance overvoltage alarms For this reason the HF filter card on 380 500 V range drives contains a set of relay contacts in the ground connection of the filter capacitors The relay is tied into the RFI HF switch on the interface card which can be manually Switched off This disconnects the ground references to all filters should unbalanced phase to ground voltages create nuisance overvoltage conditions For 525 600 690 V drives there are no relay contacts that disconnect to ground 2 6 VLT is a registered Danfoss trademark LI PCA8 CBANKI DC INDUCTOR HF CARD DC CAP BANK 700 upc J BAL CKT 1 MK100 SY Figure 2 5 Intermediate Section VLT is a registered Danfoss trademark 2 7 Inverter Section In the inverter section see Figure 2 7 gate signals are delivered from the control card through the power card and gate drive
153. g is limited to 30 VDC at 1 Amp The logic circuitry on the control card allow for the addition of option modules for synchronizing control serial communications additional relays the cascade pump controller or custom operating software 2 2 VLT is a registered Danfoss trademark Logic To Power Interface The logic to power interface isolates the high voltage components of the power section from the low voltage signals of the logic section The interface section consists of three separate circuit cards the interface card power card and gate driver card The power card has been designed to accommodate the control circuitry for the next generation of VLT drives For this reason an interface card located between the control and power cards in the current series of drives provides translation between the two signal schemes Most of the communication between the control logic and the rest of the drive passes through these two cards Communication with the power card includes monitoring the DC bus voltage line voltage output current along with control of inrush current and the gate drive firing signals Much of the fault processing for output short circuit and ground fault conditions is handled by the control card The power and interface cards provide conditioning of these signals Scaling of current feedback and voltage feedback is accomplished on the interface card before processing by the control card The power card contains
154. gt gt Q MAN USER ur AE RAS BB30 BB31 Figure 6 15 D2 IGBT Modules 2 of 3 VLT is a registered Danfoss trademark 6 23 13 Remove 2 IGBT modules by removing 16 REASSEMBLY retaining screws 8 per module and slide modules fre tromunder bus 1 Replace IGBT module in accordance with instructions provided with replacement unit 14 Clean heatsink surface with mild solvent or alcohol solution 2 Reassemble remaining parts in reverse order of their removal 3 Reinstall module and mounting screws Tighten remaining T25 and 8mm screws to 20 in Ibs 2 25 Nm and T30 and 10 mm to 35 in Ibs 4 Nm IGBT module Retaining screw Step 13 Figure 6 15 D2 IGBT Modules 3 of 3 6 24 VLT is a registered Danfoss trademark 6 17 IGBT Modules D1 Units 6 Remove high frequency by removing 2 retaining screws and 1 retaining nut 1 Removecontrol card cassette per instructions 6A For units with brake option DC input bus 2 Removeinput terminal mounting plate per assembly must be removed to access and instructions remove bus bars between IGBT bus bar assembly see step 10 in Figure 6 15 2 of 3 and brake 3 Note IGBT gate signal cables connected between IGBT Remove DC input bus bar assembly per gate drive card connectors MK102 U MK103 steps 3 5 of SCR Diode Module Removal D1 V and MK104 W and IGBT module units connectors These will need to be reconnected in same
155. han value set in parameter 223 Warning Low Current Drive will continue to operate EXCEPTIONS Control microprocessor stopped for unknown cause and drive not XXXX operating Cause may be due to noise on the power line motor leads or control wires FEEDBACK HIGH Warning of a feedback signal higher than value set in parameter 228 Warning High Feeaback Drive will continue to operate FEEDBACK LOW Warning of a feedback signal lower than value set in parameter 227 Warning Low Feedback Drive will continue to operate FREEZE OUTPUT Drive output frequency frozen at current rate via digital input or serial communication FREQUENCY Warning of drive frequency higher than value set in parameter 226 HIGH Warning High Frequency Drive will continue to operate Warning Low Frequency Drive will continue to operate terminal 27 or serial communication signal on terminal 27 high terminal 27 or serial communication LOCAL RAMPING Local control selected and motor speed and drive output frequency is changing LOCAL RUN JOG Local control selected and drive is running at a fixed frequency set in parameter 213 Jog Frequency via digital input or serial communication reference or serial communication LOCAL UNIT Local control selected and 0 V on terminal 27 READY VLT is a registered Danfoss trademark 1 3 1 4 Table 1 1 5000 Series Status Definitions continued DISPL
156. has detected an open circuit in the U phase This fault may be manually reset Parameter 234 VLT 5000 only can disable the tripping or missing motor phase This can be due to a faulty connection between drive and motor or a faulty motor Check motor wiring See Output Phase Imbalance Test 5 2 8 in Section 5 3 10 VLT is a registered Danfoss trademark ALARM 31 MISSING MOT PHASE V The unit has detected an open circuit in the V phase This fault may be manually reset Parameter 234 VLT 5000 only can disable the tripping or missing motor phase This can be due to a faulty connection between drive and motor or a faulty motor Check motor wiring See Output Phase Imbalance Test 5 2 8 in Section 5 ALARM 32 MISSING MOT PHASE W The unit has detected an open circuit in the W phase This fault may be manually reset Parameter 234 VLT 5000 only can disable the tripping or missing motor phase This can be due to a faulty connection between drive and motor or a faulty motor Check motor wiring See Output Phase Imbalance Test 5 2 8 in Section 5 WARNING ALARM 34 PROFIBUS COMMUNICATION FAULT The Profibus option is no longer communicating A trip can be manually reset In a warning state this may indicate the cable has been disconnected or the master PLC has stopped In an alarm state it may indicate the option card is disturbed by noise or possibly defective Check connections on serial communic
157. hat motor ratings coincide with drives Check that drive s motor parameters 102 106 are set according to motor ratings Output to motor wiring Check for loose connections Check for switching components in output circuit Check for faulty contacts in switch gear Programming Check that drive parameter settings are correct according to motor application and I O configuration Proper These drives require top and bottom clearance adequate to ensure proper air clearance flow for cooling in accordance with the drive size Drives with exposed heat sinks out the back of the drive must be mounted on a flat solid surface Vibration Though somewhat subjective look for an unusual amount of vibration that the drive may be subjected to The drive should be mounted solidly or the use of shock mounts employed VLT is a registered Danfoss trademark 3 0 FAULT SYMPTOMS 3 1 DISPLAY 3 1 1 No Display The LCP display provides two display indications One by means of the backlit LCD alphanumeric display The other is three LED indicators lights near the bottom of the LCP If the green power on LED is illuminated but the backlit display is dark this indicates that the LCP itself is defective and must be replaced ALARM WARNING Be certain however that the display is completely dark Having single character in the upper corner of the LCP or just a dot indicates that communications may have fa
158. heck mechanical load on motor Ensure that para 221 222 215 are set correctly Check ramp up settings See Drive and Motor Application in Section 4 for more information WARNING ALARM 13 OVERCURRENT The peak output current limit of the unit has exceeded the limit After 1 5 seconds the unit will trip See ratings tables in introduction section of this manual This fault may be caused by shock loading or fast accel ramps with high inertia loads Incorrect settings of various group 1 parameters may also be the cause This fault results in a Trip Locked condition See Drive and Motor Application in Section 4 for more information ALARM 14 EARTH FAULT The unit has sensed output leakage current sufficient enough to determine that there is a ground fault in the motor or motor wiring This fault results in a Trip Locked condition See ratings tables in introduction section of this manual Short circuit to ground in motor or motor wiring or faulty current sensor Measure resistance to ground of motor leads with megohmmeter to check for earth faults Perform current sensor test section 5 See Internal Drive Problems in Section 5 VLT is a registered Danfoss trademark ALARM 15 SWITCH FAULT The internal plus and or minus 18 VDC power supply voltage is not within the specified range This fault results in a Trip Locked condition This is normally due to a faulty Control Card Remove all
159. heir presence from the control card to the power card as follows 12 Insert signal test board into interface card connector MK104 13 With scope probe ground connected to terminal 4 common of signal board measure Six gate signals at signal board terminals 25 through 30 CONTINUED ON NEXT PAGE 5 22 VLT is a registered Danfoss trademark 14 Place drive in run at 30 Hz The waveform should appear as in Figure 5 15 Input 8 00 6 00 4 00 2 00 0 00 2 00 4 00 5 00 8 00 100 us 50 us Div IGBT Gate Signal measured with the Signal Test Board 2 volts per division vertical scale 50 microseconds per division time scale Unit running at 30 Hertz Figure 5 15 Gate Signal Waveform from Signal Test Board 15 Using a DVM again check these same signal board terminals DVM should read 2 2 to 2 5 VDC An incorrect reading of a gate signal indicates either the power card is defective or the signal has been lost prior to arriving at the power card There is no test to verify the signals directly out of the control card The power card would be suspected if a single gate signal is incorrect The control card would be suspect if all six signals are incorrect Replace the corresponding card in accordance with the disassembly procedures in Section 6 or 7 VLT is a registered Danfoss trademark 5 23 5 2 10 IGBT Switiching Test Using the test cable 176F8439 while the drive is powered and th
160. icate a problem with the gating of the SCR This may be due to a defective SCR or in the gate signals from the power card to the module including the possibility of the wire harness from the power card to the SCR gates Further tests on the proper gating of the SCRs requires an oscilloscope equipped with current probes Proceed to testing the input waveform and input SCR in accordance with their procedures 5 2 6 InputWaveform Test Testing the current waveform on the input of the drive can assist in troubleshooting mains phase loss conditions or suspected problems with the SCR Diode modules Phase loss caused by the AC supply can be easily detected In addition the rectifier section is controlled by SCR Diode modules Should one of the SCR Diode modules become defective or the gate signal to the SCH lost the drive will respond the same as loss of one of the phases The following measurements require an oscilloscope with voltage and current probes Under normal operating conditions the waveform of a single phase of input AC voltage to the drive appears as in Figure 5 9 Input 0 0 ms 5 ms Div Figure 5 9 Normal AC Input Voltage Waveform The waveform shown in Figure 5 10 represents the input current waveform for the same phase as Figure 5 9 while the drive is running at 4096 load The two positive and two negative jumps are typical of any 6 diode bridge It is the same for drives with SCR Diode modules Input B 0 0 ms 5 ms
161. iled with the control card This is typically seen when a serial bus communication option has been installed in the drive and is either not connected properly or is malfunctioning If neither indication is available then the source of the problem may be elsewhere Proceed to the No Display test in Section 5to carry out further troubleshooting steps 3 1 2 Intermittent Display Cutting out or flashing of the entire display and power LED indicates that the power supply SMPS is shutting down as a result of being overloaded This may be due to improper control wiring or a fault within the drive itself The first step is to rule out a problem in the control wiring To do this disconnect all control wiring by unplugging the control terminal blocks from the control card If the display stays lit then the problem is in the control wiring external to the drive All control wiring should be checked for shorts or incorrect connections If the display continues to cut out follow the procedure for No Display as though the display were not lit at all 3 1 3 Display Line 2 Flashing This indicates that a local stop command has been given by pressing the stop key on the front of the LCP keypad The drive cannot accept any further run command until the local stop is cleared This is accomplished by pressing the START key For the VLT 4000 6000 8000 the HAND START or AUTO START keys provide the same result AWARNING Drive may start i
162. in turn Each reading should show a diode drop Incorrect Reading With the Part Ill test connection the diodes in the main rectifier diode modules are forward biased The meter reads the diode drops If a short circuit or an open circuit exists the diode module is damaged 5 1 3 5 Main Rectifier Circuit Test E frames Part IV 1 Reverse meter leads by connecting negative meter lead to negative DC bus connector MK105 B on power card 2 Connect positive meter lead to L1 L2 and L3 in turn Each reading should show infinity Each reading should show infinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the drive being charged by the meter Incorrect Reading With the Part IV test connection the diodes in the main diode modules are reversed biased If a short circuit exists the diode module is damaged Continue to Soft Charge Rectifier Tests E frames 5 1 4 VLT is a registered Danfoss trademark 5 1 4 Soft Charge Rectifier Test E frame Size The DC cable at connector MK3 remains disconnected for this procedure Since the rectifier test requires the soft charge resistor to be in the circuit verify the resistor is good before proceeding 1 Measure resistance between pins A and B of connector MK4 on soft charge card It should read 27 ohms 10 for 380 500 V drives or 68 ohms 10 for 525 690 V drives A reading outside this range indicate
163. ing deceleration of the load inertia of the system acts to sustain the running speed Once the motor frequency drops below the running Speed the load begins overhauling the motor At this point the motor becomes a generator and starts returning energy to the drive This is called regenerative energy Regeneration occurs when the speed of the load is greater than the commanded speed This return voltage is rectified by the diodes in the IGBT modules and raises the DC bus If the amount of returned voltage is too high the drive will trip There are a few ways to overcome this situation One method is to reduce the deceleration rate so it takes longer for the drive to decelerate A general rule of thumb is that the drive can only decelerate the load slightly faster than it would take for the load to naturally coast to a stop A second method is to allow the overvoltage control circuit to take care of the deceleration ramp When enabled in VLT 5000 parameter 400 the overvoltage control circuit regulates deceleration at a rate that maintains the DC bus voltage at an acceptable level In VLT 4000 6000 8000 drives auto ramping enables a similar function in parameter 208 One caution with overvoltage control is that it will not make corrections to unrealistic ramp rates For example if the deceleration ramp needs to be 100 seconds due to the inertia and the ramp rate is set at 3 seconds overvoltage control will initially engage and then disengage and
