VLT 3000/3500 1-50 HP SM
Contents
1. oda MK200 oad MK20 MK202 ILD CARD Section Three TESTING INPUT RECTIFIERS Theoretically the input current drawn on each ofthe three input phases should be equal These currents will vary however due to variations in phase to phase input voltage and due to some single phase loads within the drive Given that the input phase voltages are equal the input currents phase to phase should not vary more than 596 Current imbalances in excess of 596 may indicate one of the diodes is not conducting properly When the VLT is lightly loaded it may not be possible to detect a current imbalance If suspect the modules should be statically tested Refer to the Static Test procedures beginning on page 3 1 REPLACEMENT PROCEDURES REMOVING amp REPLACING THE CONTROL CARD Section Four NOTE The Control Card comes mounted to a metal plate When installed this plate sits in a slot provided on the left hand side ofthe unit enclosure and is secured by two press fit mounting clips attached to the right hand side of the enclosure These mounting clips provide the earth ground connection for the Control Card If loose or damaged the Control Card may experience electrical noise problems resulting in an Except Fault see page 2 4 REMOVAL Remove the two ribbon cables from plugs MK200 and MK201 Insert a screwdriver at the points indicated2. Table of Contents Introduction Safety Precautions 0 2 icr aa eai UL GEAR UNE Sco 0 3 Section One Description of Operation cu vis va eee ta UE RU PRX es 1 1 Sequence of Operation 1 4 Section Two Fault Indicators and Messages 2 1 Troublesh ting TIDS gig Gg ad ese CX EQ Wem dake aquqa eee Y 2 5 Troubleshooting Flowchat 2 6 Symptom Cause Chart qus eate eed ao RUE NOR A 2 9 Section Three Static Test Procedures Cure dose CN dC RUE EORR EOM CARCER 3 1 Dynamic Test Procedures 3 6 Section Four Component Replacement Procedures 4 1 Section Five uere w rm mn 5 1 Ground 5 3 Overcurrent TripS 5 3 Overvoltage 5 4 Faull Memory 4 679 aU Uere Sc 5 6 Section Six Spare Parts Tables 4 4 e mere hie testes 9 6 1 Appendix Component Locations rule teritur e hw RUE o e 7 1 7 5 Block Diagrams eo Io 7 2 7 6 VLT Series Service Manual INTRODUCTION ESD SAFETY The purpose of this manual is to provide technical information and instructions that will enable the userto identify faults and affectrepairs on the following Danfoss Series 3000 and
3. ULLD VLT 3006 3032 230V VLT 3508 3532 230V VLT 3011 3052 380V 460V VLT 3511 3562 380V 460V When poweris first applied the normally open Bus Contactor forces the input line current to flow through the Positive Temperature Coefficient PTC resistors PTC resistors increase in resistance as the temperature increases The Danii SEQUENCE OF OPERATION Bus Contactor MOVs Section One PTC resistors are placed in series with the inputs of the Rectifier Module to limit the initial charge current of the DC Bus capacitors The rectified line voltage is then applied to the DC Bus filter As the DC Bus voltage increases the Interface Card power supplies energize As the power supplies stabilize the Interface Card sends a Signal to the Relay Card to pull in the Bus Contactor The Relay Card energizes the contactor coil with a short burst of a high amplitude full wave rectified voltage to pull in the Bus Contactor The Relay Card then switches the Bus Contactor coil voltage to a lower rectified holding voltage As soonas the DC Bus Contactor closes the PTC resistors are effectively removed from the circuit and the DC Bus Capacitors quickly finish charging Providing that the charging process proceeds normally the Interface Card power supplies will provide the Control Card with low voltage control power and the Control Card display will indicate that the unit is ready for operation Following a run command and a speed refere
4. Note Slight variations in phase currents are normal Variations greater than 5 require investigation POSSIBLE CAUSES Current Limit set too low One half of one inverter phase missing Test output phase balance Input line voltage unbalanced Faulty connection on input wiring Fault in plant power transformer Input Rectifier module faulty open diode Open motor winding Faulty motor connection Fault in inverter section see Symptom No 6 STATIC TEST PROCEDURES TESTING THE INPUT RECTIFIER NTC Resistors u v wee UDC UDC Section Three All tests willbe made with a meter capable of testing diodes Use a digital VOM set on diode scale or an analog ohmmeter set on R x 100 scale Before making any checks disconnect all input power motor and brake option connections CAUTION Allow sufficient time for the DC Bus to fully discharge before beginning testing The presence of bus voltage can be tested by setting your voltmeter for 1000VDC and reading the voltage at the labeled terminals shown in the drawings The purpose of making static tests on the input rectifier is to rule out failures in this device either shorted or open diodes Failure of the rectifier module will usually result in blown line fuses It should be noted that blown input line fuses can also be the result of shorts in the IGBT module s or a damaged bus capacitor See Testing the Inverter
5. 175 7086 175H7086 175H7086 175H7086 Control Card VLT 3500 175H4539 175H4539 175H4539 175H4539 175H4539 ILD Card 175 7067 175H7068 175H7069 175H7088 175 7087 ILD Card VLT 3504 175H7077 DC Card 175H7020 175H7020 175H7021 175H7022 175H7023 Six Pack IGBT 175 7017 175H7017 175H7017 175H7017 N A IGBT Module N A N A N A N A 175H7016 DC Link N A N A N A N A 175H1162 Recifier Module 612L2026 612L2026 612L2026 612L2026 612L2026 Brake Control 175H7031 175H7031 175H7031 175H7031 175H7031 Brake IGBT 175H7029 175H7029 175H7029 175H7029 175H7029 Top Fan IP54 175H0327 175 0327 175H0327 175H0327 175H0327 Only on VLT 3000 Section Six SPARE PARTS VLT 3011 3032 380 VLT 3516 3542 380 VLT 3011 3016 VLT 3022 VLT 3032 VLT 3516 VLT 3522 VLT 3532 VLT 3542 Control Card VLT 3000 175H7086 175H7086 175 7086 175H7086 Control Card VLT 3500 175H4539 175H4539 175H4539 175H4539 Interface Card VLT 3000 175H5386 175H5387 175H5388 175H5389 Interface Card VLT 3500 175H5392 175H5393 175H5394 175H5395 IGBT VLT 3500 175H0266 175H0266 175H7005 175H7005 3000 IGBT 175 0266 175H0266 175H7005 175H0268 IGBT Snubber 175 0810 175H0810 175H0810 175H0810 Recifier 612L9261 612L9261 612L
6. 175H5377 175H5379 175H5382 IGBT Module 175H5340 175H5340 175H5341 175H5341 175H4510 IGBT Snubber 175H0810 175H0810 175H0810 175H0831 175 0831 Recifier 612L9471 612L9471 612L9472 612L9473 612L9264 Relay Card 175H4481 175H4481 175H4481 175H4483 175H4485 Current Sensor N A N A N A N A 175H1789 Bus Charge Contactor 175H1761 175H1761 175H1761 175H1762 175H1762 Bus Contactor Coil Cap 175H2852 175H2852 175H2852 175H2852 175H2852 Time Delay Relay Module 047H0173 047H0173 047 0173 047 0173 047 0173 DC Cap Resistor 175H2324 175H2324 175H2324 175H2324 175H2324 DC Bus Capacitor 612B6762 612B6598 612B6708 612B6864 612B6864 Brake Control 175H5398 175H5398 175H5398 175H5398 175 5398 Brake IGBT 175 5370 175H5370 175H5370 175H5371 175H4508 MOV 175H7305 175H7305 175H7305 175H7305 175H7305 24V Internal Fan IP54 N A 175H0827 175H0827 175 0827 175H0827 Top Fan 24VDC 24VDC 24VDC 230VAC 230VAC IP20 175H0827 175H0827 175H0827 175H0761 175H0761 Top Fan AC IP54 175H0753 175H0753 175H0761 175H0761 175H1807 Only on VLT 3000 SPARE PARTS VLT 3002 3008 380V VLT 3502 3511 380V Section Six VLT 3002 VLT 3003 VLT 3004 VLT 3006 VLT 3008 VLT 3502 VLT 3504 VLT 3508 VLT 3511 VLT 3505 Control Card VLT 3000 175H7086
7. Test completed Incorrect readings indicate a damaged IGBT module See Removal and Replacement Instructions on page 4 4 Section Three STATIC TEST PROCEDURES TESTING THE HEATSINK THERMAL SWITCH DYNAMIC TEST PROCEDURES TESTING FOR OUTPUT PHASE VOLTAGE IMBALANCE There thermal switches included on all units covered by this manual The smaller drives monitor the ambient temperature within the unit The thermal switch is mounted on the ILD Card All units with Interface Cards have a stand alone thermal switch mounted on the heatsink VLT 3006 3022 230V VLT 3508 3532 230V VLT 3011 3052 380V 460V VLT 3516 3562 380V 460V The heatsink temperature is sensed by a thermal switch The thermal switch harness is connected to the top of the Interface Card at connector MK401 The switch will open when the heatsink temperature exceeds 100 C 212 F and will close when the heatsink temperature falls below 50 C 122 F By unplugging the connector from the Interface Card the thermal switch continuity can be checked When testing phase imbalances itis practical to measure both voltage and current A balanced voltage reading but unbalanced current indicates the motor is drawing uneven current This could be caused by a fault in the motor windings or in the wiring connections between the drive and motor When both voltage and current are unbalanced it indicates a switching problem or a faulty connection within the unit its
8. This message will flash when the DC Bus voltage has fallen below the lower limit This is an indication of low line voltage This is only a warning message however If the condition persists it will result in a unittrip on Under Voltage Refer to table for specific value VOLTAGE HIGH This message will flash when the DC Bus voltage has exceeded the upper limit This is an indication of high line voltage or regenerative energy being returned to the bus This is only a warning message however ifthe condition persists it will result in a unit trip on Over Voltage Refer to table for specific value INVERT TIME This message willflash when the inverter ETR value has reached 9896 The inverter ETR Electronic Thermal Relay begins counting up as soon as the output current exceeds 105 ofthe unit s continuous current rating At an inverter ETR value of 100 the unit trips on Invert Time MOTOR TIME This message will flash if Motor Thermal Protection has been activated in parameter 315 Warning has been selected as the Data Value and the Motor ETR value has reached 9896 The Motor ETR value begins counting up if the motor is run at Slow speed or if the motor is consuming more than 11696 ofthe motor s nominal rated current as entered in parameter 107 At a Motor ETR value of 10096 the unit will respond based on the setting in parameter 315 If Trip has been selected the unit will trip on Motor Time OVERCURRENT This messag
