Vlt6000 Hvac 5g5i4t

VLTº Series Drives Service Manual VLT 4006 - 4072 VT, 380-460V VLT 4006 - 4032 VT, 200-240V VLT 4006 - 4072 VT, 550-600V

VLT 6002 - 6072, 380-460V VLT 6002 - 6032, 200-240V VLT 6002 - 6072, 550-600V

VLT 5001 - 5062, 380-500V VLT 5001 - 5027, 200-240V VLT 5001 - 5062, 550-600V

VLT 8006 - 8072 AQUA, 380-460V VLT 8006 - 8032 AQUA, 200-240V VLT 8002 - 8072 AQUA, 550-600V

Document Version 3.0

Table of Contents

Introduction ................................................................................................................... 5 ESD Precaution ............................................................................................................ 5 Warnings ............................................................................................................................. 6

Tools Required .............................................................................................................. 6 Product Overview.......................................................................................................... 7 Enclosures .................................................................................................................... 7 Component Cross-reference......................................................................................... 8 Hardware Configurations .............................................................................................. 9 RFI Filter ........................................................................................................................... 10 Servicing ........................................................................................................................... 10

Description of Operation ............................................................................................. 11 Logic Section .............................................................................................................. 11 Logic to Power Interface ............................................................................................. 12 Power Section ............................................................................................................. 13 Intermediate Voltage Limits .............................................................................................. 13

Voltage and Current Values ........................................................................................ 14 Key Diagram ..................................................................................................................... 15 List of Warnings and Alarms ............................................................................................. 16

Warning and Alarm Descriptions ................................................................................ 17 Ground Fault Trips ............................................................................................................ 23

Overcurrent Trips ....................................................................................................... 24 Overcurrent Trips: Unequal Phase to Ground Input Voltage ...................................... 24 Overvoltage Trips: Regenerative Applications ........................................................... 25 AMA Faults ....................................................................................................................... 26 Input Phase Loss Trips ..................................................................................................... 27

Output Phase Loss Trips ........................................................................................... 27 Troubleshooting ......................................................................................................... 28 General Troubleshooting Tips .................................................................................... 28 Troubleshooting Recommendations .......................................................................... 29 Troubleshooting Flow Chart ...................................................................................... 31 Symptom/Cause Charts ............................................................................................ 34

Table of Contents (continued) Static Test Procedures............................................................................................... 36 Test Equipment Setup ............................................................................................... 36 Input Rectifier Testing ....................................................................................................... 37

Soft Charge Circuit Testing ........................................................................................ 38 Inverter Testing........................................................................................................... 39 Dynamic Test Procedures .......................................................................................... 40 Output Phase Imbalance Testing ............................................................................... 40 Gate Drive Firing Circuit Testing ....................................................................................... 41

Current Sensors Testing ............................................................................................. 43 Component Replacement Procedures ....................................................................... 44 Control Card Removal and Replacement ................................................................... 44 Power Components Disassembly NEMA 1 (IP20) .................................................... 45 Power Card Replacement .......................................................................................... 45 Power Card Mounting Plate Removal ........................................................................ 45 Replacement of IGBT Modules NEMA 1 (IP20) .............................................................. 46 Power Components Replacement NEMA 12 (IP54) ........................................................ 53 Power Card Replacement NEMA 12 (IP54) ..................................................................... 53 Replacement of ICBT Modules NEMA 12 (IP54) ............................................................ 54

Spare Parts List ......................................................................................................... 60 Power Card Block Diagram .............................................................................................. 63

4

Introduction

The purpose of this manual is to provide technical information and instructions that will enable the to identify f8iuIts and repair Danfoss VLT® adjustable frequency drives. The following drive series and power ranges are addressed in this manual:

VLT 4006 - 4072, 380-460V VLT 4006 - 4032, 200- 240V

VLT 4006 - 4072, 550-600V

VLT 500J 5062,380 500V VLT 500J- 5027,200-240V VLT 500J -5062,550-600V VLT 6002 - 6072, 380-460V VLT 6002 - 6032, 200- 240V VLT 6002 6072, SEO 600V VCT 8006 — 8O72 , 380—460V

VLT 8006 — 8032, 200— 240V VLT 8002 — 8072, 550—600V

This manual begins with the product overview and sequence of operations. Next fault messages cre defined along with suggested remedies. A troubleshooting section lists general tips and recommendations. A flow dicgrcm provides

troubleshooting followed by symptoWcause charts. Tests and methods used to evaluate the dnves condition are described. Finally, the removal and replacement of the various components is covered.