164. ining nut on bus bar BB41 Step 3 E LM _ gt xcm pee De lt IGBT board oO ES ia E a _ 9 E 5 9 S P _ 5 Wire retaining nuts for dcm S output bus bars BB42 I Steps 5 amp 6 L D i WX 1177 Figure 7 12 IGBT Modules 1 of 4 VLT is a registered Danfoss trademark 7 18 8 lIfunitis not equipped with load sharing option proceed to step 9 If unit is equipped with load sharing load share minus bus bar must be removed as follows a Remove 2 retaining nuts 13 mm connecting load share bus bar to the SCR output bus bar b Remove retaining nut 17 mm connecting load share bus bar to load share terminal on opposite end of bus bar not shown c Remove load share bus bar Load sharing option qd retaining studs q D M SCR and Diode input bus bar BB41 Step 10 7 14 VLT is a registered Danfoss trademark 9 Remove both positive and negative SCR output bus bars by removing 6 connection screws T50 There are 3 screws per bus bar 10 Remove three SCR and Diode input bus bars by removing 6 connecti
165. ion errors Drive CPU exception faults Unexplained drive trips Rectifier Y Y A disturbance to other nearby equipment is more common Generally other industrial control equipment has a high level of EMI immunity However non industrial commercial and consumer equipment is often susceptible to lower levels of EMI Detrimental effects to these systems may include the following Pressure flow temperature signal transmitter signal distortion or aberrant behavior Radio and TV interference Telephone interference Computer network data loss Digital control system faults Sources of EMI Modern adjustable frequency drives see Figure 4 1 utilize Insulated Gate Bipolar Transistors IGBTs to provide an efficient and cost effective means to create the Pulse Width Modulated PWM output waveform necessary for accurate motor control These devices rapidly switch the fixed DC bus voltage creating a variable frequency variable voltage PWM waveform This high rate of voltage change dV dt is the primary source of the drive generated EMI Filter reactor AC Line 1 PI Filter capacitor Y e DC Bus Inverter a Motor IGBT iE r er PWM waveform Sine wave Figure 4 1 Adjustable Frequency Drive Functionality Diagram The high rate of voltage change caused by the IGBT switching creates
166. iring Considerations for Drive Electromagnetic Compatibility 4 5 Effects Of EMI etes e Creuse ce e neci dia daniel chk ah piel 4 5 Sources sette denen i ind one d 4 5 EMI Propagation irre fte ft ee d eR e a 4 6 Preventative Measures x pulita dee BT la E iiec 4 7 Proper EMC Installation iii niiina dte dee bane 4 8 SECTION 5 TEST PROCEDURES ssssscsssssssssssssesessesnsenennsaneseesesstenseneanseneeneansatentesesnueneaneanseneaueaes 5 1 INTRODUCTION titer deae eripiet e Rd adiit Dad eite ie 5 1 TOOLS REQUIRED FOR treten deste De a Enea 5 1 Signal Test Board 5 1 Test 5 1 5 0 TEST PROGEDURES idet ta tele e ea Pede 5 2 51 STATIC TEST PROCEDURES 2 2 te done tea nte De td Ere tiene cus 5 2 5 1 1 Soft Charge and Rectifier Circuits Test D frame Size ss 5 9 5 1 2 Soft Charge Rectifier Test D frame Size sese 5 5 5 1 3 Soft Charge and Rectifier Circuits Test E frame Sizes sss 5 6 5 1 4 Soft Charge Rectifier Test E frame Size sse 5 8 5 1 5 Inverter Section Tests 0 ssssecsessscessesseestesceneeseeeessesteaceneeateaeensssseseateseat
167. is installed Drive display Warnings alarms drive status fault history and many other important items are available through the display on the local control panel of drive Drive interior Drive interior must be free of dirt metal chips moisture and corrosion Check for burnt or damaged power components or carbon deposits that were the result of a catastrophic component failure Check for cracks or breaks in the housings of power semiconductors or pieces of broken component housings loose inside the unit EMC considerations Check for proper installation with regard to electromagnetic capability Refer to the drive instruction manual and Section 4 of this manual for further details Environmental Under specific conditions these units can be operated within a maximum conditions ambient of 50 C 122 F Humidity levels must be less than 9596 non condensing Check for harmful airborne contaminates such as sulfur based compounds Grounding The drive requires a dedicated ground wire from its chassis to the building ground It is also suggested that the motor be grounded to the drive chassis as well The use of conduit or mounting of the drive to a metal surface is not considered a suitable ground Check for good ground connections that are tight and free of oxidation Input power Check for loose connections Check for proper fusing Check for blown fuses wiring Motor Check nameplate ratings of motor Ensure t
168. isplays are not programmable 12 VLT is a registered Danfoss trademark Factory Default Display Settings Any of the values shown by scrolling through the display in line 2 are also available to display in the three meter displays on line 1 See the drive instruction manual for procedures on programming drive parameters Factory default values and associated parameters for VLT 5000 series drives are shown below Line 1 displays Line 2 display 010 Reference 96 009 Frequency Hz 011 Motor current A 012 Power kW Factory default values and associated parameters for VLT 4000 6000 8000 series drives are shown below Line 1 displays Line 2 display 008 Reference 96 007 Frequency Hz 009 Motor current A 010 Power hp Table 1 1 defines the status line display shown in VLT 5000 Series drives Table 1 1 VLT 5000 Series Status Definitions DISPLAY DESCRIPTION ADAPT Motor Adaptation AMA and drive performing adaptation function BRAKE CHECK OK Brake check function is completed and brake resistor and transistor tested successfully BRAKING BRAKING MAX Drive brake functioning at maximum Drive brakes to its maximum when running 10096 duty cycle parameter 219 Catch up Slow down Value drive is ready for operation CURRENT HIGH Warning of drive output current higher than value set in parameter 224 Warning High Current Drive will continue to operate CURRENT LOW Warning of drive output current lower t
169. itive meter lead to drive output terminals U V and W Meter should indicate a diode drop 8 Leaving negative meter lead connected to cable MK105 run drive at 30 Hz 5 24 VLT is a registered Danfoss trademark 9 In turn again connect positive meter lead to drive output terminals U V and W Meter should indicate effectively a short circuit or around a 0 035 diode drop which indicates upper IGBTs are turned on and shorting meter to positive bus NOTE Some voltage leakage within unit may cause meter to indicate a small negative voltage drop Incorrect Reading An incorrect reading indicates some of the IGBTs are not turning on Replace the IGBT module in accordance with the disassembly instructions in Section 6 or 7 5 2 11 Brake IGBT Test Use the signal test board to test the operation of the dynamic brake IGBT and gate drive circuitry The following procedure can be used to force the brake circuit to activate for testing 1 Connect signal test board to connector MK104 on control card 2 Set voltage test switch labeled Over V to ON position 3 Turn potentiometer on test board until brake circuit activates This causes brake IGBT to turn on and off at approximately 1 2 KHz Duty cycle pulse width increases as potentiometer is increased 4 Measure with oscilloscope or DVM at terminal 13 Terminal 13 represents gate signal to brake IGBT This should be 4 04 VDC when brake is OFF and drop to zero when brake
170. ke resistor connected or a faulty connection to the brake resistor defective brake resistor or a defective brake IGBT faulty brake firing circuit Power Check all brake resistor connection check resistor perform Brake IGBT test Static Test Section WARNING 25 BRAKE RESISTOR FAULT Not applicable for the VLT 4000 6000 8000 The brake resistor or the connection is short circuited The unit will be able to operate in this condition however the brake function will be inoperative Manual reset is possible Ground fault in brake resistor circuit shorted resistor cable too low resistance in resistor Check all brake resistor connections for short circuits check resistor value WARNING 26 BRK PWR WRN 100 Not applicable for the VLT 4000 6000 8000 Brake resistor power 100 The monitoring function has been activated in parameter 403 The power transmitted to the brake resistor is monitored over a 120 second period The power is based on the values entered in parameters 401 and 402 If the calculated power being dissipated exceeds 100 a warning will occur based on the choice in parameter 403 If warning is selected the warning will disappear when the dissipated power drops below 8096 Manual reset is possible Overhauling motor load load inertia too high ramp down time incorrectly set Check ramp down time para 208 settings Check for overhauling motor load If load inertia is too high load must
171. l changes being necessary in specifications already agreed upon Phone 800 432 6367 Fax 815 639 8002 Rev D FEBRUARY 2006 175R0987
172. l or external to the drive disconnect the motor from the drive output terminals Perform the output phase imbalance test procedure 5 2 8 on all three phases with an analog voltmeter If the three voltage measurements are balanced the drive is functioning correctly The problem therefore is external to the drive If the voltage measurements are not balanced the drive is malfunctioning This typically means that one or more output IGBT is not switching on and off correctly This can be a result of a defective IGBT or gate signal from the gate driver card Perform the IGBT gate signal test 5 2 9 VLT is a registered Danfoss trademark INTERNAL DRIVE PROBLEMS The vast majority of problems related to failed drive power components can be identified by performing a visual inspection and the static tests as described in the test section There are however a number of possible problems that must be diagnosed in a different manner The following discusses many ofthe most common of these problems Overtemperature Faults In the event that an overtemperature indication is displayed determine whether this condition actually exists within the drive or whether the thermal sensor is defective Of course this can easily be detected by feeling the outside of the unit if the overtemperature condition is still present If not the temperature sensor must be checked This can be done with the use of an ohmmeter in accordance with the thermal
173. le after the ETR counter has counted to Zero WARNING ALARM 11 MOTOR THERMISTOR The motor thermistor function has been activated in parameter 128 and a thermistor is connected to either terminal 53 or 54 and programmed as such in parameter 308 or 311 Parameter 128 provides a choice of warning or alarm Manual reset is possible This warning or trip occurs when the input to terminal 53 or 54 is more than 3K Ohms impedance between that terminal and terminal 50 or when the voltage to the selected terminal is less than 8 VDC This could indicate an overheated motor It is also possible that the connection has been broken Check for overheated motor if Thermistor function is being used Check for open connection by measuring voltage between corresponding terminal and terminal 55 A reading of less than 8 VDC indicates an open connection WARNING ALARM 12 TORQUE LIMIT CURRENT LIMIT The torque requirement of the motor is higher than the value set in parameter 221 for the VLT 5000 or 215 for the VLT 4000 6000 8000 in motor operation or parameter 222 regenerative operation The warning will be present until the time programmed in parameter 409 for VLT 5000 or 412 for the VLT 4000 6000 8000 expires Manual reset is possible This normally indicates a mechanical overload on the motor or incorrect setting of para 221 222 or 215 for the VLT 4000 6000 8000 or incorrectly set ramp up time para 207 206 VLT 4000 6000 8000 C
174. lly gated when forward biased acting as a result similar to an uncontrolled rectifier 24 VLT is a registered Danfoss trademark When the DC bus capacitors are fully charged the voltage on the DC bus will be equal to the peak voltage of the input AC line Theoretically this can be calculated by multiplying the AC line value by 1 414 VAC x 1 414 However since AC ripple voltage is present on the DC bus the actual DC value will be closer to VAC x 1 38 under unloaded conditions and may drop to VAC x 1 32 while running under load For example a drive connected to a nominal 460 V line while sitting idle the DC bus voltage will be approximately 635 VDC As long as power is applied to the drive this voltage is present in the intermediate circuit and the inverter circuit It is also fed to the Switch Mode Power Supply SMPS on the power card and is used for generating all other low voltage supplies LI DC INDUCTOR 9 r 7777 SCRI SCR SCR3 DISC FUSE OPTION RFI OPTION TT 4 Ful E
175. loosen Step 3 oh Lie UA EE OLD Vo ET T 6K ELA WE 2 dm MILL Figure 6 7 D2 Soft Charge Resistor 66 VLT is a registered Danfoss trademark 6 9 Soft Charge SC Resistors D1 Units 1 Remove capacitor bank per instruction 2 Removeinput terminal mounting plate per instructions 3 Note the color coding for each of three wires attached to terminal 1 for each SCR Diode module Ensure that correct wire is attached to applicable stud upon reassembling Remove wiring from studs Remove retaining screw T25 from terminal 1 of each of 3 SCR Diode modules and remove bus bar CONTINUED ON NEXT PAGE Soft Charge Resistor SS Bus bar BB2 Step 3 Retaining screw Step 3 x s Y NES gt QA LT e IS PY LS Figure 6 8 D1 Soft Charge Resistor 1 of 3 VLT is a registered Danfoss trademark 6 7 4 Remove six retaining screws T25 from SCR Diode modules terminals 2 and 3 in each module 5 Remove four 10mm retaining nuts from DC inductor input bus bars and four retaining nuts not shown from side mounted bus bars Side mounted bus bars are only present on units with load sharing Remove DC input bus assembly CONTINUED ON NEXT PAGE Retaining nuts Soft Charge Resistor Step 5 arg DC input bus assembly BB3 Step 5 x Retaining screws Step 4
176. loss by monitoring the amount of ripple voltage on the DC bus Ripple voltage on the DC bus is a product of a phase loss The main concern is that ripple voltage causes overheating in the DC bus capacitors and the DC coil Left unchecked the lifetime of the capacitors and DC Coil would be drastically reduced When the input voltage becomes unbalanced or a phase disappears completely the ripple voltage increases causing the drive to trip and issue an Alarm 4 In addition to missing phase voltage increased bus ripple can be caused by a line disturbance or imbalance Line disturbances may be caused by line notching defective transformers or other loads that may be effecting the form factor of the AC waveform Line imbalances which exceed 396 cause sufficient DC bus ripple to initiate a trip Output disturbances can have the same effect of increased ripple voltage on the DC bus A missing or lower than normal output voltage on one phase can cause increased ripple on the DC bus Should a mains imbalance trip occur it is necessary to check both the input and output voltage of the drive Severe phase imbalance or phase loss can easily be detected with a volt meter Line disturbances most likely need to be viewed on an oscilloscope Conduct tests for input phase imbalance input waveform and output phase imbalance as described in Section 5 Control Logic Problems Problems with control logic can often be difficult to diagnose since there is us
177. ltage is correct check fan voltage being supplied to fans themselves Voltage can be read at power card connector MK107 pins 8 and 11 with respect to pin 1 Voltage at pins 8 and 11 correspond to fan s commanded speed 200 VAC for low speed and 230 VAC for high Speed If the correct voltage is available but the fan is not running that fan is defective If no voltage is available verify that the fans should be running If so the power card is defective Replace the fan or power card in accordance with the disassembly instructions in Section 6 or 7 5 2 13 3 Fan Control Circuit To verify that the fan control circuit is receiving appropriate commands from the control card the signal test board can be used to verify those signals 1 Remove power from drive and allow DC bus to fully discharge 2 Install signal test board into interface connector MK104 3 Reapply power to drive 4 Connect negative meter lead of a voltmeter to signal board terminal 4 common 5 With positive meter lead check signal at terminal 6 of signal board Meter should read zero 0 volts with fans commanded to run 5 VDC if control card commands fans off 6 Verify cooling fans sequence of operation to ensure they should be running In addition signal board contains a fan test switch When switched on fans should start and run at high speed The signals at terminals 5 and 10 of the signal board determine fan speed See Section 8 for more o