9. 175H7075 175H7076 ILD Card VLT 3511 175H7054 DC Card 175H7024 175H7024 175H7025 175H7026 175H7026 Six Pack IGBT 175 7017 175H7017 175H7017 175H7017 N A IGBT Module N A N A N A N A 175H7016 DC Link N A N A N A N A 175H1162 Recifier Module 612L9351 612L9351 612L9351 612L9351 612L9351 Brake Control Card 175H7031 175H7031 175H7031 175H7031 175H7031 Brake IGBT 175 7029 175H7029 175H7029 175H7029 175H7029 Top Fan IP54 175H0327 175H0327 175H0327 175H0327 175H0327 Insulator Foil 175H1415 175 1415 175H1415 175H1415 175H1415 Only on VLT 3000 SPARE PARTS VLT 3011 3032 460V VLT 3516 3542 460V VLT 3011 VLT 3016 VLT 3022 VLT 3032 VLT 3516 VLT 3522 VLT 3532 VLT 3542 Control Card VLT 3000 175H7086 175H7086 175H7086 175H7086 Control Card VLT 3500 175H4539 175H4539 175H4539 175H4539 Interface Card 175H5378 175H5380 175H5381 175H5383 IGBT Module 175H5342 175H5342 175H5343 175H6251 IGBT Snubber Cap 175 0810 175 0810 175H0810 175H0831 Recifier 612L9474 612L9474 612L9475 612L9476 Relay Card 175H4482 175H4482 175H4482 175H4484 Bus Charge Contactor 175H1761 175 1761 175H1761 175H1762 Bus Contactor Coil Cap 175H2852 175H2852 175H2852 175H2852 DC Capacitor 612 7095 612B7096 612B7098 612B7096
10. 21 Start VLT by pressing Start on the keypad CAUTION Prior to running in Local insure all other equipment associated with the VLT is ready to function or has been isolated 20 Is the display frozen i e the display cannot be changed or is undefinable NO YES Replace the Control Card if this does not help the fault might be electrical noise Check whether the following precautions have been taken Have shielded cables been used Are the shields correctly terminated Is the unit properly grounded to earth Is the motor connected correctly YES NO 23 Try to run the VLT in local Local control parameters On VLT Series 3000 003 Local 004 Frequency reference change by means of and On VLT Series 3500 003 keypad HOA Press the Local Hand key change speed by the and Does the motor run Correct the motor wiring Insure motor overloads are reset and output contactor Closed 25 Replace Control Card Does the motor run NO 26 Verify that the control signals are connected to the correct terminals and the appropriate parameter settings have been entered Replace Interface ILD Card Does the motor run NO 21 Consult factory SYMPTOM CAUSE CHARTS Section Two S
11. 3500 Adjustable Frequency Drives VLT 3002 3022 230V VLT 3502 3532 230V VLT 3002 3052 380 460V VLT 3502 3562 380 460V The manual has been divided into five sections The first section covers the description and sequence of operations Section two covers fault messages and provides troubleshooting charts both in the form of flow and symptom cause Section three describes the various tests and methods used to evaluate the drives condition Section four covers the removal and replacement of the various components Section five discusses application specific information Electrostatic discharge Many electronic components are sensitive to static electricity Voltages so low that they cannot be felt seen or heard can reduce the life affect performance or completely destroy sensitive electronic components When performing service proper ESD equipment should be used to prevent possible damage from occurring toe iu EN __ E h Pan fois VLT Series Service Manual The Adjustable Frequency Drive AFD contains dangerous voltages when connected to the line voltage Only a competent technician should carry out the service WARNING 1 DO NOT touch the electrical parts of AFD when the AC line is COH TON connected After the AC line is disconnected wait at least 15 minutes before touching any of the components 2 When repairs or inspection is made the AC line must be disconnected 3 T
12. Brake Control Card 175H5399 175H5399 175H5399 175H5399 Brake IGBT 175H5372 175H5372 175H5372 175H5373 MOV 175H7306 175H7306 175H7306 175H7306 24V Internal Fan IP54 N A 175H0827 175H0827 175 0827 Top Fan 24VDC 24VDC 24VDC 230VAC IP20 175H0827 175H0827 175H0827 175 0761 Top Fan 460VAC 460VAC 230VAC 230VAC IP54 175H0754 175H0754 175H0761 175H0761 Fan Start Cap IP20 N A N A N A 175H7327 Fan Start Cap IP54 N A N A 175H7327 175H7327 Fan Series Cap IP20 N A N A N A 175H7328 Fan Series Cap IP54 N A N A 175H7328 175H7328 HF Card IP20 175 7303 175H7303 175 7303 175H7303 HF Card 54 175 7304 175H7304 175H7304 175H7304 DC Balance Resistor 175 2324 175H2324 175H2324 175H2324 Interface Insulator Foil 175H1785 175H1785 175H1785 175H1783 Only on VLT 3000 Section Six Section Six SPARE PARTS VLT 3042 3052 460V VLT 3552 3562 460V VLT 3042 VLT 3052 VLT 3552 VLT 3562 Control Card VLT 3000 175H7086 175H7086 Control Card VLT 3500 175H4539 175H4539 Interface Card 175H5384 175H5385 IGBT Module 175 6251 175H1371 IGBT Snubber 175 0831 175 0831 Recifier 612L9476 612L9477 Relay Card 175H4486 175H4486 Bus Charge Contactor 175H1762 175H1762 Bus Contactor Coil Cap 175H2852 175H2852 DC Capacitor 612B7097
13. Section and Testing the Bus Capacitors For measurements where an open circuit is expected the meter may show some initial continuity as the DC Bus capacitors charge up This is normal and to be expected VLT 3002 3004 230V VLT 3502 3504 230V VLT 3002 3008 380V 460V VLT 3502 3511 380V 460V 1 Remove the Control Card to expose the ILD Card Locate the UDC connector on the ILD Card MK102 The red lead at the top side of the connector will be used for the UDC test point and the black lead at the bottom of the connector will be the UDC test point The UDC and UDC fast on terminals on the DC Card as shown can also be used 2 Connect the positive meter lead to UDC Connect the negative meter lead to terminals 91 L1 92 L2 and 93 L3 in turn Each reading should be open 3 Reverse the meter leads connecting the negative meter lead to UDC and the positive meter lead to power terminals 91 L1 92 L2 and 93 L3 in turn Each reading should show a diode drop 4 Connect the positive meter lead to the red lead UDC Connect the negative meter lead to power terminals 91 L1 92 L2 and 93 L3 in turn Each reading should show a diode drop 5 Reverse the meter leads connecting the negative meter lead to the UDC and the meter lead to power terminals 91 L1 92 L2 and 93 L3 in turn Each reading should show open Test is complete Incorrect readings could indicate a faulty
14. Some messages indicate the operational status of the unit while others provide warnings of an impending fault In addition there are the alarm messages which indicate that the unit s operation has stopped due to a fault condition In this section we will deal with only those messages which interrupt the unit s operation A complete list of status messages can be found in the Instruction Manual The particular type of status warning or alarm message will be indicated on the bottom line of the display CURRENT LIMIT This message will flash in the display when the unit is operating above the current limit setting as recorded in parameter 209 Parameter 310 may be set to provide a fixed time delay after which the unit will trip REF FAULT This message will flash in the display should any live zero signal be operating outside of its range For example 4 20mA has been selected as the speed reference Should the current loop be broken the display will flash REF FAULT Parameters 414 and 415 may be used to select the unit s response to this condition NO 24 VOLT This message will flash if the 24 volt power supply is missing or out of tolerance The 24 volt supply is used only for the customer s remote connections NO MOTOR This message will flash if Motor Check has been activated in parameter 313 terminal 27 is enabled and no motor is detected Section Two WARNING MESSAGES 100 0 REFERENCE UOLTRGE LOW VOLTAGE LOW
15. The VLT relies on this feedback for proper output waveform control and for providing fault protection Problems with the current sensors can cause unstable operation over current trips and ground fault trips A simple test ofthese signals can be made with a voltmeter The measured voltage will be proportional to the current signal produced by each current sensor At very light loads the AC voltage signal may be no more than 100mV to 300 purpose of this test is to verify that all three sensors are functioning and that the signals are approximately equal when compared to each other 1 Apply power to the unit Leave the unit in stop mode 2 Using a DC voltmeter connect the negative meter lead to the Control Card test point labeled GND Connect the positive meter lead in turn to pins 4 5 and 6 ofthe Control Card MK200 connector pin 1 of MK200 is on the lower side closest to the MK201 connector All three readings should be within 20 millivolts of zero 3 Start the drive and bring the motor up to stable speed Change the voltmeter to read AC voltage and measure the Same signals at pins 4 5 and 6 of MK201 All readings should be approximately equal Severe imbalances in the readings indicate a faulty current sensor or an uneven current draw by the motor See Testing for Output Phase Voltage Imbalance on page 3 6 The current sensors will vary with unit size Consult Appendix drawings for assistance in finding compon