178. lugging control terminals 2 Remove grounding clamps by removing two competent technician should carry out service screws holding each in place Save screws for reassembly ELECTROSTATIC DISCHARGE ESD Many electronic components within the adjustable frequency 3 Disconnect cable between LCP and control card drive are sensitive to static electricity Voltages so low that they cannot be felt seen or heard can reduce the life affect 4 Unplug two ribbon cables from side of control performance or completely destroy sensitive electronic card components 5 Loosen two captive screws to free cassette T20 ACAU TIO N Slide cassette free from mounting tabs Use proper electrostatic discharge ESD procedures when servicing drive to prevent 7 Remove and replace control card in accordance damage to sensitive components NOTE Frame size is used throughoutthis manual where ever procedures or components differ between drives based upon the unit s physical size Refer totables in the Introduction Section to determine E1 frame size definitions Control card Control terminals Step 1 Captive screws Step 5 Grounding clamp with instructions included with replacement card Reinstall in reverse order of this procedure Ensure that two ribbon cables are not crossed Tighten control card mounting Screws to 10 in Ibs 1 Nm LCP local control panel Ribbon cables 22 Step 4 Figure 7 1 Control Card Cassette
179. management of the motor conductors has the greatest influence on the EMI characteristics of the system These conductors should receive the highest attention whenever EMI is a problem Single conductor wires provide the least protection from EMI emissions Often if these conductors are routed separately from the signal and AC line wiring then no further consideration is needed If the conductors are routed close to other susceptible conductors or if the system is suspected of causing EMI problems then alternate motor wiring methods should be considered Installing shielded power cable is the most effective means to alleviate EMI problems The cable s shield forces the noise current to flow directly back to the drive before it gets back into the power network or takes other undesirable and unpredictable high frequency paths Unlike most signal wiring the shielding on the motor cable should be terminated at both ends If shielded motor cable is not available then 3 phase conductors plus ground in a conduit will provide some degree of protection This technique will not be as effective as shielded cable due to the unavoidable contact of the conduit with various points within the equipment Malns supply 2 oo Min 10mm2 Serial communications cable selection There are various serial communication interfaces and protocols on the market Each of these recommends one or more specific types of twisted pair shielded
180. med in parameter 224 Warning High frequency This is a customer programmable indicator of operating conditions No corrective action needed WARNING ALARM 63 IMOTOR I LOW Output current low The output current is lower than the value programmed in parameter 221 Warning Low current Select the required function in parameter 409 function in case of no load WARNING 64 MOTOR gt I HIGH The output current is higher than the value programmed in parameter 222 Warning High current This is a customer programmable indicator of operating conditions No corrective action needed 3 12 VLT is a registered Danfoss trademark WARNING 65 FEEDBACK FDB LOW The resulting feedback value is lower than the value programmed in parameter 227 Warning Low feedback This is a customer programmable indicator of operating conditions No corrective action needed WARNING 66 FEEDBACK gt FDB HIGH The resulting feedback value is higher than the value programmed in parameter 228 Warning High feedback This is a customer programmable indicator of operating conditions No corrective action needed WARNING 67 REF lt REF LOW Remote reference low The remote reference is lower than parameter 225 Warning Low reference This is a customer programmable indicator of operating conditions No corrective action needed WARNING 68 REF gt REF HIGH The remote reference is higher than the value programmed in para
181. ment of 0 ohms indicates good continuity Replace any open fuse infinite resistance 5 6 VLT is a registered Danfoss trademark MK3 disconnect for soft charge and rectifier tests Fuses F1 F2 F3 Figure 5 4 Soft Charge Card Fuse Location 5 1 3 2 Main Rectifier Circuit Test E frames Part 1 Connect positive meter lead to positive DC bus connector MK105 A on power card 2 Connect negative meter lead to terminals L1 L2 and L3 in turn If a disconnect option is used measure on top side of fuses Each reading should show infinity The meter will start at a low value and slowly climb towards infinity due to capacitance within the drive being charged by the meter Incorrect Reading With the Part test connection the SCR modules are blocking current flow A short indicates a shorted SCR module 5 1 3 3 Main Rectifier Circuit Test E frames Part Il 1 Reverse meter leads by connecting negative meter lead to positive DC bus connector MK105 on power 2 Connect positive meter lead to L1 L2 and L3 in turn Each reading should show open Incorrect Reading With the Part Il test connection the SCR modules are blocking current flow A short indicates a shorted SCR module 5 1 3 4 Main Rectifier Circuit Test E frames Part Ill 1 Connect positive meter lead to negative DC bus connector MK105 B on power card 2 Connect negative meter lead to terminals L1 L2 and L3
182. meter 226 Warning High reference This is a customer programmable indicator of operating conditions No corrective action needed WARNING 69 TEMP AUTO DERATE Temperature auto derate The heatsink temperature has exceeded the max value and the auto derating function par 411 is active Warning Temp auto derate See Warning Alarm 29 WARNING 99 UNKNOWN ALARM An unknown fault has occurred which the software is not able to handle This may be due to noise interference or a faulty Control Card Cycle power and or reinitialize the VLT to clear the fault Possible replacement of control card is needed 3 4 AFTER REPAIR TESTS Following any repair to a drive or testing of a drive suspected of being faulty the following procedure must be followed to ensure that all circuitry in the drive is functioning properly before putting the unit into operation 1 Perform visual inspection procedures as described in Table 3 1 Perform static test procedures 5 1 1 5 1 2 and 5 1 5 for D frame size units or 5 1 3 5 1 4 and 5 1 5 for E frame size units to ensure drive is safe to start Disconnect motor leads from output terminals U V W of drive Apply AC power to drive Give drive a run command and slowly increase reference speed command to approximately 40 Hz Using an analog volt meter or a DVM capable of measuring true RMS measure phase to phase output voltage on all three phases U to V U
183. meter settings are displayed by pressing the MENU key on the LCP keypad See the operator s manual for detailed information on accessing and displaying parameters and for descriptions and procedures for service information available in the 600 parameter group FAULT MESSAGE TABLE Wherever an X is placed under both warning and alarm a Table 1 3 lists the drive s fault messages and indicates whether warning precedes the alarm An alarm always precedes or a warning alarm or a trip locks occurs After atrip lock input Simultaneously accompanies a trip lock Which faults are power must be removed the cause of the fault corrected reported may vary depending on the particular drive model and the input power restored to reset the drive Table 1 3 Fault Messages Description Warning Alarm Trip Locked 1 Under 10 volts 10 VOLT LOW X 2 Live zero fault LIVE ZERO ERROR X X 4 Input phase imbalance MAINS IMBALANCE X X X 5 Voltage warning high DC LINK VOLTAGE HIGH X 6 Voltage warning low DC LINK VOLTAGE LOW X 7 Overvoltage DC LINK OVERVOLT X X 8 Undervoltage DC LINK UNDERVOLT X X 9 Inverter overloaded INVERTER TIME X X 10 Motor overloaded MOTOR TIME X X 11 Motor temp high MOTOR THERMISTOR X X 12 Current limit reached CURRENT LIMIT X X 13 Overcurrent OVERCURRENT X X 14 Ground f
184. minals 1 Remove AC input power cabling as required 2 RemoveR L1 S L2 T L3 terminals by removing 3 retaining screws Reinstall in reverse order of this procedure Tighten mounting nuts per specifications in the unit s instruction manual Retaining screw Step 2 Retaining screws Step 2 AC input cable connector Step 1 AC input terminal Figure 6 14 AC InputTerminals VLT is a registered Danfoss trademark 6 21 6 16 IGBT Modules 02 Units 1 Remove capacitor banks per instructions 2 Note IGBT gate signal cables connected between SCR Diode input bus bar retaining nut and stud Steps 3 amp 4 SCR Diode terminal screw Step 5 gate drive card connectors MK102 U MK103 V and MK104 W and IGBTs These will need to be reconnected in same locations during reassembly Units with brake option will have brake cabling from MK105 in addition Disconnect cables at connectors on IGBT modules Remove retaining nuts 8mm from SCR input bus bars Snubber capacitor IGBT gate signal input terminal Step 2 Note the color coding for each of three wires attached to retaining studs Ensure that correct wire is attached to applicable stud upon reassembling Remove wiring from studs Remove screw T25 from terminal 1 of each SCR Diode module by accessing screw through access hole in SCR Diode input bus bar Remove SCR input bus bars Remove each IGBT output bus
185. mmediately If drive is being operated in local control or remote control with a maintained run signal drive will start immediately 3 1 4 WRONG or WRONG LCP Displayed If the message WRONG or WRONG LCP appears this is due to a faulty LCP or the use of an incorrect LCP such as an LCP from a VLT 6000 series drive being connected to a VLT 5000 series unit Replace the LCP with a correct and functioning one VLT is a registered Danfoss trademark 3 3 3 2 MOTOR 3 2 1 Motor will not run In the event that this symptom is detected first verify that the unit is properly power up display is lit and that there are no warning or alarm messages displayed The most common cause of this is either incorrect control logic or an incorrectly programmed drive Such occurrences will result in one or more of the following status messages being displayed LCP Stop The Stop Reset key VLT 5000 has been pressed Line 2 of the display will also be flashing when this occurs Press the Start key Note For VLT 4000 6000 8000 the status message Stop will be displayed Pressing the Hand Start or Auto Start will correct this Standby This indicates that there is no start signal at terminal 18 Ensure that a start command is present at terminal 18 Refer to the Input Terminal Signal Test in Section 5 Unit ready Terminal 27 is low no signal Ensure that terminal 27 is logic 1 Refer to the Input Terminal Sign
186. motor or open connection to motor Perform Output Phase Imbalance Test in section 5 to ensure drive is providing correct output see Motor Runs Rough above Check motor for open windings Check all motor wiring connections Motor Will Not Brake Possible fault in brake circuit Possible incorrect setting in brake parameters Ramp down time too short Note May be accompanied by an alarm or warning message Check all brake parameters and ramp down time parameters 208 400 401 402 Perform Brake Check in section 5 VLT is a registered Danfoss trademark 3 5 3 3 WARNING AND ALARM MESSAGES WARNING 1 10 VOLT LOW The 10 VDC supply on terminal 50 of the control card is too low Max capacity of terminal 50 is 17ma The 10 VDC supply on terminal 50 is supplied from a 13 volt regulator that supplies option boards and the LCP This condition may be caused by overloading terminal 50 or a short circuit in the Speed Potentiometer or related wiring If the 10 VDC is missing or low the most common link would be the control card as the faulty part after the external wiring was removed and verified Also see the Analog Input Test 5 2 14 2 in Section 5 WARNING ALARM 2 LIVE ZERO ERROR The current signal on terminal 60 is less than 5096 of the value programmed in parameter 315 and parameters 317 and 318 have been programmed for the time out function to be active It is possible to choose between a warning only or a war
187. mum 240 VAC 2 A Minimum 24 VDC 10 mA or 24 VAC 100 mA Can be used for indicating status and warnings Physically located on power card 04 05 Form A relay output 30 VAC 42 5 VDC Can be used for indicating status and warnings 12 13 Voltage supply to digital inputs and external transducers For the 24 VDC to be used for digital inputs switch 4 on the control card must be closed ON position The maximum output current is 200 mA 16 33 Programmable digital inputs for controlling the drive R 2 kohm Less than 5 V logic O open Greater than 10 V logic 1 closed 20 Common for digital inputs 39 Common for analog and digital outputs 42 45 Analog and digital outputs for indicating values such as frequency reference current and torque The analog signal is O to 20 mA or 4 to 20 mA at a maximum of 500 Q The digital signal is 24 VDC at a minimum of 600 Q 50 10 VDC 17 mA maximum analog supply voltage for potentiometer or thermistor 53 54 Oto 10 VDC voltage input R 10 kQ Used for reference or feedback signals A thermistor can be connected here Table 1 4 Control Terminals and Associated Parameter Term 16 17 18 19 27 29 32 33 53 54 60 42 45 1 3 4 5 Para 300 301 302 303 304 305 306 307 308 311 314 319 321 323 326 Control terminals must be programmed Each terminal has specific functions it is capabl
188. n either constant torque or variable torque with limited overload capabilities They include specific features and options which make them well suited for use on a variety of water pumping and processing applications These models are available in Chassis IPOO NEMA 1 IP21 or NEMA 12 IP54 enclosures AWARNING Drives contain dangerous voltages when connected to line voltage Only a competent technician should carry out service AWARNING For dynamic test procedures main input power is required and all line powered devices and power supplies are energized at rated voltage Use extreme caution when conducting tests on a powered drive Contact with powered components could result in electrical shock and personal injury FOR YOUR SAFETY 1 DO NOT touch electrical parts of drive when AC line is connected After AC line is disconnected wait 20 minutes before touching any components in D frame size units see page 2 or 40 minutes for E frame size units 2 When repair or inspection is made AC line must be disconnected 3 STOP key on control panel does not disconnect AC line 4 During operation and while programming parameters motor may start without warning Activate STOP key when changing data ACAUTION When performing service use proper ESD procedures to prevent damage to sensitive components ELECTROSTATIC DISCHARGE ESD Many electronic components within the adjustable frequency drive are sensitive to static ele
189. n the soft charge rectifier are shorted To isolate between SCRs or the soft charge rectifier perform the Soft Charge Rectifier Test Although an open reading is possible it is unlikely since that indicates that both the diodes in the SCR diode modules and the lower diodes in the soft charge rectifier are open Should that occur replace both diodes 5 1 1 5 Main Rectifier Circuit Test Part IV 1 Reverse meter leads by connecting negative meter lead to negative DC bus connector MK105 B on power card 2 Connect positive meter lead to L1 L2 and L3 in turn Each reading should show infinity Each reading should show infinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the drive being charged by the meter Incorrect Reading With the Part IV test connection the diodes in the SCR Diode modules are reversed biased as well as the lower diodes in the soft charge rectifier If a short circuit exists it would be possible that either the diodes in the SCR Diode modules or the lower diodes in the soft charge rectifier are shorted To isolate between SCRs or the soft charge rectifier perform the Soft Charge Rectifier Test 5 1 2 5 1 2 Soft Charge Rectifier Test D frame Size Testing the soft charge rectifier requires access to the soft charge card connectors It requires removing the control card and power card mounting plate Refer to removal instructions for soft charge car