16. computer or a programmable logic controller control card provides two voltages for use from the 1 customer terminal strip The 24VDC is used primarily u to control functions such as Start Stop and Forward Reverse The 24VDC is provided from a separate section RELAY ofthe unit s power supply is delivered to the control card from the Interface ILD Card via the two conductor ribbon cable Section One LOGIC SECTION A 10VDC supply is also available for use as a speed reference when connected to an appropriate potentiometer These two voltage references are limited in the amount of available current they can provide see specifications in Instruction Manual Attempting to power devices which draw currents in excess of that available may result in an eventual failure of the power supply In addition if the supply is loaded too heavily sufficient voltage will not be available to activate the control inputs During the troubleshooting process it is important to remember that the control card can only respond to the commands it receives It is also possible that due to a failure the Control Card will not respond to control commands For this reason it is necessary to isolate the fault to the control commands control programming or the drive itself If for example the drive stops unexpectedly the control commands should first be checked This would include confirming that co
17. do not exist in the VLT Series 3500 PARAMETERS 103 104 105 107 These parameters when incorrectly set have an effect on other parameters as well as the unit s interpretation of the load In setting these parameters enter the name plate data from the motor into the appropriate parameter Use the conversion chart to change from HP to KW 1 2 3 5 7 10 15 50 kW 0 75 15 22 40 55 75 11 15 37 HP 100 125 150 200 250 300 kw 75 90 110 160 185 200 Section Five PARAMETER 108 Motor Magnetization Current is the current required to maintain the magnetic field in the motor Magnetization Current is factory set based on the motor power entered in parameter 103 This current value can also be found by running the motor without anything connected to the shaft and recording the current Data charts in motor catalogs also contain this information PARAMETER 109 Start voltage is factory set based on the motor power entered in parameter 103 In most cases the factory setting is sufficient however a slight increase in start voltage may be required for high inertia loads High current at low speeds results in an increased voltage drop in the motor and hence the need for additional start voltage If multiple motors are connected to a single unit itis usually necessary to increase the start voltage Smaller motors have greater voltage drops at low frequencies so additional start voltage is usually required It is also possible
18. is then stored in an EEPROM which provides security during power down and also allows flexibility for future changes as needed A custom integrated circuit generates the PWM waveform which is then sent on to the Interface ILD Card gate drive circuits Also part of the logic section is the keyboard display mounted on the control card The keyboard provides the interface between the digital logic and the human programmer The LCD Liquid Crystal Display provides the operator programmer with menu selection unit z DATA status and fault diagnostic information Programming ADRESS is accomplished through the use of four of the eight U U 1 keys available on the keyboard The additional four keys 8 Wc D m a various local controls depending on the type of 8 j unit CONTROL A series of customer terminals are provided for the input ROWER of remote commands such as Run Stop and Speed lt INPUTS Reference Terminals are also provided to supply outputs to peripheral devices for the purpose of monitoring and control Two programmable relay outputs are also available to interface the unit with other devices D gt ANALOG mA In addition the control card is capable of communicating as via a Serial link with outside devices such as a personal
19. of the unit 4 Remove and inspect the Interface Card Insulation Foil not on 230V units Replace the Insulation Foil 6 Slide the left hand side of the Interface Card in the appropriate enclosure slot and snap the right hand side of the plastic board supports Make sure that all wire harnesses are accessible prior to seating the Interface Card 7 Re connect all wire harnesses and the ground screw 1 Remove all wire harnesses from the Relay Card 2 Release the Relay Card from all plastic mounting clips and remove Use the tip of a fla head screw driver for the black plastic clips and needle nose pliers if white plastic stand offs are used 3 For units with the current sensors mounted on the Relay Card note the wire labeling and orientation prior to moving the board Remove the three leads connected to the drive side of the motor terminal strip and feed the leads back through the current sensors 4 Reverse the steps above to replace Section Four Rectifier Module 1 2 oU cr Remove the five terminal screws from the module Note the wire orientation and disconnect all wire leads Remove the two mounting screws securing the rectifier module to the heatsink and remove the module Clean the thermal grease from the enclosure heatsink and from underneath the Rectifier Module Apply silicon grease 3 mils thick to the entire base of the Rectifier Module Install the m
20. on the output of the unit or by instantaneous high currents occurring so rapidly that the unit s current limit cannot respond Short circuit trips are generally a result of a phase to phase short in the motor windings or in the wiring between the unit and the motor Short circuit trips are easily diagnosed by removing the motor leads from the unit and performing a phase to phase resistance test on the motor leads This resistance read in ohms will normally be quite low so it is important to have the ohmmeter set on its lowest resistance scale to avoid mis interpreting the readings observed Section Five OVERCURRENT TRIPS OVERVOLTAGE TRIPS DUE TO REGENERATIVE APPLICATIONS Instantaneous overcurrent trips are caused by the current rising so fast on the output that the unit cannot respond One example of this situation is in applications where the unit is running at speed and an output contactor is closed between the unit and the motor At the point the contactor is closed the motor is effectively Seen as a short circuit to the unit During this time the unit will attempt to gain control of the motor by employing current limit If the current limit function is unable to limit the current to acceptable levels the result will be an trip This example is not to imply that output contactors should not be used In fact that is quite the contrary as the VLT has been designed to withstand this type of operatio
21. on the right side of the control card plate and pry upward Lift the control card plate out and set aside REPLACEMENT Inspect Control Card mounting clips to ensure they are not loose or damaged Insert the left side of the control card plate into the slot on the left side of the enclosure and slide the card down against the metal stop to ensure proper alignment with front cover Reconnect the two ribbon cables to plugs MK200 and MK201 Firmly press down on the right side of the control card plate until it snaps into place Section Four REMOVING amp REPLACING THE ILD CARD DC CARD RECTIFIER CARD AND IGBT VLT 3002 3004 230V VLT 3502 3504 230V VLT 3002 3008 380V 460V VLT 3502 3511 380V 460V ILD Card 1 2 3 Remove the ground screw s on the ILD Card The screws are located at the bottom and possibly at the top right on the board Remove all wire harnesses from the ILD Card The three leads connecting the ILD Card to the motor coils may need to be removed from the Motor Coil side The replacement ILD Card will show if these leads should be disconnected from the ILD Card or from the Motor Coils Pay close attention to the orientation and routing of these wire leads Use the tip of a flat head screw driver to release the ILD Card from the plastic mounting clips and lift the card upward 4 5 6 To install make sure that the Insulation Foil is in place Connect the ILD Card to M
22. to have start voltage set too high and result in start up trouble The bestrule of thumb is to start at the factory setting and make changes in small increments Start and stop the unit to test the results PARAMETER 110 VLT SERIES 3000 ONLY Start compensation is factory set based on the motor power entered in Parameter 103 In most cases the factory setting is sufficient however a slight increase in start compensation may be necessary with loads requiring high starting torques and loads with changing demands as speed increases If multiple motors are connected to a single unit the start compensation must be set to zero Itis also possible to have start compensation set too high resulting in excessive current drawn at start up and motor instability PARAMETER 209 Current limit is factory set based on the motor size and voltage selected Current limit settings which are too low may result in difficulty starting or premature trips Current limit will automatically reset to 16096 of the value entered into parameter 107 unless this would exceed the maximum allowable value GROUND FAULT TRIPS OVERCURRENT TRIPS Section Five Trips occurring from ground faults are usually the result of short circuits to earth ground either in the motor or the wiring to the motor The VLT detects ground faults by monitoring all three phases of output current and looking for severe imbalances in those currents When a Ground Fault trip o
23. 0 Rectifier Module BLOCK DIAGRAM for reference only N LT 3006 3011 230V NLT 3506 3522 230V INTERFACE CARD MOTOR PHASE CURRENT SENSORS MEAT THERMAL SWITCH 3 IGBT MODULES gt 71 RECTIFIER MODULE Appendix ELE INTERFACE CARD m LH mx MEAT SK SWITCH Bg 3 IGBT MODULES 24V0C INTERNAL FAN gt lt gt DC COIL RECTIFIER MODULE BUS DC CONTACTOR wit d BUS Fe CAPS 230VAC soy FAN Peces R 1 BRAKE It RESISTOR MOTOR PHASE MOTOR COR S CURRENT SENSORS BLOCK DIAGRAM BLOCK DIAGRAM for reference only VLT 3011 3022 460V VLT 3516 3532 460V ie INTERFACE CARD HEAT SINK THER EWITCH 175480138 24 0 3 IGBT MODULES la 7 RECTIFIER DE COIL E MODULE BUS CONTACTOR MOTOR PHASE CURRENT SENSORS MOTOR COILS INTERFACE CARD 3 IGBT MODULES RECTIFIER MODULE BUS CONTACTOR R R HF CARD ESISTOR m l
24. 000 units only The Dynamic Brake option combines a power IGBT the electronics for controlling it and a resistor bank of sufficient wattage to dissipate the unwanted energy Dynamic Brake option monitors the level ofthe DC Bus voltage When the voltage level exceeds permissible limits the IGBT is switched on and the excess DC Bus voltage is dissipated in the resistor bank Particular attention must be paid to the proper sizing ofthe resistor bank Consult your local representative or the factory for assistance in selecting the appropriate Dynamic Brake option and dynamic brake resistors for your application Section Five FAULT MEMORY VLT stores faults which have occurred in its fault memory register The register stores the last 8 occurrences on a first in first out basis You can access the fault memory by calling up parameter 602 In doing so you can then scroll through the register using the Data key to view each fault code stored The codes that are displayed correspond to the numbers in parenthesis printed next to the Alarm Messages described on page 2 3 In addition there are six more codes which may appear in parameter 602 10 Trip Locked Indicates a trip lock fault has occurred 11 CT OP Card Fault Indicates a software fault has occurred in either the Control Card or an installed option card 12 Ref Fit Timeout Indicates the Reference Fault Timeout has occurred as controlled by Parameters 414 a
25. 3502 3504 230V VLT 3502 3511 380V 460V 1 Disconnect the motor leads from the unit The low winding resistance within the motor will affect test measurements in the inverter section 2 Remove the Control Card to expose the ILD Card Locate the UDC connector on the ILD Card MK102 The red lead at the top side of the connector will be used for the tUDC test point and the black lead at the bottom of the connector will be the UDC test point The UDC and UDC fast on terminals on the DC Card as shown can also be used 3 Connect the positive meter lead to terminal UDC Connect the negative meter lead to motor terminals 96 U 97 V and 98 W in turn Each reading should be open 4 Reverse the meter leads connecting the negative meter lead to 4UDC and the positive meter lead to motor terminals 96 U 97 V and 98 W in turn Each reading should show a diode drop 5 Connect the positive meter lead to UDC Connect the negative meter lead to motor terminals 96 U 97 V and 98 W in turn Each reading should show a diode drop 6 Reverse the meter leads connecting the negative meter lead to UDC and the positive meter lead to motor terminals 96 U 97 V and 98 W in turn Each reading should show open Test is complete Incorrect readings indicate a damaged IGBT module See Removal and Replacement Instructions on page 4 3 STATIC TEST PROCEDURES TESTING THE IN
26. 612B7097 Brake Control Card 175H5399 175 5399 Brake IGBT 175 4509 175H4509 MOV 175H7306 175H7306 24V Internal Fan IP54 175H0827 175H0827 Top Fan IP20 230VAC 175H0761 175H0761 Top Fan IP54 230VAC 175H1807 175H1807 Fan Cap IP20 175H4487 175 4487 Fan Cap IP54 175H4487 175 4487 Fan Start Cap IP20 175H7327 175H7327 Fan Start Cap IP54 175H7328 175H7328 Fan Series Cap IP20 175H7328 175H7328 Fan Series Cap IP54 175H1855 175H1855 HF 20 175 7303 175H7303 HF Card 54 175 7304 175H7304 DC Balance Resistor 175H2324 175H2324 Current Transducer 175H1789 175H1789 Interface Insulator Foil 175H1783 175H1783 Only on VLT 3000 COMPONENT LOCATION VLT 3002 3004 230V VLT 3502 3504 230V VLT 3002 3008 380 460V 3502 3511 380 460V O ON OOP Nes Terminal Strip 11 Position Front Cover Terminal Strip 5 Position Power Terminal Strip Motor Terminal Strip Bottom Cover Bonding Plate Top Cover DC Coil DC Bus Capacitor DC Card ILD Insulator Foil Input Line Driver ILD Card Control Card Display Keypad Terminal Strip 10 Position Standoff ILD Card to Ground Motor Coil Rectifier Module Standoff DC Card IGBT Six Pack Module Appendix BLOCK DIAGRAM for reference only 4 73H48 118 VLT 3002 3004 230V VLT 3502 3504 230V VLT 3002 3006 460V VLT 3502 3506 460V CONTRO
27. 9262 612L9263 Relay Card 175 4712 175H4712 175H4712 175H4713 Pre Series 7 175H1099 175H1099 175H1099 175H1143 Bus Charge Contactor 175H1761 175H1761 175H1761 175H1762 Pre Series 7 175H0841 175H0844 175H0841 175H0842 Bus Contactor Coil Cap 175H2852 175H2852 175H2852 175H2852 DC Capacitor 612 6762 612B6598 612B6708 612B6864 Brake Control Card 175 1572 175H1572 175H1572 175H1572 Brake IGBT 1175 7059 175H7059 175H7059 175H7060 MOV 175H4204 175H4204 175H4204 175H4204 24V Internal Fan IP54 N A 175H0827 175H0827 175 0827 Top Fan 24VDC 24VDC 24VDC 230VAC IP20 175H0827 175H0827 175H0827 175H0765 Top Fan IP54 400VAC 175 0668 175H0668 175H0668 175H0765 Fan Cap IP20 175H4487 Fan Cap IP54 175 4487 175H4487 Card IP20 175H7303 175H7303 175H7303 175H7303 HF Card 54 175 7304 175H7304 175H7304 175H7304 DC Balance Resistor 175H2324 175H2324 175H2324 175H2324 Interface Insulator Foil 175H1786 175H1786 175H1786 175H1784 Only on VLT 3000 Series included in unit serial number Example 0000 07 2000 Series 7 SPARE PARTS VLT 3042 3052 380V VLT 3552 3562 380V VLT 3042 VLT 3052 VLT 3552 VLT 3562 Control Card VLT 3000 175H7086 175 7086 Control Card VLT 3500 175H4539 175 4539 Interface Card VL
28. L CARD SIX PACK MODULE ILD CARD Appendix BLOCK DIAGRAM for reference only VLT 3008 3508 460V IGBT MODULES 5 1 1 ul m MOTOR COILS BLOCK DIAGRAM for reference only VLT 3511 460V 4 176 4118 DC CHOKE RECTIFIER MODULE MOTOR COILS ILD CARD Appendix COMPONENT LOCATION Appendix VLT 3006 3022 230V VLT 3508 3532 230V VLT 3011 3052 380 460 3516 3562 380 460V 1 Top fan 2 Top Cover 3 Heat Sink Thermal Switch 4 Interface Insulator Foil not on 230V 5 Interface Card 6 Brake Control Card Support not on VLT 3500 7 Brake Control Card not on VLT 3500 8 Control Card 9 Display Keyboard Unit 10 10 Position Thermal Strip 11 11 Position Terminal Strip i 12 Front Cover Ne 3 27 ET 29 IN 28 27 4 26 4 25 24 22 i 21 13 5 Position Terminal Strip 22 Balance Resistor 14 Safety Shield 23 Motor Coil 15 Relay Card 24 DC Bus Capacitor 16 LINE MOTOR Terminal Strip 25 DC Coil 17 Rubber Grommet 26 Brake IGBT not on VLT 3500 18 Bus Contactor 27 Clamp Capacitor 19 Bottom Cover 28 IGBT Module 20 BRAKE Terminal Strip not on VLT 3500 29 MOV 21 RFI Option 3
29. Rectifier Module See Removal and Replacement Instructions If there is an open circuit reading when a diode drop reading is expected see Testing the Soft Charge Circuit Section Three STATIC TEST PROCEDURES TESTING THE INPUT RECTIFIER Black Lead Bus Contactor Ce ps ne Em iL 2 2 LINA DC Bus Capacitors Red Lead TA je Balance Resistors VLT 3006 3022 230V VLT 3508 3532 230V VLT 3011 3052 380V 460V VLT 3516 3562 380V 460V 1 Remove any plastic shields covering the DC Bus Capacitors and locate the 18 gauge red and black leads connected to the Bus Capacitor bus bars as shown These leads indicate the positive UDC and negative UDC DC Bus test points The number and location of the bus capacitors will vary between units 2 Connect the positive meter lead to UDC Connect the negative meter lead in turn to the terminals 1 L1 3 L2 and 5 L3 as labeled on the top side of the Bus Contactor Each reading should be open 3 Reverse the meter leads connecting the negative meter lead to UDC and the positive meter lead in turn to the terminals 1 L1 3 L2 and 5 L3 on the top side of the Bus Contactor Each reading should read a diode drop 4 Connect the positive meter lead to UDC Connect the negative meter lead in turn to the terminals 1 L1 3 L2 and 5 L3 on the top side of the Bus Contact
30. T 3000 175H5390 175H5391 Interface Card VLT 3500 175H5396 175H5397 IGBT Module 175 0268 175 4100 Snubber 175 0831 175 0831 Recifier 612L9264 612L9264 Relay Card 175H4714 175H4714 Pre Series 7 175H1143 175H1143 Current Transducer 175H1789 175H1789 Bus Charge Contactor 175H1762 175H1762 Pre Series 7 175H0842 175H0842 Bus Contactor Coil Cap 175H2852 175H2852 DC Capacitor 612 6598 612B6708 Brake Control 175H1572 175 1572 Brake IGBT 175 7061 175H7061 MOV 175H4204 175H4204 24V Internal Fan IP54 175H0827 175H0827 Top Fan IP20 400 175 0765 175 0765 IP54 400 175 0765 175 1808 20 175 4487 175 4487 Fan Cap IP54 175 4487 175H4487 HF Card IP20 175H7303 175H7303 HF Card IP54 175H7304 175 7304 DC Balance Resistor 175H2324 175H2324 Interface Insulator Foil 175H1784 175H1784 Only on VLT 3000 Series included in unit serial number Example 0000 07 2000 Series 7 Section Six Section Six SPARE PARTS VLT 3002 3008 460V VLT 3502 3511 460V VLT 3002 VLT 3003 VLT 3004 VLT 3006 VLT 3008 VLT 3502 VLT 3504 VLT 3506 VLT 3508 VLT 3511 Control Card VLT 3000 175H7086 175H7086 175H7086 175H7086 175H7086 Control Card VLT 3500 175H4539 175H4539 175H4539 175H4539 175H4539 ILD Card 175H7072 175H7073 175H7074