190. n those signals In addition if aheat sink overtemperature trip has occurred the fans will automatically be switched to high speed Given the fact that the fans should be running if the signal at terminal 6 is correct and the fan test switch activates the fan the control card is defective Otherwise the power card is defective Replace the appropriate assembly in accordance with the disassembly instructions in Section 6 or 7 5 2 14 Input Terminal Signal Tests The presence of signals on either the digital or analog input terminals of the drive can be verified on the drive display Digital or analog input status can be selected in the display using the DISPLAY MODE key and the and keys on the keypad 5 2 14 1 Digital inputs With digital inputs displayed control terminals 16 33 are shown left to right with a 1 indicating the presence of a signal ey SETUP 1 If the desired signal is not present in the display the problem may be either in the external control wiring to the drive or a faulty control card To determine the fault location use a volt meter to test for voltage at the control terminals Verify the control voltage power supply is correct as follows 1 With a voltmeter measure voltage at control card terminal 12 and 13 with respect to terminal 20 Meter should read between 21 and 27 VDC If the 24 V supply voltage is not present conduct the Control Card Test 5 2 15 earlier in this section If the
191. ncorrect Reading Make all continuity checks using an ohmmeter set to Rx1 An incorrect reading would indicate a defective fan transformer scale Digital or analog ohmmeter can be used Replace the fan transformer To aid in making the measurements unplug the connector When finished be sure to reconnect CN2 CN2 from its mate CN2 terminals correspond to the terminal 5 1 9 3 Ohm Test of Fans numbers labeled on the transformer 1 Measure between terminals 11 and 13 of power 5 1 9 1 Checking Continuity of Connections card connector MK107 A reading of 20 ohms For the following tests read the plug end of connector CN2 should be indicated that is not connected to the transformer 2 Disconnect spade connectors from door fan and 1 Measure from L3 T to CN2 terminal 1 A repeat measurement A reading of 21 ohms reading of lt 1ohm should be indicated should be indicated 2 Measure from L2 S to CN terminal 3 3 Read terminals of door fan with wires reading of 1 ohm should be indicated disconnected A reading of 400 ohms should be indicated 3 Measure from CN2 terminal 2 to terminal 12 of power card connector MK107 A reading of 1 4 Reconnect wires to door fan ohm should be indicated Incorrect Reading Incorrect Reading An incorrect reading of one or both of the fans indicates a An incorrect reading would indicate a faulty cable connection defective fan Replace the defective fan Replace the cable assembly 5 1 9
192. nductor 4 24 Capacitor bank assembly ge Se CBANK1 PCA9 ga ___ Fan fuse Input terminal mounting FU4 plate assembly AC input bus bar Main AC power input terminals TB1 Fan transformer TR1 IGBT snubber C2 C3 C4 C5 C6 C7 IGBT module IGBT1 2 SCR Diode module SCR1 2 3 Fan assembly F1 C1 Current sensor L2 L3 L4 Output motor terminals TB2 Exploded View D2 Frame Size VLT is a registered Danfoss trademark Intro 5 Interface card Local Control Panel Control card cassette Control card Control input terminals Power card 2 5 5 LL e e 5 So o9 2 cr E 50 o S ET La 5 Le ac E 5 8 Du 08 20 2 oo cnn 25 o 2 ecco g w Or ana o m 5 Soft charge fuses Fan inductor not on all units Soft charge resistor assy IGBT output bus bar 2 7 o S a EE o o c o x c lt 2 c 88 5 3 5 20 5 4 2 x S9 Ga S uw E oy 2 or 5 5 oz 26 2 2 gt lt 3 Oo o E om 5 q c Co cs co o c 2 5 tn 2N lt 3m 84 or Fan assembly F1 C1 Exploded View E1 Frame Size VLT is a registered Danfoss trademark Intro 6 Mains supply
193. ne the status of the sensors 1 Apply power to drive 2 Ensure that motor check pre magnetizing DC hold DC brake or other parameter setups are disabled that create a holding torque while at zero speed Current displayed will exceed 1 to 2 amps if such parameters are not disabled 3 Run drive with a zero speed reference Note output current reading in display Display should indicate approximately 1 to 2 amps If the current is greater than 1 to 2 amps and a current producing parameter is not active the test will need to be made again with the motor leads disconnected 4 Remove power from drive Monitor DC bus voltage at power card connector MK105 A and B to ensure bus is fully discharged 5 Remove output motor leads from terminals U V and W 6 Apply power to drive 7 Run drive with a zero speed reference Note output current reading in display Display should indicate less than 1 amp If an incorrect reading was obtained from the above tests further tests of the current feedback signals are required using the signal test board Testing current feedback with the signal test board 8 Remove power to drive Ensure DC bus is fully discharged 9 Install signal test board into interface card connector MK104 10 Using DVM measure resistance between terminals 1 and 4 2 and 4 and 3 and 4 of signal test board Resistance should be the same for all three readings Table 5 2 shows approximat
194. ning and trip based on the selection of parameter 318 Manual reset is possible once the fault is corrected Faulty connection in control wiring or faulty signal generating device PLC transducer etc Check connections of control wiring Perform the Analog Input Test 5 2 14 2 in Section 5 WARNING ALARM 3 NO MOTOR Not applicable for the VLT 4000 6000 8000 series The motor check function has been activated in parameter 122 During stop conditions the motor check is performed This warning will appear if the VLT fails to detect a motor Ensure connection between drive and motor WARNING ALARM 4 AC LINE PHASE LOSS This alarm is derived from reading the AC ripple on the DC Bus It is intended to indicate a missing phase on the input AC main voltage One phase of the input AC line is missing or extremely low or Severe waveform distortion is present on the input line Measuring the voltage and current and verifying the wave form of both the input AC line and the output to the motor may be the first step to restoring proper operation of the drive Refer to section 5 Dynamic Test Procedures Input Voltage Test Input Phase Imbalance Test Output Phase Imbalance Test See Mains Phase Loss Trips in Section 4 for more details 3 6 VLT is a registered Danfoss trademark WARNING 5 DC LINK VOLTAGE HIGH The intermediate circuit voltage DC is above the upper warning limit See ratings tables in introduction section o
195. nterface PCA and Power PCA Connector Identification eere 5 2 5 2 Soft Charge Card Fuses 5 3 5 3 Charge Card Connectors sesenta rtentnn tette trennt 5 5 5 4 Charge Card Fuse Location terrent tette 5 6 5 5 Soft Charge Card Connectors sesenta tentent tte ttnn entente tnn 5 8 5 6 Fan Transformer and Fuse Location sse 5 11 5 7 Fan and DC Bus Fuse Locations c csscssssessssessssesscsessesessesescseeacsesacsesaeeeseseesesseseeaeseeataeeacass 5 12 5 8 Drive Power Terminals D size Frames seen 5 13 5 9 Normal AC Input Voltage Waveform sse eene rnnt tn trnn entere nter 5 17 5 10 AC Input Current Waveform with Diode Bridge eene 5 17 5 11 Input Current Waveform with Phase LOSS sse teretes 5 18 5 12 SCR Gate Sigal auae Let pcd ier it deed direi Ee 5 19 5 13 Gate Drive Card Test Connectors sese tette tente 5 21 5 14 Gate Signal Waveform from Gate Drive Card sse 5 22 5 15 Gate Signal Waveform from Signal Test Board
196. ntrol Card 10 TEMP_HS Analog signal inversely proportional to HS temp 11 VPOS 18 VDC regulated supply 16 5 to 19 5 VDC 12 VNEG 18 VDC regulated supply 16 5 to 19 5 VDC EXT24V 937 VACpeak 165 of CT current rating AC waveform output frequency of the drive Approx 400mv RMS 100 load 937 VACpeak 165 of CT current rating AC waveform output frequency of the drive 937 VACpeak 165 of CT current rating AC waveform output frequency of the drive Approx 400mv RMS 100 load equal to 25C signal 5VDC OFF command OVDC SCRs enabled OVDC inactive OVDC no backup Logic common This common is for all signals lt Will read 3 3 volts if the heat sink is disconnected As HS temperature goes up the voltage goes down Formula VDC 2 82 0 035 T 30 where T is the temperature in degrees Celsius 18 VDC regulated supply 16 5 to 19 5 VDC Red LED indicates voltage is present between VPOS and VNEG terminals Red LED indicates voltage is present between VPOS and VNEG terminals 18 VDC regulated supply 16 5 to 19 5 VDC VLT is a registered Danfoss trademark 8 3 Schematic Function Description Reading Using a Digital Acronym Volt Meter DBGATE 4 5 8 Brake IGBT gate pulse train Signal to brake IGBT Brake IGBT 5V logic level signal Indicates voltage across brake IGBT Varies w brake du
197. nts Signal conductors are especially vulnerable when they are run parallel to the power conductors for any distance EMI coupled into these conductors can affect either the drive or the interconnected control device See Figure 4 4 While these currents will tend to travel back to the drive imperfections in the system will cause some current to flow in undesirable paths thus exposing other locations to the EMI VFD AC Line Motor Motor cable m Stray capacitance AC Line Figure 4 4 Alternate Signal Conductor Currents HF currents can be coupled into the AC line supplying the drive when the AC line conductors are located close to the motor cables Preventative Measures EMI related problems are more effectively alleviated during the design and installation phases rather then after the System is in service Many of the steps listed here can be implemented at a relatively low cost when compared to the cost to later identify and fix the problem in the field Grounding The drive and motor should be solidly grounded to the equipment frame A good HF connection is necessary to allow the HF currents to return back to the drive rather than to travel thorough the power network The ground connection will be ineffective if it has high impedance to HF currents therefore it should be as short and direct as practical Flat braided cable has lower HF impedance than round cable Simply mounting the drive or motor onto a p
198. o drive 2 lf voltage is not present ensure proper line voltage is applied to drive Conduct Input Voltage test 5 2 1 1 voltage is present at input of drive but not at MK106 of power card conduct static test of Soft charge fuses 5 1 1 4 f voltage is present at MK106 check voltage at fan transformer read from connector CN2 located near transformer With a volt meter read AC voltage at CN2 pins 1 and 3 Voltage should correspond to main AC line voltage applied to drive 5 If voltage is not present ensure jumpers are in place at power card connector 103 Otherwise connect an external source of power to terminal FK103 for fan supply voltage If the jumpers are in place or an auxiliary supply is connected and powered but no voltage is present at the fan transformer connector CN2 the power card is likely defective Replace the power card in accordance with the disassembly instructions in Section 6 or 7 5 2 13 2 Transformer Output If the appropriate voltage is present at CN2 pins 1 and 3 next check the output of the transformer Prior to making this test ensure the fan transformer fuse is good 1 With a volt meter measure AC voltage from CN2 terminal 1 to terminal 2 Voltage should equal 6696 of main AC supply voltage 4896 for drives 525 600 690 VAC applied to drive or that of auxiliary supply If voltage is incorrect replace fan transformer 5 26 VLT is a registered Danfoss trademark 2 If vo
199. o standoffs Remove IGBT output bus bar CONTINUED NEXT PAGE Figure 7 12 IGBT Modules 3 of 4 VLT is a registered Danfoss trademark 7 15 15 Remove 18 retaining screws T30 on IGBT input 20 Retaining screw brake IGBT option terminals Note snubber capacitors come off when screws are removed There are 6 screws for each IGBT module Remove 2 retaining nuts 8 mm connecting each IGBT Cap bus bar assemblies to IGBT Ind bus bar assembly and remove the IGBT Cap bus bar assembly There are three IGBT Cap bus bar assemblies board frequency board board and remove board If unit has Brake IGBTs remove the 4 retaining Remove 2 retaining screws T25 from high Disconnect wire assembly from high frequency screws T30 connecting IGBT Ind bus bar Step 20 Snubber capacitor 7 16 pbs cas ncm Remove retaining nut 8 mm from high frequency assembly to Brake IGBT Note that there are 2 screws per Brake IGBT module Remove 4 retaining nuts 13 mm connecting IGBT Ind bus bar assembly to two
200. observe the current in the display of the drive With the motor disconnected the current should of course be zero A drive with a defective current sensor will indicate some current flow Because the current sensors for the higher horsepower drives have less resolution an indication of a fraction of an amp on a drive is tolerable However that value should be considerably less than one amp Therefore if the display shows more than one amp of current there is a defective current sensor To determine which current sensor is defective measure the voltage offset at zero current of each current sensor See the current sensor test procedure 5 2 12 Signal and Power Wiring Considerations for Drive Electromagnetic Compatibility Following is an overview of general signal and power wiring considerations when addressing the Electromagnetic Compatibility EMC concerns for typical commercial and industrial equipment Only certain high frequency phenomena RF emissions RF immunity are discussed Low frequency phenomena harmonics line voltage imbalance notching are not covered Special installations or compliance to the European CE EMC directives will require strict adherence to relevant standards and is not presented here Effects of EMI While Electromagnetic Interference EMI related disturbances to drive operation are uncommon the following detrimental EMI effects may be seen Motor speed fluctuations Serial communication transmiss
201. ode modules are forward biased by the meter current will not flow through the SCRs without providing a signal to their gates The upper diodes in the soft charge rectifier are forward biased so the meter reads the voltage drop across those diodes If an open reading were present it would indicate the upper diodes in the soft charge rectifier are open It could also indicate that one or more of the soft charge fuses are open It could further indicate that the soft charge resistor is open To isolate between the three possibilities perform the Soft Charge Fuse Test and Soft Charge Rectifier Test Ashort circuit reading indicates either one or more of the upper soft charge rectifier diodes are shorted or the SCRs are shorted in the SCR Diode module To isolate between SCRs or the soft charge rectifier perform the Soft Charge Rectifier Test 5 4 VLT is a registered Danfoss trademark 5 1 1 4 Main Rectifier Circuit Test Part Ill 1 Connect positive meter lead to negative DC bus connector MK105 B on power card 2 Connect negative meter lead to terminals L1 L2 and L3 in turn Each reading should show a diode drop Incorrect Reading With the Part Ill test connection the diodes in the SCR Diode modules are forward biased as well as the lower diodes in the Soft charge rectifier The meter reads the diode drops If a short circuit exists it would be possible that either the diodes in the SCR Diode modules or the lower diodes i