31. VERTER SECTION DC Bus Capacitors Black Lead r Contactor j 216 Red Lead Balance Resistors Section Three VLT 3006 3022 230V VLT 3508 3532 230V VLT 3011 3052 380V 460V VLT 3516 3562 380V 460V 1 Prior to making any measurements it is necessary to disconnect the motor leads from the unit The low winding resistance within the motor will make it appear that there is a short circuit in the inverter section 2 Remove any plastic shields covering the DC Bus capacitors and locate the 18 gauge red and black leads connected to the capacitor bus bars These leads indicate the positive 10 and negative UDC DC Bus test points as shown 3 Connect the positive meter lead to the red lead to UDC Connect the negative meter lead in turn to motor terminals T1 U T2 V and T3 W Each reading should be open 4 Reverse the meter leads connecting the negative meter lead to 4UDC and the positive meter lead in turn to motor terminals T1 U T2 V and T3 W Each reading should show a diode drop 5 Connect the positive 4 meter lead to UDC Connect the negative meter lead in turn to motor terminals T1 U T2 V and T3 W Each reading should shoe a diode drop 6 Reverse the meter leads connecting the negative meter lead to UDC and the positive meter lead in turn to motor terminals T1 U T2 V and T3 W Each reading should show open
32. YMPTOM CAUSE charts are generally directed towards the more experienced technician The intent of these charts is to provide a range of possible causes for a specific symptom In doing so these charts provide a direction but with limited instruction SYMPTOM 1 Control Card Display Is Not Lit 2 Blown Input Line Fuses POSSIBLE CAUSES Incorrect or missing input voltage Incorrect or missing DC bus voltage Remote control wiring loading the power supply Defective Control Card Defective Interface ILD Card Defective Relay Card Defective or disconnected ribbon cables Shorted Rectifier module Shorted IGBT Shorted DC Bus Shorted brake IGBT Mis wired Dynamic Brake option 3 Motor Operation Unstable Speed Fluctuating Start compensation set too high Slip Compensation set too high Improper current feedback PID Regulator or Auxiliary Reference mis adjusted Control signal noise 4 Motor Draws High Current But Cannot Start May appear to rock back and forth Start voltage set too high Open winding in motor Open connection to motor One inverter phase missing Test output phase balance Section Two SYMPTOM CAUSE CHARTS SYMPTOM 5 Motor Runs Unloaded But Stalls When Loaded Motor may run rough and VLT may trip 6 Unbalanced Input Phase Currents Note Slight variations in phase Currents are normal Variations greater than 5 require investigation 7 Unbalanced Motor Phase Currents
33. age 2 7 See Item 12 page 2 7 9 10 Symptom No information in display Is the correct line voltage present on the input terminals L1 R 91 L2 S 92 L3 T 93 14 YES NO Section Two 11 12 Disconnect all control signal plugs on the control card Does the fault disappear NO YES Check Input Disconnect and fusing Iffuses are blown check for a short circuit in the Power Section 13 The fault may be caused UA rm Eb ha Is the DC Bus voltage OK Should read 1 4 x the AC line V Measure the DC Bus voltage between terminal VDC and VDC Also refer to pages 3 1 and 3 2 TEITE Litt li T Er by a short circuit in the control signals Check control wiring for proper connection 15 YES NO Test the soft charge circuit input rectifier and DC Bus capacitors 16 ILD Card Replace the Interface Does the fault disappear YES NO Resume operation Replace the Control Card Does the fault disappear NO YES Replace the Relay Card Resume operation 2 7 Section Two 18 Motor stationary info in display but no fault message displayed 19
34. care is required when probing into the power section components The DC Bus voltage can rise well over 700VDC on 460V units Although this voltage begins to decrease upon removal of input power it can take up to fifteen minutes to discharge the DC Capacitor Bank to safe levels A fault in the power section will usually result in at least one of the customer provided line fuses being blown Replacing fuses and re apply power without further investigation is not recommended The tests listed under Static Test Procedures in Section Three should be performed to insure that there are no shorted components in the power section It is recommended that the motor leads be disconnected from the unit prior to re applying power This precaution opens the path for short circuit currents through the motor in case a faulty component remains DC BUS INVERTER SIMPLFIED PWM POWER SECTION Section One SEQUENCE OF OPERATION MOVs Rectifier Module VLT 3002 3004 230 VLT 3502 3504 230V VLT 3002 3008 380V 460V VLT 3502 3508 380V 460V When input power is first applied the Rectifier Module converts the line voltage into a DC voltage The rectified output is then connected to the DC Bus filter establishing a fixed DC Bus voltage To limit the inrush charge current in the DC Bus capacitors three Negative Temperature Coefficient NTC resistors are added in series with the inputs ofthe Rectifier Mo
35. ccurs it is necessary to measure the resistance of the motor windings and wiring with respect to earth ground The instrument normally used for this purpose is a Megohmmeter or commonly referred to as a Megger Many times these resistance readings are taken with a common Ohmmeter which is actually incapable of detecting any shorts other than those that are virtually direct A Megger has the capability of supplying higher voltages typically 500 volts or more which enables the Megger to detect breakdowns in insulation or higher resistance shorts which cannot be picked up through the use ofan Ohmmeter When using a megger itis necessary to disconnect the motor leads from the output of the VLT The measurements should then be taken so that the motor and all associated wiring and connections are captured in the test When reading the results of the Megger test the rule of thumb is any reading less than 500 Megohms should be suspect Solid dry wiring connections normally result in a reading of infinity Since the VLT monitors output current to detect ground faults there is also the possibility that the current sensors and or the detection circuitry in the VLT could also be the cause of a ground fault Tests can be made on this circuitry to isolate the possibilities Refer to the Dynamic Test procedures on Testing for Current Feedback page 3 7 Consult the factory for additional assistance Trips due to OVERCURRENT can be caused by short circuits
36. cies below 10Hz the voltmeter reading will tend to bounce around as the pulses rise and fall Above 10Hz the reading will stabilize When using an oscilloscope the test points remain the same as shown These tests must be made with the motor disconnected The internal impedance of a meter or scope can induce problems to the IGBTs 1 With power off remove and re install the Control Card as shown to allow easy access to the Interface ILD Card 2 Measure the resistance at each ofthe six test points Each test point should read approximately 2 2kQ 3 Apply power and run the unit up to 20Hz Measure each of the six IGBT gate pulse signals 4 If gate pulses are missing or the readings are inconsistent remove power remove the three IGBT gate wire harnesses from the Interface ILD Card and measure the gate pulse signals directly at the Interface ILD Card Connectors There may be a slight DC shift in voltage readings between the positive and negative half IGBT gate signals Interface ILD Card Section Three To Expose the Interface ILD Card Leaving the Ribbon Cables attached remove the Control Card Mountthe card by snapping the right side edge of the Control Card into the two 2 mounting clips CHignd Gate pulses 9 20Hz 10V Div 10mS Div GATE PULSE INTERFACE CARD PIN OUTS MK600 K700 p ooo 00 000 U U Vt W
37. d in parameter 107 motor nominal current fortoo long inverse time function This fault may also be caused from running the motor at a low speed and high current for too long a period of time This trip will only occur if the Motor Thermal Protection has been activated in parameter 315 Prior to the trip the Motor Time warning will be displayed To remedy this fault reduce the load on the motor or raise the motor s speed This fault returns a Trip Locked During the trip the counter will count down Upon reaching 096 the Trip Locked will change to Trip CURRENT LIMIT 9 This message will be displayed if the unit has run in current limit for a time which exceeds the setting in parameter 310 To remedy this fault reduce the motor s load or verify thatthe correct settings have been entered in parameter 209 Current Limit and parameter 310 Current Limit Trip Delay This fault returns a Trip See Current Limit Trips MOTOR TRIP 15 This message will be displayed if parameter 400 is to Thermistor and motor thermistor connected between terminals 50 and 16 has increased to a resistance of 3KQ To remedy this fault remove the motor over temperature condition This fault returns a Trip The Reset Button can be held to allow access to the parameters EXCEPT FAULT This fault is usually the result of electrical noise caused by a poor earth ground connection to the VLT This fault may also be seen if Adaptive Motor Tuning is att
38. dule NTC resistors decrease in resistance as temperature increases Providing thatthe charging process proceeds normally the power supplies will come up and provide the Control Card with low voltage control power At this time the Control Card display will indicate that the unit is ready for operation Following a run command and a speed reference the Control Card delivers three Pulse Width Modulation PWM signals to the ILD Card The ILD Card in turn receives these three signals and creates the six individually isolated gate drive signals These gate pulses are fed directly to the Insulated Gate Bi polar Transistor IGBT output power devices The IGBTs are switched on and off to develop the PWM waveform which is ultimately delivered to the motor As the unit operates the ILD Card monitors the unit s operational status Currents and voltages out of specified limits or excessive temperatures will result in the ILD Card responding to the fault The ILD Card sends the appropriate fault message to the Control Card and in virtually all cases causes the unitto trip Section 2 of this manual describes the fault messages and provides direction in determining the cause and the solution for the fault Bus Coil O 4NDC 3 H rT MOV Bus j JA e Capacitors O VDC
39. e corrective action which can be taken to correct the fault condition For a more detailed explanation see the Symptom Cause Section and the Application Section Also note the numbers in parenthesis by each alarm message These are the codes which will appear in the Fault memory parameter 602 INVERTER FAULT 1 This message indicates a fault in the power section of the unit This fault returns a Trip Locked Also see Testing The Inverter Section OVER VOLTAGE 2 This message indicates the DC Bus voltage upper limit has been exceeded This fault can be caused by high line voltage or regenerative energy being returned from the motor To remedy this fault condition reduce the line voltage or extend the Decel Ramp This fault returns a Trip Also see Over Voltage Trips UNDER VOLTAGE 3 This message indicates the DC bus voltage has fallen below the lower limit To remedy this fault increase the line voltage to the correct value for the unit rating This fault returns a Trip Also see Testing the Soft Charge Circuit OVER CURRENT 4 This message indicates a short circuit on the output ofthe inverter This fault may also be caused by the unit reaching it s peak current rating so rapidly that the unit can not respond with current limit An example may be running the drive at speed and closing an output contactor connecting the drive to a high inertia load To remedy this fault check the output wiring and motor for short circuits This
40. e indicates at least one of the three output phases has reached the units peak current rating During this time the control card attempts to initiate current limit If the current rises too fast or the control card cannot control the condition by means of current limit the unit will trip on Over Current DC BUS VOLTAGE LIMITS VLT 3002 3052 VLT 3502 3562 VLT Rating 230VAC 380VAC 460VAC SMPS stop SMPS start Undervoltage trip inverter stopped inverter enabled Control Card undervoltage warning Control Card overvoltage warning brake applied parameter 300 Overvoltage trip inverter stopped inverter enabled Only on VLT Series 3000 units ALARM MESSAGES RLRRM TRIP LOCK INUERTER FRULT O Alarm Section Two Alarm messages will be indicated by the following messages appearing in the display and the red Alarm LED will flash on the unit keypad All alarm messages result in the unit s operation being interrupted and require a Manual or Automatic reset Automatic reset can be selected in parameters 309 and 312 In addition the message Trip or Trip Locked will be displayed If Trip Locked is displayed the only possible reset is to cycle power and then perform a manual reset Manual reset is accomplished by means of the front panel push button or by a remote contact closure on the appropriate control terminal Remedies listed with each alarm message give a basic description of th
41. elf This can be caused by improper gate drive signals as a result of a faulty interface board A faulty IGBT or loose wire connection between the IGBT and the output terminals may also be the cause NOTE When monitoring output voltage an analog voltmeter should be used Digital meters are sensitive to the switching frequency and usually read erroneously 1 Remove the motor leads from the output terminals of the unit 2 Conduct the Inverter Test Procedure in Section Three 3 If the Inverter Test Procedure proves good power the unit back up Initiate Run command with a speed reference greater than 40Hz 4 Read the phase to phase output voltage The actual value of the readings is of less importance than the phase to phase balance This balance should be within 8 volts per phase 5 If a greater than 8 volt imbalance exists measure the gate drive firing signals 6 If the phase to phase output voltage is balanced recheck motor and connections for faults Consult the factory for additional assistance DYNAMIC TEST PROCEDURES TESTING FOR CURRENT FEEDBACK GND Test Point Section Three A current sensor is in line with each phase ofthe output These hall effect devices generate a current that is proportionalto the current being drawn in each respective motor phase
42. empted on a motor many times larger than the drive rating parameter 106 This fault is accompanied by the PC address where an illegal value was found also see page 4 1 TROUBLESHOOTING TIPS Section Two Priorto diving into a repair here a few tips that if followed will make the job easier and may prevent unnecessary damage to good components 1 7 First and foremost respect the voltages produced by the drive Always verify the presence of line voltage and bus voltage before working on the unit Also remember that some points in the drive are referenced to the negative bus and are at bus potential even though you may not expect it Never power up a unit which has had power removed and is suspected of being faulty If a short circuit exists within the unit applying power is likely to result in further damage The safe approach is to conduct the Static Test Procedures The static tests check all high voltage components for short circuits The tests are relatively simple to make and can save money and downtime in the long run The safest method of conducting tests on the drive is with the motor disconnected In this way a faulty component that was overlooked or the unfortunate slip of a test probe will generally result in a unit trip instead of further damage Following the replacement of parts test run the unit with the motor disconnected Start the unit at zero speed and slowly ramp the speed up unti
43. ent locations Control Card 20 5V Ribbon Cables 19 5 18 5V 17 45V 16 INVOK FAULT LOGIC 15 WP 14 VP L SIGNALS 18 UP 12 SYNC SERIAL COMMUNICATION SIGNAL 11 DISAB RUN MODE LOGIC x 10 COM COMMON FOR 13V 13V 45V 9 COM SAME AS GND TEST POINT 8 COM 7 SIN USED 6 CRBW 5 CRBV MOTOR CURRENT SIGNALS 4 CRBU VFB DC BUS SIGNAL 2 13V 1 43V 2 24V SEPERATE CONTROL LOGIC 1 COMI POWER SUPPLY Section Three TESTING GATE DRIVE FIRING CIRCUITS CAUTION gate firing signals are referenced to the negative DC Bus and are therefore at Bus potential Extreme care must be taken to prevent personal injury or damage to equipment Oscilloscopes When used should be equipped with isolation devices The individual gate drive firing pulses originate on the Interface ILD Card These signals are then distributed to the individual IGBT s An oscilloscope is the instrument of choice when observing waveforms however when a scope is not available a simple test can be made with a DC voltmeter When using a voltmeter compare the gate pulse voltage readings between phases A missing gate pulse or an incorrect gate pulse have a different average voltage when compared with the other pulse outputs At very low frequen
44. fault returns a Trip Locked Also see Over Current Trips Section Two ALARM MESSAGES RLRRM TRIP LOCK GROUND FRULT GROUND FAULT 5 This message indicates a leakage to ground on the output of the inverter To remedy this fault check the output wiring and motor for ground faults It is also necessary to ensure thatthe VLT has been properly grounded This fault returns a Trip Locked Also see Ground Fault Trips OVER TEMP 6 This message indicates that the unit s heatsink temperature or the unit s internal ambient temperature has exceeded permissible limits All units covered by this manual use a resetting thermal switch The thermal switch is located on either the ILD Card or is mounted on the heatsink of units which use the Interface Card To remedy the fault correct the over temperature condition This fault returns a Trip Also see Overtemp Trips INVERT TIME 7 This message indicates the unit has delivered greater than 10596 of the unit s continuous current rating for too long inverse time function Prior to this fault condition the Invert Time warning will be displayed To remedy this fault reduce the motor load to ator below the unit s continuous current rating This fault returns a Trip Locked During the trip the counter will count down Upon reaching 9096 the Trip Locked will change to Trip MOTOR TIME 8 This message indicates the motor has consumed greater than 11696 ofthe value entere
45. he STOP key on the control panel does not disconnect the AC line 4 During operation and programming of the parameters the motor may start without warning Activate the STOP key when changing data TOOLS REQUIRED The following tools will be sufficient to troubleshoot and repair all units covered by this manual Digital multi meter Clamp on ammeter Analog voltmeter Flat head screw drivers Phillips screw drivers Torx drivers T10 T15 T20 T27 Socket 7mm Pliers Torque wrench Danfoss Section One DESCRIPTION OF Refer to the overall schematic in the Appendix OPERATION This manual in not intended to give a detailed description of the unit s operation It is intended to provide the reader a general overview of the function of each of the unit s main assemblies With this information the repair technician should have a better understanding of the unit s operation and therefore aid in the troubleshooting process The VLT is divided primarily into three sections commonly referred to as logic interface and power LOGIC SECTION The control card contains the majority ofthe logic section The heart ofthe control card is a microprocessor which controls and supervises all functions of the unit s operation In addition a separate PROM contains the parameter sets which characterize the unit and provide the user with the definable data enabling the unit to be adjusted to meet the customer s specific application This definable data