202. og Frequency via digital input or serial communication REM RUN OK Remote control selected and motor is running and speed corresponds to reference REM STOP Remote control selected and drive stopped via control panel digital input or serial communication REM UNIT READY Remote control selected and 0 V on terminal 27 SLOW DOWN Drive output frequency reduced by percentage value selected in parameter 219 Catch up Slow down Value STAND BY Drive will start when a start signal received via digital input or serial communication START Input on digital inputs and parameter data are in conflict FORW REV START INHIBIT OFF1 OFF2 OFF3 condition has been rectified Drive cannot start until OFF 1 bit is toggled OFF1 set from 1 to 0 then to 1 Fieldbus selected in parameter 512 UNIT NOT READY Drive not ready for operation because of a trip or because OFF 1 OFF2 or OFF3 is a logic 0 Only on units with external 24 VDC supply VLT is a registered Danfoss trademark Table 1 2 defines the status line display shown in VLT 4000 6000 8000 series drives Table 1 2 VLT 4000 6000 8000 Series Status Definitions DISPLAY DESCRIPTION CONTROL POINT AUTO Drive in Auto mode which means that Run Stop control is carried out remotely via input control terminals and or serial communication HAND Drive in Hand mode which means that Run Stop control is carried out via keys on the ke
203. ol Terminals Ld eds 1 8 Control Terminals Electrical Diagram esses trennt tnnt 1 10 Grounding Shielded Cables sesenta tentent treten entente 1 11 2 1 Control Gard Logie Ee id 2 1 DELENIT EC 2 1 2 3 Typical PoWer Section 2 a nitrate reete He e 2 9 2 4 Rectifier Circuit ic erii cett Bele a cade eden 2 5 2 5 Intermediate Section snini seseecsessscsectesessessteseeseeeeneseeseseesesateneeseeseeessseseateseeateaseneeaeeesnssneateateasens 2 7 2 6 Output Voltage and Wave Forms scscsssecsessesseeseeseseeseeseeseeneeseesecnsseeteateasestesesneeseeteateateatenseness 2 8 2 7 inverter Section statini te abe 2 9 2 8 _ Brake Operation edat aside an te tene eue er esee destaca 2 10 4 1 Adjustable Frequency Drive Functionality Diagram eene 4 5 4 2 Grourid CUITerilS sal std esL teen de det idein odes 4 6 4 3 Signal Conductor Current essssessessessessecseseeeseseesesseeseeseeseeesneeceeteseaeeateaeeateeeaseseeseateaneaneaees 4 6 4 4 Alternate Signal Conductor Currents sse tentent tentent tn trnn enne 4 7 4 5 Proper ECM Installation esssesseeseeneete tenente tnter teret te tnnt 4 8 5 1 I
204. om mains input L3 T to MK106 pin 6 on power card A measurement of 0 ohms indicates good continuity Replace any open fuse infinite resistance To replace a soft charge fuse follow the soft charge disassembly instructions in Section 6 Fuses F1 F2 F3 Figure 5 2 Soft Charge Card Fuses VLT is a registered Danfoss trademark 5 1 1 2 Rectifier CircuitTest Part 1 Connect positive meter lead to positive DC bus connector MK105 A on power card 2 Connect negative meter lead to terminals L1 L2 and L3 in turn Each reading should show infinity The meter will start at a low value and slowly climb towards infinity due to capacitance within the drive being charged by the meter Incorrect Reading With the Part test connection the SCRs in the SCR Diode modules are reverse biased so they are blocking current flow If a short circuit exists it would be possible that either the SCRs or the diodes in the soft charge rectifier are shorted To isolate between SCRs or the soft charge rectifier perform the Soft Charge Rectifier Test 5 1 1 3 Main Rectifier Circuit Test Part Il 1 Reverse meter leads by connecting negative meter lead to positive DC bus connector MK105 A on power 2 Connect positive meter lead to L1 L2 and L3 in turn Each reading should show a diode drop Incorrect Reading With the Part Il test connection even though the SCRs in the SCR Di
205. on screws T50 There are 2 Screws per bus bar CONTINUED NEXT PAGE c Figure 7 12 IGBT Modules 2 of 4 95 9 Positive output bus bar BB42 Step 9 Positive output bus bar connecting screw Step 9 Negative output bus bar BB42 Step 9 Negative output bus bar connecting screw Step 9 gt uy 0 gt EE 0 P _______ pb 0 Retaining screw Step 11 gt O 6 Retaining nut ane gt Ole Jn o 9 2 Step 14 2 Ole 9 9 9 9 9 Output bus bar Retaining nut Step 14 p y 00 3 8 HD s e a Retaining nut E 3 Step 12 4 5 00 Over fan bus bar al p Retaining nut 9 Step 13 C o 4 m o Ts o 3 4 al Remove 6 retaining screws T30 connecting each IGBT module output to IGBT output bus bars Remove retaining nut 17 mm connecting IGBT output bus bar to IGBT over fan bus bar Note that there is one for each of three phases Remove retaining nut 17 mm or T50 Torx screw depending on unit type connecting IGBT over fan bus bar to current sensor bus bar 14 Remove retaining nuts 17 mm top and one retaining nut 8 mm at bottom attaching IGBT output bus bar t
206. ort in the soft charge rectifier or inverter section Be sure that the test for these circuits have already been performed successfully A failure in one of these sections could be read in the intermediate section since they are all across the DC bus If a short circuit is present and the unit is equipped with a brake perform the brake IGBT test next The only other likely cause would be a defective capacitor within the capacitor bank There is not an effective test of the capacitor bank when it is fully assembled Although unlikely that a failure within the capacitor bank would not be indicated by a physically damaged capacitor if suspect the entire capacitor bank must be replaced Replace the capacitor bank in accordance with the disassembly procedures in Section 6 or 7 5 1 8 Heatsink Temperature Sensor Test The temperature sensor is an NTC negative temperature coefficient device As a result high resistance means low temperature As temperature decreases resistance increases The power card reads the resistance of the NTC sensor to regulate fan speed and to monitor for over temperature conditions 1 Use ohmmeter set to read ohms 2 Unplug connector MK100 on interface card and measure across cable leads The full range of the sensor is 787 ohms to 10K ohms where 10K ohms equals 25 C and 787 ohms equals 95 C The higher the temperature the lower the resistance 5 1 9 Fan Continuity Tests D frame Size I
207. oved however the unit will not trip The voltage level detected will be displayed Manual reset is possible AC line voltage too low for too long time Check AC input line voltage See Input Voltage Test in Section 5 WARNING ALARM 9 INVERTER TIME The unit has been operating with the output current having been in the intermittent range between 10096 and 15096 for too long A warning will be displayed when the ETR counter reaches 9896 When the counter reaches 100 the drive will trip The unit can be programmed to display the ETR counter Improperly sized drive and or motor Improperly programmed drive Compare the output current as displayed by the LCP to the rated current of the drive and motor Ensure that the drive is programmed properly for the application See section 4 Drive and Motor Applications for more information Manual reset is only possible after the counter has gone below 9096 WARNING ALARM 10 MOTORTIME The unit s ETR function has calculated an over temperature condition in the motor This calculation is based on motor current speed and the length of time these conditions exist based on the settings of parameters 102 through 106 Based on the selection in parameter 128 the unit will display a warning or an alarm when the counter reaches 10096 Overloaded motor mechanical Verify parameters 102 106 are set correctly Check for mechanical overloading on motor shaft Manual reset is possib
208. part SCR gate lead connectors Step 11 SCR Diode module mounting screws Step 12 Figure 6 10 D2 SCR Diode Module 4 of 4 6 14 VLT is a registered Danfoss trademark 6 12 SCR Diode Module D1 Units 1 Remove capacitor bank per instruction 2 Removeinput terminal mounting plate per instructions 3 Remove retaining screw T25 from terminal 1 of each SCR Diode module 4 Remove 8mm retaining nut from bus bar holding bracket and remove bus bar CONTINUED ON NEXT PAGE Bus bar BB2 Step 4 7 Retaining screw access Step 3 Retaining nut Step 4 Bus bar BB1 SCR Diode module Figure 6 11 D1 SCR Diode Module 1 of 3 VLT is a registered Danfoss trademark 6 15 5 Remove six retaining screws 725 from SCR Diode modules terminals 2 and 3 in each module 6 Remove four 10mm retaining nuts from DC inductor input bus bars and four retaining nuts not shown from side mounted bus bars Side mounted bus bars are only present on units with load sharing Remove DC input bus assembly CONTINUED ON NEXT PAGE Retaining nuts Step 6 Bus bar BB4 DC input bus assembly BB3 Step 6 JS c K2 4 Y LK 453 7 07 CR E Tw SCR Diode module Retaining screws Step 5 Figure 6 11 D1 SCR Diode Module 2 of 3 6 16 VLT is a registered Danfoss trademark Note which gate leads attach to which module for reasembly Remove SCR Diode gate l
209. place the entire soft charge card in accordance with the disassembly procedures in Section 7 Reconnect MKS on shoft charge card after these tests MK4 MK2 Figure 5 5 Soft Charge Card Connectors 5 1 5 Inverter Section Tests The inverter section is primarily made up of the IGBTs used for switching the DC bus voltage to create the output to the motor IGBTs are grouped into modules comprised of six IGBTs Depending on the size of the unit either one two or three IGBT modules are present The drive also has 3 snubber capacitors on each IGBT module ACAUTION Disconnect motor leads when testing inverter section With leads connected a short circuit in one phase will read in all phases making isolation difficult Before starting tests ensure that meter is set to diode scale If removed previously reinstall the soft charge card interface and power cards Do not disconnect the cable to connector MK105 on the power card since the path for continuity would be broken 5 1 5 1 Inverter Test Part 1 Connect positive meter lead to positive DC bus connector MK105 A on power card 2 Connect negative meter lead to terminals U V and W in turn Each reading should show infinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the drive being charged by the meter 5 1 5 2 Inverter Test Part Il 1 Reverse the meter leads by connecting negative meter lead
210. plug MK107 from the power card 5 1 10 1 Checking Continuity of Connections For the following tests read connector MK107 on the power card 1 Measure from L3 T to MK107 terminal 8 Reading of lt 1ohm should be indicated 2 Measure from L2 S to MK107 terminal 1 Reading of 1 ohm should be indicated Incorrect Reading An incorrect reading would indicate a faulty cable connection Replace the cable assembly Fan Fuse Test 1 Test fan fuses on power card mounting plate by checking continuity across fuse An open fuse could indicate additional faults Replace fuse and continue fan checks 5 1 10 2 Ohm Test of Transformer For the following tests read the plug end of the wire connected to MK107 on the power card 1 Measure between MK107 terminals 1 and 8 Should read approx value A in Table 5 1 2 Measure between MK107 terminals 8 and 12 Should read approx value B in Table 5 1 3 Measure between MK107 terminals 1 and 12 Should read approx value C in Table 5 1 Table 5 1 Fan Transformer Resistance AC Voltage Drive Resistance in Ohms Heatsink Fan Fan D Inductor 380 500 5352 4452 15 12 4 21 no 6402 8452 380 500 5452 4502 4 3 1 4 yes 6502 8502 380 500 5502 4602 4 3 1 4 yes 6552 8602 380 500 5552 4652 4 3 1 4 yes 6602 8652 525 690 5402 4502 20 8 12 21 no 6502 8502 525 690 5502 4602 7 4 3 6 3 2 4 yes 6602 8602 525 690
211. r Capacitor Bank D2 Units 1 Remove control card cassette in accordance with instructions 2 Capacitor bank connection to DC bus bars can be seen recessed in the gap between upper and lower cap banks Remove left most 2 nuts 10mm from DC bus bars A minimum 4 in 100mm extension is required 3 Remove 4 retaining nuts 10 mm from cap bank cover plate and remove cover plate 4 Note that weight of cap bank is approx 20 lbs 9 Reinstall in reverse order of this procedure Tighten mounting kg Remove cap bank by pulling free from mounting studs screws to 35 in Ibs 4 Nm 6 7 2 Lower Capacitor Bank D2 Units 1 Capacitor bank connection to DC bus bars can be seen recessed in the gap between upper and lower cap banks Remove right most 2 cap bank retaining nuts 10mm from DC bus bars A minimum 4 in 100mm extension is required 2 Disconnect MK102 MK103 MK104 and MK106 from gate drive card Also remove 1 05 for units with brake and MK101 for units with RFI filter Note that IGBT gate drive card can remain attached to cap bank cover plate 3 Remove 4 retaining nuts 10mm from cap bank cover plate and remove plate 4 Note that weight of cap bank is approx 20 lbs 9 Reinstall in reverse order of this procedure Tighten mounting kg Remove cap bank by pulling free from mounting studs screws to 35 in Ibs 4 Nm 6 4 VLT is a registered Danfoss trademark Upper cover plate
212. r speed and drive output frequency is changing RUN REQ Start command given but motor will not start until a Run Permission signal is received via digital input RUNNING Motor running and speed corresponds to reference SLEEP Parameter 403 Sleep Mode Timer enabled Motor stopped in sleep mode It can restart automatically SLEEP BST Sleep boost function in parameter 406 Boost Setpoint enabled Drive is ramping up to boost setpoint STANDBY Drive able to start motor when a start command is received START Reversing and start on terminal 19 parameter 303 Digital Inputs and Start on terminal 18 parameter 302 Digital Inputs are both enabled Motor will remain stopped until either signal becomes logic 0 START DEL Start delay time programmed in parameter 111 Start Delay When delay time expires drive will start and ramp up to reference frequency START IN This status only displayed if parameter 599 Profidrive 1 selected and OFF2 or OFF3 is a logic 0 STOP Motor stopped via a stop signal from serial communication UN READY Unit ready for operation but digital input terminal 27 is logic 0 and or a Coasting Command received via serial communication XXXX Control microprocessor stopped for unknown cause and drive not operating Cause may be noise on the power line motor leads or control wires VLT is a registered Danfoss trademark WARNINGS AND ALARMS When the drive faul
213. r testing of a drive suspected of being faulty the following procedure must be followed to ensure that all circuitry in the drive is functioning properly before putting the unit into operation 1 Perform visual inspection procedures as described in Table 3 1 2 Perform static test procedures 5 1 1 5 1 2 and 5 1 5 for D frame size units or 5 1 3 5 1 4 and 5 1 5 for E frame size units to ensure drive is safe to start 3 Disconnect motor leads from output terminals U V W of drive 4 Apply AC power to drive 5 Give drive a run command and slowly increase reference speed command to approximately 40 Hz 6 Using an analog volt meter or a DVM capable of measuring true RMS measure phase to phase output voltage on all three phases U to V U to W V to W All voltages must be balanced within 8 volts If unbalanced voltage is measured refer to Input Voltage Test 5 2 1 1 7 Stop drive and remove input power Allow 40 minutes for DC capacitors to fully discharge for E frame size drives or 20 minutes for D frame size drives 8 Reconnect motor leads to drive output terminals U V W 9 Reapply power and restart drive Adjust motor speed to a nominal level 10 Using a clamp on style ammeter measure output current on each output phase All currents should be balanced If unbalanced current is measured refer to Current Sensor Test 5 2 12 VLT is a registered Danfoss trademark 5 29 SECTION 6
214. re defective This assumes of course that the proper DC bus voltage was read at power card connector MK105 A and B Replace the power card in accordance with the disassembly procedures in Section 6 or 7 5 2 3 Zero DC Bus Voltage Test If no voltage is present at power card connector MK105 and B check the condition of the DC power supply fuse For D size frames the DC power supply fuse is located beneath the power card For E size frames the fuse is located on the power card mounting plate next to the power card It can be tested without disassembling the unit 1 Remove power to drive and ensure DC bus is fully discharged by measuring voltage at power card connector MK105 A with respect to MK105 B CAUTION If DC power supply fuse is open blown it is not possible to detect the presence of bus voltage at these terminals If uncertain wait 20 minutes for D frame sizes or 40 minutes for E frames sizes to allow DC bus to fully discharge 2 With ohmmeter set on diode scale or Rx100 measure from power card connector MK105 A to any bus bars coming from DC inductor Bus bars are visible at lower edge and beneath power card mounting bracket Depending on bus bar read look for a diode drop or complete Short In either case this indicates a fuse is in the circuit providing a path for continuity An open reading indicates open fuse If the fuse is open it indicates a failure of the power supplies on the power car
215. retaining nut Sr 0 Upper cover plate Upper cap bank assy retaining nuts Wu Lower cover plate retaining nut Gate drive card Lower cap bank assy retaining nuts Figure 6 5 D2 Upper and Lower Capacitor Bank Assemblies 6 3 Single Capacitor Bank D1 Units Remove control card cassette in accordance with Retaining nuts instructions Step 2 2 Remove 2 capacitor bank retaining nuts 10mm from DC bus bars A minimum 4 in 100mm extension is required Tu e cot d e Er gt mmi 3 Disconnect MK102 MK103 MK104 and MK106 Bags from gate drive card Also remove MK105 for 1o e units with extended brake and MK101 for units D e with RFI filter Note that IGBT g
216. riations in the phase to phase input voltage and to some degree single phase loads within the drive itself A current measurement of each phase will reveal the balanced condition of the line To obtain an accurate reading it will be necessary for the drive to run at its rated load or not less than 4096 load 1 Perform input voltage test prior to checking current in accordance with procedure Voltage imbalances will automatically result in a corresponding current imbalance 2 Apply power to drive and place it in run 3 Using a clamp on amp meter analog preferred read current on each of three input lines at L1 R L2 S and L3 T Typically the current should not vary from phase to phase by more than 596 Should a greater current variation exist it would indicate a possible problem with the main supply to the drive or a problem within the drive itself One way to determine if the mains supply is at fault is to swap two of the incoming phases This assumes that two phases read one current while the third is more than 596 different If all three phases are different from one another it would be difficult to determine which leads to swap 4 Remove power to drive 5 Swap phase that appears to be incorrect with one of other two phases 6 Reapply power to drive and place it in run 7 Repeat current measurements If the phase imbalance moves with swapping the leads then the main supply is suspect Otherwise it may ind
217. rm VLT Out Heatsink Over Temperature Degrees C Mains Phase Warning 5 sec dela DC Bus Ripple VAC Mains Phase Alarm 25 sec delay DC Bus Ripple VAC Fan On Low Speed Temperature Degrees C Fan On High Sped Temperature Degrees C Fan Off Temperature Degrees C Fan Voltage Low Speed Fan VAC Fan Voltage High Speed Fan VAC VLT is a registered Danfoss trademark Intro 9 Ratings Table 525 600V 525 690V Mains supply 3 x 525 690 V 5000 amp 8000 Series Mains supply 3 x 525 600 V 6000 Series Model number VLT 5402 VLT 5502 5602 VLT 6502 6602 VLT 6652 VLT 8502 8602 8652 Normal overload current ratings 110 96 Output current Nominal A 525 550 V MAX 60 sec A 525 550 V Nominal A 551 690 V MAX 60 sec A 551 690 V Nominal kVA 550 V Nominal kVA 575 V Nominal kVA 690 V Typical shaft output kW 550 V HP 575 V kW 690 V High overload torque 160 96 Output current Nominal A 525 550 V MAX 60 sec A 525 550 V Nominal A 551 690 V MAX 60 sec A 551 690 V Nominal kVA 550 V Nominal kVA 575 V Nominal kVA 690 V Typical shaft output kW 550 V HP 575 V kW 690 V Power loss Norm
218. roblem persists replace the control card in accordance with the disassembly procedures in Section 6 or 7 5 2 2 Switch Mode Power Supply SMPS Test The SMPS derives its power from the DC bus The first indication that the DC bus is charged is the DC bus charge indicator being lit This LED however can be lit at a voltage still to low to enable the power supplies First test for the presence of the DC bus 1 Using a voltmeter read DC bus voltage at power card connector MK105 A with respect to MK105 B Meter should indicate approximately 1 38 x AC input voltage to drive 2 If voltage is correct proceed to set 3 If voltage is present but out of range proceed to DC Under Voltage test If voltage is at zero proceed to Zero DC Bus Voltage test 3 Test remaining power supplies Insert signal test board into interface card connector MK104 4 Connect negative meter lead to terminal 4 common of signal board With positive meter lead check the following terminals on signal board Terminal Supply Voltage Range 11 18V 16 5 to 19 5 VDC 12 18V 16 5 to 19 5 VDC 23 24V 23 to 25 VDC 24 5V 4 75 to 5 25 VDC In addition the signal test board contains three LED indicators that indicate the presence of voltage as follows Red LED 18VDC supplies present Yellow LED 24VDC supply present Green LED 5VDC supply present The lack of any one of these power supplies indicates the low voltage supplies on the power card a
219. s a defective soft charge resistor Replace resistor in accordance with disassembly procedures in Section 7 Continue tests Should the resistor be defective and a replacement not readily available the remainder of the tests can be carried out by disconnecting the cable at connector MK4 on the soft charge card and placing a temporary jumper across pins A and B This provides a path for continuity for the remaining tests Ensure any temporary jumpers are removed at the conclusion of the tests For the following tests set the meter to diode check or Rx100 Scale 2 Connect negative meter lead to positive A DC output to DC bus and connect positive meter lead to MK1 terminals R S and T in turn Each reading should show a diode drop 3 Reverse meter leads with positive meter lead to positive MK3 A Connect negative lead to MK1 terminals R S and T in turn Each reading should show open 5 8 VLT is a registered Danfoss trademark 4 Connect positive meter lead to negative C Connect negative meter lead to MK1 terminals R S and T in turn Each reading should show a diode arop 5 Reverse meter leads with negative meter lead to negative MK3 C Connect positive meter lead to MK1 terminals R S and T in turn Each reading should show open An incorrect reading here indicates the soft charge rectifier is faulty The rectifier is not serviced as a component Re
220. s information for calculating the output waveform in response to the changing demands of the application Parameter 107 activates the automatic motor adaptation AMA function When AMA is performed the drive measures the electrical characteristics of the motor and sets various drive parameters based on the findings Two key parameter values Set by this function are stator resistance and stator reactance parameters 108 and 109 If unstable motor operation is experienced and AMA has not been performed it should be done AMA can only be performed on single motor applications within the programming range of the drive Consult the instruction manual for more on this function Parameters 108 and 109 as stated should be set by the AMA function values supplied by the motor manufacturer or left at the factory default values Never adjust these parameters to random values even though it may seem to improve operation Such adjustments can result in unpredictable operation under changing conditions Parameter 221 Torque Limit sets the limit for drive torque The factory setting is 16096 for VLT 5000 series and 11096 for VLT 4000 6000 8000 series and will vary with motor power setting For example a drive programmed to operate a smaller rated motor will yield a higher torque limit value than the same drive programmed to operate a larger size motor It is important that this value not be set too low for the requirements of the application In some
221. s to the incorrect gate signal reading VLT is a registered Danfoss trademark 5 19 5 2 8 Output Phase Imbalance Test Checking the balance of the drive output voltage and current measures the electrical functioning between the drive and the motor In testing the phase to phase output both voltage and current are monitored It is recommended that static tests on the inverter section of the drive be conducted prior to this procedure If the voltage is balanced but the current is not this indicates the motor is drawing an uneven load This could be the result of a defective motor a poor connection in the wiring between the drive and the motor or if applicable a defective motor overload If the output current is unbalanced as well as the voltage the drive is not gating the output properly This could be the result of a defective power card gate drive connections between the gate drive card and IGBTs or the output circuitry of the drive improperly connected NOTE Use an analog volt meter for monitoring output voltage Digital volt meters are sensitive to waveform and switching frequencies and commonly return erroneous readings The initial test can be made with the motor connected and running its load If suspect readings are recorded then the motor leads may have to be disconnected to further isolate the problem 1 Using a volt meter measure AC output voltage at drive motor terminals 96 U 97 V and 98 W Me
222. s to the power card where they are buffered and delivered to the control card These current Signals are used by the control card logic to determine proper waveform compensations based on load conditions They further serve to detect overcurrent conditions including ground faults and phase to phase shorts on the output 2 8 VLT is a registered Danfoss trademark During normal operation the power card and control card are monitoring various functions within the drive The current sensors provide current feedback information The DC bus voltage and AC line voltage are monitored as well as the voltage delivered to the motor A thermal sensor mounted on the heatsink provides temperature feedback Figure 2 6 Output Voltage and Current Waveforms 0 TB2 e c2 C4 HH H mE ur UP VP WP x T aj v IW 2d M s zl UN VN WN
223. sections of this manual provide symptoms alarms and other conditions which require additional test procedures to further diagnose the drive The results of these tests indicate the appropriate repair actions Again because the drive monitors input and output signals motor conditions AC and DC power and other functions the source of fault conditions may exist outside of the drive itself Testing described here will isolate many of these conditions as well Sections 6 and 7 Disassembly and Assembly Instructions describes detailed procedures for removing and replacing drive components as required D or E sized drives respectively Drive testing is divided into 5 1 Static Tests 5 2 Dynamic Tests and 5 3 Initial Start Up or After Repair Drive Tests Static tests are conducted without power applied to the drive Most drive problems can be diagnosed simply with these tests Static tests are performed with little or no disassembly The purpose of static testing is to check for shorted power components Perform these tests on any unit suspected of containing faulty power components prior to applying power AWARNING For dynamic test procedures main input power is required All line powered devices and power supplies are energized at rated voltage Use extreme caution when conducting tests on a powered drive Contact with powered components could result electrical shock and personal injury Dynamic tests are performed with power applied
224. shing oci iced eade 3 3 3 1 4 WRONG or WRONG LCP Displayed sse eere ttes 3 3 3 2 MOTOR 3 4 3 2 1 MOtOE WII MOEN UI iss s s eio oriens rsen nuc lanes ema te deus runs 3 4 3 2 2 Incorrect Motor Operation terc eim ec e ces 3 5 Table of Contents continued 3 3 WARNING AND ALARM MESSAGES 3 6 9 4 AFTER REPAIPTESTS nri ede ee erp obe Melia iia btc 3 13 SECTION 4 DRIVE AND MOTOR 4 1 Torque Limit Current Limit and Unstable Motor Operation esses 4 1 Overvolt dge Trips 22 1 2 etr teat Perge Latine de ere Boetii hd debate dece 4 2 Mains Phase Loss Trips accent tt decet refte ree fe a do a saa a a dede n 4 2 Control Logic Problems cesssssecsecseseessscteseesteseenesseseateseesteaceneeaeenesnsseeateseesteaeenssnseeatesteateatense 4 3 Programming Problems fccit date o te a a 4 3 Motor Load Problem 4 3 INTERNAL DRIVE PROBLEMS iint ctia itu tte 4 4 Overtemperature Faults sees esses netten tette treten tentat 4 4 Current Sensor Faults 2 2 4 4 Signal and Power W
225. sistor 76 VLT is a registered Danfoss trademark 7 10 SCR and Diode Modules 5 Remove wire retaining nut 8 mm from SCR 1 Remove lower DC capacitor bank in accordance output bus bars BB42 One from DC bus bar with procedure and one from DC bus bar 2 Remove input terminal plate in accordance with 6 Note color coding for each wire attached to procedure retaining studs Ensure that correct wire is attached to applicable stud upon reassembly 3 Remove wire retaining nut 10 mm from each of Remove wiring from studs 3 SCR input bus bars BB41 7 Remove 4 retaining nuts 13 mm on side of bus 4 Note color coding for each of 3 wires attached to bars 2 on each bus bar retaining studs Ensure that correct wire is attached to applicable stud upon reassembly CONTINUED NEXT PAGE Remove wiring from studs Retaining nuts Step 7 Wire retaining nut on bus bar BB41 Step 3 i Ss TE C i SCR module J c 6 AA o amp 9 d Diode module o 7 jo Y lt C 9 9 9 y f SAI 9 IC D icr cl Wire retaining nuts for dL output bus bars 42 00 am Steps 5 amp 6 r 3 D
226. st Cable Connector and SCR Shorting Plug VLT is a registered Danfoss trademark 5 1 5 0 TEST PROCEDURES 5 1 STATIC TEST PROCEDURES Alltests should be made with a meter capable of testing diodes Use a digital volt ohm meter VOM set on the diode scale or an analog ohmmeter set on Rx100 scale Before making any checks disconnect all input motor and brake resistor connections Figure 5 1 nterface PCA and Power Card PCA Connector Identification is provided as a reference for finding the appropriate connectors described in the test procedures in this section Some connectors are optional and not on all drive configurations MK100 MK104 MK102 MK103 2 MK111 Interface Card FK100 MK110 XN NN CLE acc an zi ANN FK100 FK101 Loa NOTE For best troubleshooting results it is recommended that static test procedures described in this section be performed in the order presented Diode Drop A diode drop reading will vary depending on the model of ohmmeter Whatever the ohmmeter displays as a typical forward bias diode is defined as a diode drop in these procedures With a typical DVM the voltage drop across most components will be around 300 to 500 The opposite reading is referred to as infinity and most DMVs will display the value OL for overload Current scaling card MK102 MK104 MK105 A DC MK105 B DC MK400 MK107 Power Card Fig
227. steners 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 TB1 2 3 4 176F8373 SPARE LABEL SET TERMINAL BLK VLT5122 5302 Mains motor load share and brake terminal block label set 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 TB1 2 BB10 176F8374 SPARE BB TERMINAL MAINS MOTOR VLT51 22 5152 Mains and motor terminals Includes fasteners 6 6 6 6 6 6 6 6 6 TB1 2 BB33 176F8375 SPARE BB TERMINAL MAINS MOTOR VLT5202 5302 Mains and motor terminals Includes fasteners 6 6 6 6 6 6 6 TB3 BB13 176F8395 SPARE BB TERMINAL LS BK VLT5122 5302 Brake terminals Includes fasteners 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 BB16 176F8395 SPARE BB TERMINAL LS BK VLT5122 5302 Load share terminals 2 2 2 2 2 2 2 2 2 TB4 BB38 176F8399 SPARE BB TERMINAL LS LT VLT5202 5302 Load share terminal left Includes fasteners 1 1 1 1 1 1 1 4 BB37 176F8404 SPARE BB TERMINAL LS RT VLT5202 5302 Load share terminal right Includes fasteners 1 1 1 1 1 1 1 PCA3 176F8470 SPARE INSUL MYLAR IF BOARD VLT5122 5302 Mylar insulator for Interface PCA manufactured prior to week 33 2004 1 1 1 1 1 176F3330 SPARE Insul Mylar IGBT Bus D2 Frame Mylar insulator under IGBT input bus bar assemblies 1 1 1 1 1 1 176 8545 SPARE Insul Mylar IGBT Bus D1 Frame Mylar insulator under IGBT input bus bar assem 1 1 1 1 1 1 1 1 1 176F8546 SPARE Insul between mains fuse T6 7 Insulator between mains fuses 1 1 1 1 176F8547 SPARE Insul IGBT snubber cap support Mounts between IGBT and snubber capacitor One per IGBT mod