46. is necessary to investigate the wiring practices used For example the control signal wiring should not be run in parallel with higher voltage wiring including power motor and brake resistor leads The reason being that voltages can be induced from one conductor onto another through Capacitive or inductive coupling This type of problem can be corrected by rerouting the wiring or through the use of shielded cable When using shielded cable it is important to properly terminate the drain wire The drain wire should be terminated only at the drive end of the cable Specific termination points are provided on each unit The opposite end of the shielded cable drain wire is then cut back and taped offto prevent it ffom coming in contact with other terminals or acting as an antenna LOGIC POWER INTERFACE INPUT LINE DRIVER ILD CARD POWER SECTION RECTIFIER Section One The logic to power interface isolates the high voltage components of the power section from the low voltage signals of the logic section This is accomplished by use ofthe Interface ILD Card All communication between the control logic and the rest of the unit passes through the Interface ILD Card This communication includes DC Bus voltage monitoring line voltage monitoring feedback from the current sensors temperature sensing and control of the gate drive firing signals The Interface Card contains a Switch Mode Power Supply SMPS which provide
47. l the speed is at least above 40 Hz Monitor the phase to phase output voltage on all three motor terminals to check for balance an analog voltmeter will work best here If balanced the unit is ready to be tested on a motor If not further investigation is necessary Never attempt to defeat fault protection devices within the drive This will only result in unwanted component damage may result in personal injury as well Always use factory approved replacement parts The unit has been designed to operate within certain specifications Incorrect parts may effect performance and result in further damage to the unit Read the instruction and service manuals A thorough understanding of the unit is the best approach If ever in doubt consult the factory or an authorized repair center for assistance Section Two VLT 3002 3022 230V VLT 3502 3532 230V VLT 3002 3052 400 500V VLT 3502 3562 400 500V 1 2 Symptom Is the output phase to phase voltage and current balanced Motor operation unstable 3 Verify correct settings have Test the inverter been entered in Group 1 section page 3 4 Load amp Motor Symptom Is there light in the display 8 Motor will not run Are fault messages displayed NO YBS Is the correct line voltage present on the input terminals See Item 18 L1 R 91 L2 S 92 L3 T 93 page 2 8 See Diagnostics section Alarm Messages See Item 11 p
48. ll wire leads to the Six Pack Module IGBT Modules VLT 3008 380V 460V VLT 3508 3511 380 460V 1 Remove all wire leads connected to the IGBT modules 2 Remove the hardware holding the DC Link PCB to the IGBT Modules 3 Remove the hardware which connects the Motor Coil to the IGBT lead on the module to be replaced 4 Remove the two mounting screws and remove from the unit 5 Clean the heatsink grease from the enclosure heatsink and underneath the IGBT Module 6 Apply silicon grease 3 mils thick to the entire base of the IGBT Module 7 Installthe module and tighten the mounting hardware to 21 23 LB IN 2 5Nm 8 Reverse the steps above to replace Section Four REMOVING amp REPLACING THE INTERFACE CARD RELAY CARD RECTIFIER AND IGBT VLT 3006 3022 230V VLT 3508 3532 230V VLT 3011 3052 380V 460V VLT 3516 3562 380V 460V To gain access to some assemblies remove the Control Card page 4 2 It may also be necessary to remove one of the enclosure cross support braces to gain access to components on some units Interface Card 1 Remove all wire harnesses from the Interface Card 2 Remove the ground screw from the top right hand corner on units without Interface Card ground wire 3 Note in which enclosure slot the left side of the interface card was mounted Use the tip of a flat head screw driver to release the right side of the Interface Card from the plastic board supports and lift the board out
49. n without failure The important consideration in applications such as this is that the unit is properly sized to handle the inrush currents A second example of instantaneous overcurrent is that experienced in applications with windmilling loads A large fan has not yetbeen commanded to run however air movement is causing the fan to rotate When the unit is started it must first drive the fan to zero speed and then begin the acceleration process from there The amount of current required may be so great and rise so rapidly that the current limit function cannot control the process The result is an OVERCURRENT trip However this situation can also be solved by a VLT feature Flying Start With the flying start feature employed the VLT will interrogate the motor to determine its effective frequency and match the VLT outputto that same frequency Flying start results in a smooth start and full control of the load current Regenerative energy is created when the load overhauls the motor This means that the motor is being forced by the inertia of the load to rotate at a speed greater than the command speed When overhauling occurs the motor acts as a generator and the voltage generated is returned to the DC capacitor bank in the unit Regeneration is most commonly found in applications with high inertia loads and medium to fast decel ramps However even an unloaded motor ramped down fast enough can cause regeneration to occur It is most c
50. nce the Control Card delivers a PWM signal one per Phase to the Interface Card The Interface Card in turn receives these three signals and creates six individual isolated gate drive pulses From here the gate pulses are fed directly to the Insulated Gate Bi polar Transistor IGBT output power devices The IGBTs are switched on and off to develop the PWM waveform which is ultimately delivered to the motor As the unit operates the Interface Card monitors the unit s operational status Currents and voltages out of specified limits or excessive temperatures will result in the Interface Card responding to the fault The Interface Card sends the appropriate fault message to the Control Card and in virtually all cases causes the unitto trip Section Two ofthis manual describes the fault messages and provides direction in determining the cause and the solution for the fault Rectifier Bus Coil Module rr O4VDC A A T MOV Bus PTCs 9 EN Capacitors oS e e 0107 O VDC Only two PTC resistors on some units Bus Coil m The VLT 3511 380 460V units have the Bus Contactor relay and PTC resistors mounted on the ILD Card FAULT INDICATORS AND MESSAGES STATUS MESSAGES 180 075 REFERENCE CURRENT LIM Section Two A variety of messages are displayed by the control card
51. nd 415 13 Adaptive Tune Fail Indicates the Adaptive Tuning Process failed initiated by parameter 106 14 DC Supply Fault Indicates one or more of the low voltage DC power supplies have fallen out of tolerance 15 Motor Thermistor Indicates the motor thermistor as selected in parameter 400 has caused the trip SPARE PARTS VLT 3002 3004 230V VLT 3502 3504 230V VLT 3002 VLT 3003 VLT 3004 VLT 3502 VLT 3504 Control Card VLT 3000 175H7086 175H7086 175H7086 Control Card VLT 3500 175H4539 N A 175H4539 ILD Card 175H7064 175H7065 175H7066 DC Bus Card 175H7018 175H7018 175H7019 Six Pack IGBT 175H7017 175H7017 175H7017 Recifier Module 612L2026 612L2026 612L2026 Brake Control Card 175H7030 175H7030 175H7030 Brake IGBT 175H7029 175H7029 175H7029 Top Fan IP54 175H0327 175 0327 175 0327 Insulator Foil 175H1415 175 1415 175H1415 Only on VLT 3000 Section Six Section Six SPARE PARTS VLT 3006 3022 230V VLT 3508 3532 230V VLT 3006 VLT 3008 VLT 3011 VLT 3016 VLT 3022 VLT 3508 VLT 3511 VLT 3516 VLT 3522 VLT 3532 Control Card VLT 3000 175H7086 175H7086 175H7086 175H7086 175H7086 Control Card VLT 3500 175H4539 175H4539 175H4539 175H4539 175H4539 Interface Card 175H5375 175H5376
52. nd the spring mechanism is functional The armature resistance should be approximately 5000 2 Check the resistance of the P TC resistors located on the Relay Card At room temperature the resistance value should be about 300 3 Remove the Balance Resistors from the DC Bus capacitors Use an ohmmeter to insure that the resistance values are correct 18K Q 4 If all measurements are correct re install all components and proceed with dynamic tests Incorrect readings could indicate a damaged Bus Contactor Relay Card or problems with the DC Bus capacitors If a balance resistor is damaged replace the bus capacitors the resistor mounted across as well as any series connected Bus Capacitors See Replacing the Bus Contactor replacing the Relay Card and replacing the Bus Capacitors page 4 4 Section Three STATIC TEST PROCEDURES TESTING THE INVERTER SECTION NTC Resistors ur 203 PED u v wee Red Lead UDC Black Lead UDC Rectifier Module The purpose of static testing the inverter section is to rule out failures in the IGBT power devices If a short circuit is discovered during the testing the particular module can be pinpointed by noting the output terminal indicating the short circuit When looking in units with multiple IGBT modules the U phase is on the left V phase in the middle and the W phase is on the right VLT 3002 3004 230V VLT 3002 3008 380V 460V VLT
53. ntact closures and analog input signals are present at the proper terminals of the drive Never assume that a signal is present because it is supposed to be A meter should be used to confirm the presence of signals at the drive terminals Secondly the programming of the drive should be confirmed to insure that the terminals used are set to accept the signals connected Each digital and analog input terminal can be programmed to respond in very different ways If there is a concern whether the remote controls are functioning correctly it is possible to take local control of the drive to confirm proper operation A word of caution here prior to taking local control insure that all other equipment associated with the drive is prepared to operate In many cases safety interlocks are installed which can only be activated through the use of a normal remote control start As there must be a command in order for the Control Card to respond there may also be situations where the Control Card displays unknown data or that performance may be affected such as in the case of speed instability In these cases the first thought may be to replace the Control Card However this type of erroneous operation is usually due to electrical noise injected onto control signal wiring Although the Control Card has been designed to reject such interference noise levels of sufficient amplitude can in fact affect the performance of the Control Card In these situations it
54. odule and alternately torque the screws to 19 21 LB IN 2 2Nm Replace all wire leads to the Rectifier Module terminals and torque the erminal hardware to 19 21 LB IN 2 2 Nm IGBT Module Ui N 7 8 Remove the HF Card does not apply to 230V units Remove all hardware mounting the IGBT bus bars and the Clamp Capacitors Remove the remaining wire connecting the IGBT to the Motor Coil Remove the mounting screws on the IGBT and remove from the unit Clean the thermal grease from the enclosure heatsink and from underneath the IGBT Module Priorto installing the IGBT module apply silicon grease 3 mils thick to the entire base of the module Install the module and lightly tighten the mounting screws Tighten the mounting screws to a final torque of 19 21 LB IN 2 2Nm Re install the IGBT bus bars clamp capacitors and Motor Coil lead The IGBT terminal hardware including the 7mm HF Card standoffs should be torqued to 27 29 LB IN 3 2 Nm 9 Replace the HF Card and HF Card foil The HF Card mounting screws should be tighten down to 12 14 LB IN 1 5Nm APPLICATIONS CURRENT LIMIT TRIPS UNSTABLE MOTOR OPERATION Section Five Excessive loading of the VLT may result in CURRENT LIMIT trips This is nota concern ifthe unit has been properly sized and intermittent load conditions cause anticipated operation in current limit Nuisance current limiting and unstable motor ope
55. ommon that regeneration is experienced during ramping although loads such as flywheels will generate regenerative energy to some degree on every cycle Since the unit can absorb approximately 15 percent of the motor s rated power in regenerated energy this phenomena will go unnoticed in most applications OVERVOLTAGE TRIPS DUE TO REGENERATIVE APPLICATIONS Section Five When the energy returned combined with the DC Bus voltage exceeds the upper voltage limit the unit responds in different ways to limit the voltage rise If the returned energy is occurring during ramp down to stop orto a lower speed the unit will automatically adjust the decel ramp in an attempt to limit the voltage In more severe instances the ramp may even stop for periods of time to allow the voltage to dissipate During these periods while regeneration is occurring the words HIGH VOLTAGE can be observed flashing in the control card display If the returned energy is returned at a high enough level and or so fast that the unit cannot respond the unit will trip on OVERVOLTAGE To preventa trip from occurring one solution is to lengthen the decel ramp Another solution is to release the motor using the Motor Coast function The Flying Start function is usually employed when using this method In very high inertia applications where a short decel time is required the only solution may be that of adding a Dynamic Brake Option only VLT Series 3
56. or Each reading should show a diode drop 5 Reverse the meter leads connecting the negative meter lead to UDC and the positive meter lead in turn to the terminals 1 L1 3 L2 and 5 L3 on the top side of the Bus Contactor Each reading should show open Test completed Incorrect readings indicate a faulty rectifier module S ee Removal and Replacement Instructions on page 4 4 If the rectifier module is shorted it is important to inspect the Bus Charge Contactor See page 3 3 for testing the soft charge circuit STATIC TEST PROCEDURES TESTING THE SOFT CHARGE CIRCUIT NTC Resistors u v wee Black Lead UDC Red Lead UDC Rectifier Module Section Three The purpose of the soft charge circuit is to provide an initial high impedance current path for building up a charge on the Bus Capacitors The size of the unit determines whether NTC resistors or PTC Contactor combination are used VLT 3002 3004 230V VLT 3502 3504 230V VLT 3002 3008 380V 460V VLT 3502 3511 380V 460V Measure the three NTC resistors R303 R304 R305 located on the ILD Card The resistance should read about 10Q 200 at room temperature VLT 3006 3022 230V VLT 3508 3532 230V VLT 3011 3052 380V 460V VLT 3516 3562 380V 460V 1 Inspect the Bus Charge Contactor Remove the MK6 harness from the Relay Card see Appendix for component location and check that the contacts measure open a
57. otor Coil wire leads Reverse the rest of the installation steps DC Card 1 2 3 Remove the wires connecting the DC Card to the Bus Coil and the IGBTs Remove the mounting screws and the green yellow ground lead Use the tip of a flat head screw driver to release the DC Card from the plastic mounting clips and lift the card upward This may require a little flexing of the side of the enclosure to accomplish Remove wires connecting the DC Card to the rectifier module and remove the DC Card Reverse the steps above to replace Rectifier Module 1 Remove the wire harness from the module terminals Note the wire orientations Remove the two mounting screws and remove the module Clean the thermal grease from the enclosure heatsink and from underneath the Rectifier Module Install the wire harness to the module Apply silicon grease 3 mils thick to the entire base of the Rectifier Module Secure the Rectifier with the two screws Torque to 12 14 LB IN 1 5Nm Section Four Six Pack IGBT Module 1 Remove all wire leads connected to the Six Pack module 2 Remove the mounting hardware and remove from the unit 3 Clean the remaining heatsink compound from the enclosure heatsink and the Six Pack module 4 Apply silicon grease 3 mils thick to the entire base of the Six Pack module 5 Install the module and alternately tighten the mounting hardware to 21 23 LB IN 2 5Nm 6 Re connect a
58. ration can however be caused by improperly setting specific parameters The following parameters are those which are most critical to the VLT Motor relationship 100 Load Type 103 Motor Power 104 Motor Voltage 105 Motor Frequency 107 Motor Current 108 Motor Magnetizing Current 109 Start Voltage 110 Start Compensation VLT 3000 only 209 Current Limit PARAMETER 100 Load type is selected based on application demands VLT Series 3000 drive can be set for both constant and variable torque applications The VLT Series 3500 drive is specifically designed for variable torque applications The available selections vary between these different series An incorrect setting may provide an improper voltage to frequency V F ratio to the motor with respect to load demand For example a constant torque CT load requires a higher V F ratio at start up than a variable torque VT load If a VT mode of operation has been selected for a CT load sufficient starting torque will not be available When a VLT Series 3000 unit is set for one of the variable torque modes adjustments to parameters 109 113 will have no effect The various VT modes have direct control over these parameters When one ofthe CT Start VT modes is selected on a VLT Series 3000 unit the above mentioned parameters will have effect only until the reference has been reached At this point the unit reverts to VT operation It should be noted that parameters 110 113
59. s the unit with 24VDC 13VDC and 5VDC The switch mode type supply is used due to its efficiency and linearity Another benefit of the SMPS is that it uses the DC Bus voltage as a power source In the event of a powerloss the power supply remains active for a longer period of time versus conventional power supplies During the troubleshooting process it is important to determine whether the Interface Card is receiving or sending the signal that appears to be at fault For example the gate drive signals are generated by the Interface Card Conversely an over temperature fault can result from the Interface Card receiving an open from the heatsink thermal switch Ifthe fault could stem from a signal received by the Interface Card it is necessary to isolate the fault to either the signal source or the Interface ILD card It is critical to check all possibilities to avoid costly errors and long downtime In any case the Interface ILD Card is relatively easy to change so if itis suspect a quick exchange will confirm a faulty board The Input Line Driver ILD Card is used on VLT 3002 3004 230V VLT 3502 3504 230V VLT 3002 3008 380V 460V and VLT 3502 3511 380V 460V All other units covered by this manual use the Interface Card The power section contains the Rectifier the DC Capacitor Bank and the IGBT power components Also included in the power section are the DC Bus Coils and the Motor Coils During the troubleshooting process extreme
60. t j MOTOR PHASE CURRENT SENSORS for reference only VLT 3032 3052 460V BLOCK DIAGRAM
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