228. stered Danfoss trademark Intro 11 SECTION 1 OPERATOR INTERFACE AND DRIVE CONTROL INTRODUCTION VLT drives are designed with self diagnostic circuitry to isolate fault conditions and activate display messages which greatly simplify troubleshooting and service The operating status of the drive is displayed in real time Virtually every command given to the drive results in some indication on the local control panel LCP display Fault logs are maintained within the drive for fault history The drive monitors supply and output voltages along with the operational condition of the motor and load When the drive issues a warning or alarm it cannot be assumed that the fault lies within the drive itself In fact for most service calls the fault condition will be found outside of the drive Most of the warnings and alarms that the drive displays are generated by response to faults outside of the drive This service manual provides techniques and test procedures to help isolate a fault condition whether in the drive or elsewhere Familiarity with the information provided on the display is important Additional diagnostic data can be accessed easily through the LCP Normal Display In normal operational mode after start up the top line of the display line 1 identifies the value displayed in line 2 The large display line 2 shows a value in this case the drive output in hertz The setup number and direction of motor rotation is also sho
229. t IGBT failures may be caused by the drive being exposed to repeated short circuits or ground faults or by extended drive operation outside of its normal operating parameters Following an IGBT failure it is important to verify the gate drive signals are present and of the correct waveform See the dynamic test section on checking IGBT gate drive signals 5 1 5 5 Gate ResistorTest Mounted to each IGBT module is an IGBT gate resistor board containing among other components the gate resistors for the IGBT transistors Based on the nature of the failure a defective IGBT can produce good readings from the previous tests In nearly all cases the failure of an IGBT will result in the failure of the gate resistors Located on the gate drive card near each of the gate signal leads is a 3 pin test connector These are labeled MK 250 350 450 550 650 750 and if the drive is equipped with a brake option 850 For the sake of clarity refer to the 3 pins as one two and three reading left to right Pins 1 and 2 of each connector are in parallel with the gate drive signal sent to the IGBTs Pin 1 is the signal and Pin 2 is common 1 With ohm meter measure pins 1 and 2 of each test connector Reading should indicate 7 8K ohms for units with single IGBT module 3 9K ohms for units with dual IGBT modules and 2 6K ohms for units with three IGBT modules Incorrect Reading An incorrect reading indicates that either the gate signal wires
230. t circuitry detects a fault condition or a pending fault a warning or alarm is issued A flashing display on the LCP indicates an alarm or warning condition and the associated number code on line 2 A warning may precede an alarm Table 1 3 Fault Messages defines whether or not a waming precedes an alarm and whether the drive suspends operations trips Alarms An alarm causes the drive to trip suspend operation The drive has three trip conditions which are displayed on line 1 TRIP RESET TORQUE LIMIT TRIP AUTO RESTART means the drive is programmed to restart automatically after the fault is removed The number of automatic reset attempts may be continuous or limited to a programmed number of attempts This will change to TRIP RESET if the selected number of automatic reset attempts is exceeded TRIP RESET requires resetting the drive prior to operation after a fault is cleared The drive can be reset manually by pressing the reset key on the keypad a digital input or a serial bus command For VLT 5000 series drives the stop and reset key are the same If the stop rest key is used to reset the drive the start key must be pressed to initiate a run command in either local or remote TRIPLOCK DISC MAINS requires that the main AC input power to the drive must be disconnected long enough for the display to go blank The fault condition must be removed and power reapplied Following power up the fault indication will
231. taining the DC coils often referred to as the intermediate or DC bus circuit and the output IGBT modules which make up the inverter Section In conjunction with the SCR Diode modules the soft charge circuit limits the inrush current when power is first applied and the DC bus capacitors are charging This is accomplished by the SCRs in the modules being held off while charging current passes through the soft charge resistors thereby limiting the current The DC bus circuitry smoothes the pulsating DC voltage created by the conversion from the AC supply The DC coil is a single unit with two coils wound on a common core One coil resides in the positive side of the DC bus and the other in the negative The coil aids in the reduction of line harmonics The DC bus capacitors are arranged into a capacitor bank along with bleeder and balancing circuitry Due to the requirement for higher power capacity some drives have two capacitor banks connected in parallel RECTIFIER SCR DICDES CIRCUIT 1 L2 gt L3 gt SOFT CHARGE CIRCUITRY INTERMEDIATE B A The inverter section is made up of six IGBTs commonly referred to as switches One switch is necessary for each half phase of the three phase power for a total of six The six IGBTs are contained in a single module Due to higher current handling requirements some models contain two or three larger six
232. the motor will continue to run but not in the correct manner The symptoms and causes may vary considerably Many of the possible problems are listed below by symptom along with recommended procedures for determining their causes Wrong Speed Unit Will Not Respond To Command Possible incorrect reference speed command Ensure that the unit is programmed correctly according to the reference signal being used and that all reference limits are Set correctly as well Perform Input Terminal Signal Test in section 5 to check for faulty reference signals Motor Speed Unstable Possible incorrect parameter settings faulty current feedback circuit loss of motor output phase Check settings of all motor parameters including all motor compensation settings Slip Compensation Load Compensation etc For Closed Loop operation check PID settings Perform Input Terminal Signal Test in section 5 to check for faulty reference signals Perform Output Phase Imbalance Test in section 5 to check for loss of motor phase Motor Runs Rough Possible over magnetization incorrect motor settings or an IGBT misfiring Note Motor may also stall when loaded or the drive may trip occasionally on Alarm 13 Check setting of all motor parameters Perform Output Phase Imbalance Test in section 5 If output voltage is unbalanced perform Gate Drive Signal Test in section 5 Motor Draws High Current but Cannot Start Possible open winding in
233. this procedure Tighten mounting T omo ca Ex yi i screws to 20 in lbs 2 25 Nm upcalansauentennaeneuh gun mn E 7 6 Soft Charge Card 1 Disconnect MK1 MK2 MK3 and MK4 cusa ure CENSUM 2 Remove 4 mounting screws T25 from standoffs Fi igure 7 3 Gate Drive Car 3 Remove soft charge card Note insulation sheet below soft charge card Remove and keep insulation with card for reinstallation Reinstall by mounting insulation onto standoffs Mount soft charge Nm card and tighten mounting screws to 20 in Ibs 2 3 MK4 MK2 Mounting screw Step 2 MK3 Figure 7 4 Soft Charge Card Assy VLT is a registered Danfoss trademark 7 3 7 7 T f 1 Upper Capacitor Bank Reinstall in reverse order of this procedure Tighten electrical connection nuts 8 mm to 20 in Ibs 2 3 Nm and mechanical Remove control card cassette and gate drive card in accordance with instructions Capacitor bank connection to DC bus bars can be seen recessed in gap between upper and lower capacitor banks Minimum 6 inch 150 mm extension required Remove 6 electrical connection nuts 8 mm for upper capacitor bank from DC bus bars Remove control card cassette mounting bracket by remove 3 nuts 10 mm Remove 4 retaining nuts 10 mm from capacitor bank and remove air dam Note that the weight of capacitor bank is approximately 20 pounds 9 kg Remove c
234. ting breakers perform static tests described in section 5 1 If the Input Voltage Test was successful check for voltage to the control card 5 2 1 2 Basic Control Card Voltage Test 1 Use voltmeter to measure 24 VDC control voltage at terminal 12 with respect to terminal 20 Meter should read between 21 and 27 VDC If an external 24 VDC supply is used for control voltage it would be likely for switch 4 on the control card to be open This opens the common connection to terminal 20 If this is the case measure terminal 12 with respect to terminal 39 An incorrect reading here could indicate the supply is being loaded down by a fault in the customer connections Unplug the terminal strip and repeat the test If this test is successful then continue Remember to check out the customer connections If still unsuccessful proceed to the Switch Mode Power Supply SMPS test 2 Measure 10 V DC control voltage at terminal 50 with respect to terminal 55 Meter should read between 9 2 and 11 2 VDC An incorrect reading here could indicate the supply is being loaded down by a fault in the customer connections Unplug the terminal strip and repeat the test If this test is successful than continue Remember to check out the customer connections If still unsuccessful proceed to the SMPS test A correct reading of both control card voltages would indicate the LCP or the control card is defective Replace the LCP with a known good one If the p
235. ting screw Step 10 Step 9 Figure 7 8 SCR and Diode Modules 2 of 3 7 8 VLT is a registered Danfoss trademark 11 Note which gate lead connects to each SCR REASSEMBLY module Ensure that correct wire is attached to applicable SCR upon reassembly Remove wiring CAUTI from each SCR modules Connector is keyed for i proper reinstallation DO NOT force connection Equipment Damage Do not reverse SCR and diode modules during installation Reversing SCR and diode modules 12 Remove SCR or diode module by removing 4 can result in equipment damage retaining screws T25 from each module Note For each AC input phase there is one SCR module and one diode module The SCR is on the left diode on the right as seen facing upright unit There are three pair Only the SCR module has a connection pin for the gate signals 1 Replace SCR and diode modules in accordance with instructions included with replacement modules 2 Reassemble in reverse order Attaching Hardware Tightening Torque T50 Per spare part instruction T25 Per spare part instruction 17mm 170 in lbs 19 2 Nm 13 mm 85 in lbs 9 6 Nm 10 mm 35 in lbs 4 0Nm 8 mm 20 in lbs 2 25 Nm Diode module D1 Diode module D2 Diode module D3 SCR gate lead connection Step 11 SCR module SCR1 Retaining screw Step 12 SCR module SCR2 Figure 7 8
236. to W V to W All voltages must be balanced within 8 volts If unbalanced voltage is measured refer to Input Voltage Test 5 2 1 1 Stop drive and remove input power Allow 40 minutes for DC capacitors to fully discharge for E frame size drives or 20 minutes for D frame size drives Reconnect motor leads to drive output terminals U V W Reapply power and restart drive Adjust motor speed to a nominal level 10 Using a clamp on style ammeter measure output current on each output phase All currents should be balanced If unbalanced current is measured refer to Current Sensor Test 5 2 12 VLT is a registered Danfoss trademark 3 13 SECTION 4 DRIVE AND MOTOR APPLICATIONS Torque Limit Current Limit and Unstable Motor Operation Excessive loading of the drive may result in warning or tripping on torque limit over current or inverter time This is not a concern if the drive is properly sized for the application and intermittent load conditions cause anticipated operation in torque limit or an occasional trip However nuisance or unexplained occurrences may be the result of improperly setting specific parameters The following parameters are important in matching the drive to the motor for optimum operation These setting need careful attention particularly for the selectable torque drives of the VLT 5000 series For the VLT 4000 6000 8000 series torque settings are constant Parameters 1
237. to positive DC bus connector MK105 A on power 2 Connect positive meter lead to U V and W in turn Each reading should show a diode drop Incorrect Reading An incorrect reading in any inverter test indicates a failed IGBT module Replace the IGBT module in accordance with the disassembly instructions in Section 6 or 7 It is further recommended for units with two IGBT modules that both modules be replaced even if the second module tests correctly 5 1 5 3 Inverter Test Part Ill 1 Connect positive meter lead to the negative DC bus connector MK105 B on power card 2 Connect negative meter lead to terminals U V and W in turn Each reading should show a diode drop 5 1 5 4 Inverter Test Part IV 1 Reverse the meter leads by connecting negative meter lead to negative DC bus connector MK105 B on power 2 Connect positive meter lead to U V and W in turn Each reading should show infinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the drive being charged by the meter Incorrect Reading An incorrect reading in any inverter test indicates a failed IGBT module Replace the IGBT module in accordance with the disassembly instructions in Section 6 or 7 It is further recommended for units with two IGBT modules that both modules be replaced even if the second module tests correctly Indications of a failure in this circui
238. to provide an operational overview of the drive s main assemblies and circuitry With this information arepair technician should have a better understanding of the drive s operation and aid in the troubleshooting process The VLT series drives covered in this manual are very similar in design and construction For the purpose of troubleshooting two main differences exist First the control card and LCP for the VLT 5000 series differs from that of the other three series Second the power section is rated differently in a constant torque drive VLT 5000 versus a variable torque drive The power section of a 125 hp VLT 5000 series is similar to that of a 150 hp in the other three series and so on To simplify the discussion this section refers to the constant torque VLT 5000 drives except where necessary to detail specific variations DESCRIPTION OF OPERATION An adjustable frequency drive is an electronic controller that supplies a regulated amount of AC power to a standard three phase induction motor in order to control the speed of the motor By supplying variable frequency and voltage to the motor the drive controls the motor speed or maintains a constant speed as the load on the motor changes The drive can also stop and start a motor without the mechanical stress associated with a line start In its basic form the drive can be divided into four main sections rectifier intermediate circuit inverter and control and regulation s
239. try located on the power card Control Panel DATA ADRESS 1 D lt lt VNC Lege ANALOGO PLUS INPUTS lt 2 POWERD FEEDBACK lt DIGITALO INPUTS 2 9 2 m 1 e 2 gt CONTROL POWER lt 1 D gt ANALOG OUTPUTS 1 DIGITALO CHANNEL gt 1 RELAY Figure 2 2 Logic Section VLT is a registered Danfoss trademark 2 1 The PWM waveform is created using an improved control scheme called a further development of the earlier VVC Voltage Vector Control system VVCP 5 provides a variable frequency and voltage to the motor which matches the requirements of the motor The dynamic response of the System changes to meet the variable requirements of the load Another part of the logic section is the local control panel LCP This is a removable keypad display mounted on the front of the drive The keypad provides the interface between the drive s internal digital logic and the operator All the drive s programmable parameter settings can be uploaded into the EEPROM of the LCP This function is useful for maintaining a back up drive profile and parameter set It can also be used through its download function in programming other drives or to restor
240. ts would be called for and what the signal should be at that given test point 8 2 VLT is a registered Danfoss trademark Signal Test Board Pin Outs Description and Voltage Levels The tables on the following pages list the pins located on the signal test board For each pin its function description and voltage levels are provided Details on performing tests using the test fixture are provided in Section 5 of this manual Other than power supply measurements most of the signals being measured are made up of waveforms Although in some cases a digital voltmeter can be used to verify the presence of such signals it cannot be relied upon to verify that the waveform is correct An oscilloscope is the instrument prefered However when similar signals are being measured at multiple points a digital voltmeter can be used with some degree of confidence By comparing several signals to each other such as gate drive signals and obtaining similar readings it can be concluded each of the waveforms match one another and are therefore correct Values are provided for using a digital volt meter for testing as well Pin Schematic Function Description Reading Using a Digital No Acronym Volt Meter 1 IU1 Current sensed U phase not conditioned 2 IV1 Current sensed V phase not conditioned Current sensed W phase not conditioned COMMON AMBT N ANO INRUSH Control Card signal RL1 Control Card signal Signal to Co
241. twisted pair or proprietary cables Refer to the manufacturer s documentation when selecting these cables Similar recommendations apply to serial communication cables as to other signal cables Using twisted pair cables and routing them away from power conductors is encouraged While shielded cable provides additional EMI protection the shield capacitance may reduce the maximum allowable cable length at high data rates Proper EMC Installation Shown in Figure 4 5 is a correct installation with EMC considerations in mind Although most installations will not follow all the recommended practices the closer an installation resembles this example the better immunity the network will have against EMI Should EMI problems arise in an installation refer to this example Attempt to replicate this installation recommendation as closely as possible to alleviate such problems AN cable eniries In one side of panel PE min 10 Figure 4 5 Proper EMC Installation 4 8 VLT is a registered Danfoss trademark SECTION 5 TEST PROCEDURES INTRODUCTION AWARNING Touching electrical parts of drive may be fatal even after equipment has been disconnected from AC power Wait 20 minutes for D frame sizes or 40 minutes for E frame sizes after power has been removed before touching any internal components to ensure that capacitors have fully discharged This section contains detailed procedures for testing VLT drives Previous
242. ty cycle Monitors Brake resistor Heatsink temp Ambient temp power supplies voltages Temperature BRT_ON Voltage out of OTFLT range FAN TST Control signal for Indicates Fan Test switch is activated to force the fans on high fans FAN ON Pulse train to gate SCR s for fan voltage control In sync with line freq pulses at 3Khz Control signal for SCR front end Indicates SCR front end is enabled or disabled Disables IGBT gate voltages Ground signal to enable RFI HF capacitors Signal proportional to UDC SCR DIS Control signal from Power Card Control signal for RFI Bus Voltage scaled down 23 VDD 24 VDC power Yellow LED indicates voltage is present supply 5 0 VDC Green LED indicates voltage is present regulated supply 4 75 5 25 VDC 8 4 VLT is a registered Danfoss trademark Voltage drops to zero when brake is turned off Voltage increases to 4 04 VDC as brake duty cycle reaches max 5 10 VDC level with the brake turned off Voltage decreases to zero as brake duty cycle reaches max 5VDC No fault OVDC Fault 5VDC disabled OVDC fans on high 5VDC fans off 4 3VDC fans on 1 HI LOW Control signal Signal to switch fan speeds between high and low 5VDC fans on high from Power Card Otherwise OVDC 0 6 to 0 8 VDC SCRs enabled OVDC SCR disabled 5VDC inverter disabled OVDC inverter enabled 24VDC no RFI OVDC RFI enabled 380 500 V 1
243. ually no associated fault indication The typical complaint is simply that the drive does not respond to a given command There are two basic commands that must be given to any drive in order to obtain an output First the drive must be told to run start command Second the drive must be told how fast to run reference or speed command The drives are designed to accept a variety of signals First determine what types of signals the drive is receiving There are eight digital inputs terminals 16 17 18 19 20 27 29 32 33 three analog inputs 53 54 60 and the serial communication bus 68 69 The presence of a correct reading will indicate that the desired signal has been detected by the microprocessor of the drive See Drive Inputs and Outputs in Section 1 Using the status information displayed by the drive is the best method of locating problems of this nature By changing parameter 009 VLT 5000 or parameter 007 VLT 4000 6000 8000 line 2 of the display can be set to indicate the signals coming in The presence of a correct reading indicates that the desired signal is detected by the microprocessor of the drive If there is not a correct indication the next step is to determine whether the signal is present at the input terminals of the drive This can be performed with a voltmeter or oscilloscope in accordance with the 5 2 14 Input Terminal Signal Test If the signal is present at the terminal the control card is
244. ule 1 1 2 2 2 1 1 1 1 1 1 1 2 2 2 2 VLT is a registered Danfoss trademark 9 3 OWA 08t 08 OWA 097 085 OVA 005 085 Jed OWA 009 929 2VA 069 929 Jed pagsipa e 5 7 6 1591 VOd 2069 221 4 1 S3 EVO 5 68783971 p1eoq 158 jeuDis 2069 22 LG L TA QUVOG DIS VOd HMd 10013uvds 18783971 1001 vS ied vs iear verear verear vs iear vs tear vs teat aerd durejo ejqeo 31v 1d H1HV3 3HVdS 1 v83971 vs kedl vs tear verear verear vs teat verear verear vs tear durejo 1 MOd 2069 22 LS L A WIWO9 318v9 3HVdS 0578394 00 00 00d 00d O0dl 20 S 20cS LTA LOG 4 45 95783911 00 00 O0dl O0
245. unction as commanded It must be remembered that for every control terminal input or output there are corresponding parameters settings These determine how the drive responds to an input signal or the type of signal present at that output Utilizing an function must be thought of as a two step process The desired I O terminal must be wired properly and the corresponding parameter must be set accordingly Control terminals are programmed in the 300s parameter group Motor Load Problems Problems with the motor motor wiring or mechanical load on the motor can develop in a number of ways The motor or motor wiring can develop a phase to phase or phase to ground short resulting in an alarm indication Checks must be made to determine whether the problem is in the motor wiring or the motor itself A motor with unbalanced or non symmetrical impedances on all three phases can result in uneven or rough operation or unbalanced output currents Measurements should be made with a clamp on style ammeter to determine whether the current is balanced on the three output phases See 5 2 8 Output Phase Imbalance Test procedure An incorrect mechanical load will usually be indicated by a torque limit alarm or warning Disconnecting the motor from the load if possible can determine if this is the case Quite often the indications of motor problems are similar to those of a defect in the drive itself To determine whether the problem is interna
246. ure 5 1 Interface PCA and Power PCA Connector Identification 5 2 VLT is a registered Danfoss trademark 5 1 1 Soft Charge and Rectifier Circuits Test D frame Size Both the rectifier and soft charge circuits are tested simultaneously The soft charge circuit is made up of the soft charge rectifier fuses and the soft charge resistor The rectifier circuit is made up of the SCR Diode modules The soft charge resistor limits the inrush current when power is applied to the drive The soft charge circuit card also provides snubbing for the SCRs It is important to pay close attention to the polarity of the meter leads to ensure identification of a faulty component should an incorrect reading appear Prior to making the test it is necessary to ensure the soft charge fuses F1 F2 and F3 located on the soft charge card are good Figure 5 2 shows the soft charge card and the location of the fuses It is for reference only It is not necessary to remove the card to perform the tests 5 1 1 1 Soft Charge FuseTest Use a digital ohmmeter to test continuity on rectifier fuses F1 F2 and F3 at connector MK106 on the power card NOTE If unit has fused disconnect option make test connections L1 L2 and L3 to output drive side of disconnect Do not unplug connector 1 Measure fuse F1 from mains input L1 R to MK106 pin 10 on power card 2 Measure fuse F2 from mains input L2 S to MK106 pin 8 on power card 3 Measure fuse F3 fr
247. val At a heatsink temperature of greater than 113 F 45 C the fans are switched on at low speed This equates to approximately 200 VAC applied to the fans At a heatsink temperature of more than 122 F 50 C 230 VAC is applied to the fans to obtain full speed When the heatsink temperature returns to less than 104 F 40 C the fans return to low speed Below 86 F 30 C the fans switch off Since the internal ambient temperature is maintained by one or more 230 VAC fans the transition between low and high speeds also occurs if the internal ambient rises regardless of heatsink temperature The internal ambient temperature sensor is located on the power card If the internal temperature rises to greater than 95 F 35 the fans will switch to high speed regardless of the heatsink temperature If the internal ambient temperature returns to 86 F 30 C and the heatsink temperature remains below 122 F 50 C the fans will return to low speed The fans switch to low speed should a heatsink over temperature trip occur In addition regardless of any temperature when the load current on the drive reaches 6096 of its continuous rating the fans are switched on at low speed and then follow the temperatures as listed above Load Sharing Units with the built in load sharing option contain terminals 89 DC and 88 DC Within the drive these terminals connect to the DC bus in front of the DC link reactor and bus capacitors
248. ve two types of remote input signals digital or analog Digital inputs are wired to terminals 16 17 18 19 20 common 27 29 32 and 33 Analog inputs are wired to terminals 53 54 and 55 common or terminal 60 Analog signals can be either voltage 0 to 10 VDC connected to terminals 53 and 54 or current O to 20 mA or 4 to 20 mA connected to terminal 60 Analog signals can be varied like dialing a rheostat up and down The drive can be programmed to increase or decrease output in relation to the amount of current or voltage For example a sensor or external controller may supply a variable current or voltage The drive output in turn regulates the speed of the motor connected to the drive in response to the analog signal Digital signals are a simple binary O or 1 which in effect act as a switch Digital signals are controlled by a O to 24 VDC signal A voltage signal lower than 5 VDC is a logic O A voltage higher than 10 VDC is a logic 1 Zero is open one is close Digital inputs to the drive are switched commands such as start Stop reverse coast reset and so on Do not confuse these digital inputs with serial communication formats where digital bytes are grouped into communication words and protocols The RS 485 serial communication connector is wired to terminals 68 and 69 Terminal 61 is common and may be used for terminating shields only when the control cable is run between VLT drives not between drives
249. wn The bottom line line 4 is the status line This line displays the current operational status of the drive The illustration below indicates that the drive is running at 40 HZ output Line 1 FREGUEHCY Line 2 Line 3 Line 4 RIUHHIHG Pressing the up or down keys on the keypad in this mode changes the data shown in line 2 Thirty one different diagnostic values are identified in line 1 and displayed in line 2 by scrolling through the display data Setpoints feedback operational hours digital and analog input status relay output status and many other System functions are identified and their values shown in real time lt gt DISPLAY QUICK MENU STATUS MENU CHANGE CANCEL OK DATA 42 On the VLT 4000 6000 8000 series drives the DISPLAY STATUS key is identified as the DISPLAY MODE key and operates in the same manner described DISPLAY STATUS Line 1 Pressing the DISPLAY STATUS key on the keypad toggles between the default setting and the programmable three meter display in line 1 RUHNING To identify the 3 meters displayed in line 1 press and hold the DISPLAY STATUS key The identity of the meter is displayed while the key is pressed DISPLAY STATUS REFX T ROX CURR A RUHNING The values displayed in lines 1 and 2 can be programmed from a list of options See programming in the operator s manual for details VLT is a r
250. y control node PLC in communication network Check connections on serial communication cable 3 8 VLT is a registered Danfoss trademark WARNING 20 EE ERROR CTRL CARD Fault in the EEPROM on the control card A fault exists in the ability of the VLT to read and write information to the control card EEPROM Failed EEPROM on Control Card The drive will operate normally and in most cases once the power is cycled the warning clears If the problem halts operation replacement of control card may be needed ALARM 21 AUTO MOTOR ADAPT OK Not applicable for the VLT 4000 6000 8000 Auto optimization OK The automatic motor tuning function AMA has been completed successfully It is necessary to manually reset to resume normal operation AMA Function has been completed successfully No corrective action is needed This alarm is displayed upon completion of AMA to indicate a requirement to reset the drive after performing AMA ALARM 22 AUTO MOT ADAPT FAIL Auto optimization not OK The automatic motor tuning function failed The possible causes as shown in the display are listed below The numbers in brackets will be logged as the value in parameter 617 Check settings of p 102 106 and restart AMA In case of non standard motor set p 107 to Enable and restart AMA 0 CHECK P 103 105 AMA function was unable to be carried out due to incorrect settings or incorrect results of AMA tests Parameter 1
251. ypad OFF OFF STOP activated either by means of keypad or by digital input terminals REFERENCE LOCATION REM REMOTE selected which means reference is set via input control terminals or serial communication LOCAL LOCAL selected which means reference is set with and keys on DRIVE STATUS AMA RUN Automatic motor adaptation enabled in parameter 107 Automatic Motor Adaptation AMA and drive performing adaptation function AMA STOP Automatic motor adaptation completed Drive is now ready for operation after Reset enabled Motor may start after drive reset AUTO RAMP Parameter 208 Automatic Ramp enabled Drive is attempting to avoid a trip from overvoltage by extending decel ramp time CTR READY This status only active when a Profibus option card is installed DC STOP DC brake enabled in parameters 114 through 116 FRZ OUT Drive output frequency frozen at fixed rate from input command FRZ REQ Start command to run at current frequency given but motor will not start until a Run Permission signal is received via a digital input JOG Jog enabled via digital input or serial communication Drive is running at a fixed frequency set in parameter 209 Jog Frequency JOG REQ Start command to run at jog frequency given but motor will not start until a Run Permission signal is received via a digital input NOT READY Drive not ready for operation because of a trip or because OFF1 OFF2 or OFF3 is a logic 0 RAMPING Moto

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