ESD Precaution

Many electronic components are sensitive to static electricity. Voltages so low that they cannot be felt, seen or hecrd can reduce the life of, effect performance, or completely destroy sensitive electronic components. When performing service, proper electrostatic discharge (ESD) procedures and equipment should be used to prevent possible damage from occurring.

Electrostatic Discharge

Warnings 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 electncal pcrts of the drive when the AC line is connected. After the AC line is disconnected wait at least 1 5 minutes before touching

any of the components (30 minutes for 600V units). 2) While repairs or inspection is made, the AC line must be disconnected. 3) The STOP key on the control does not disconnect the AC line.

For Your Safety

Tools Required

4) During operation and programming of the parameters, the motor may start without warning. Activate the STOP key when ch8tnging data.

The following: tools will be sufficient to troubleshoot and repcir all units covered in this manual: Digital multi- meter Clamp on cmmeter Analog voltmeter Flat head screw drivers Phillips screw drivers Torx drivers - T1O, T15, T20, T27 Pliers Torque wrench Oscilloscope (optional)

6

Product Overview

Dcnfoss provides several models of drives designed for different applications. Operation and features have been configured for those application requirements. VLT SOOO Series VLT SOOO Process is a general purpose, high performance drive designed for industrial applications. These drives ccn be used for constant torque or variable

torque loads. They ccn be operated in open or closed loop, and speed or torque control modes. They are available in power sizes from 1 - 50 HP (200- 240V), 1 SOO H (380 500\/), and 1 250 HP (ISO 600V. The VLT SOOO Flux is similar to the VLT SOOO Process, out it utilizes Flux Vector technology for applications requiring more precise speed regulation or faster response. The same power and voltage ranges are available cs the VL” SOOO Process drive.

VLT 4000 VT Series The VLT 4000 VT is designed for industnal pumping applications. They are available in power sizes of 5 - 60 HP (200- 240V), 5 - 600 HP (380-460VJ , and 5 - 300 HP (550-600V. VLT 6000 Series The VLT 6000 Series is a VT only drive for use in HVAC equipment. Available power sizes are 1 .5 - 60 HP (200- 240V) 1 .5 - 600 HP (380-460W , and 1.5 - 300 HP (550-600V).

VLT 8000 Aqua Series The VLT 8000 Aqua Series serves the water and wastewater treatment market. Pnmanly designed for pumping applications, it is available in power ranges from 5 - 6O HP (2O0- 240V), 5 - 600 HP (380-460€, ÷nd 5 - 300 HP (550-600 .

Enclosures

All models are avaiIaDIe with Compact Protected Chassis and NEMA 1 enclosures. They are also available in NEMA 12 enclosures, except in the 550-600V range. In addition, the VLT SOOO series is available in 1 - 10 HP 380- 500V or 1 - 5 HP 200- 240V in a “Bookstyle" enclosure to enable optimum use of space when mounting the drives in a .”hese units are narrow (3.54 to 5. 1 2 in.) and are

able to be mounted side by side with no spacing required between units for cooling. This enables several units to be mounted in c relatively small crea within a

7

Component Cross-reference

Many of the VL” models use the same power components as their counterparts in the other VLT senes. A cross—reference chart showing the various models and their counterparts is shown below.

200V - 240V Model 5001 5002 5003 5004

Model

Model

Model

6002 6003 6004

Min Volt 200 200 200 200

5005

6005

200

5006 5008 5011 5016 5022 5027 5032 5042 5052 5062

6006 6008 6011 6016 6022 6027 6032 6042 6052 6062

8006 8008 801 1 8016 8022 8027 8032 8042 8052 8062

4006 4008 4011 4016 4022 4027 4032 4042 4052 4062

200 200 200 200 200 200 200 200 200 200

Model

Model

Model

Min Volt

380V - SOOV

Model 5001

380

5002

6002

380

5003 5004 5005 5006 5008 5011 5016 5022 5027 5032 5042 5052 5062 5075 5100 5125 5150 5200 5250 5300 5350 5450 SSOO SSSO

6003 6004 6005 6006 6008 601 1 6016 6022 6027 6032 6042 6052 6062 6072 6100 6125 6150 6175 6225 6275 6350 6400 6500 6550

380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380 380

8006 8008 801 1 8016 8022 8027 8032 8042 8052 8062 8072 8100 8125 8150 8200 8250 8300 8350 8450 8500 8600

4006 4008 4011 4016 4022 4027 4032 4042 4052 4062 4072 4100 4125 4150 4200 4250 4300 4350 4450 4500 4600

Component Cross-reference (continued)

Hardware Configurations

SSOV - 600V Model

Model

Model

5002 5003 5004 5005 5006 5008 5011 5016 5022 5027 5032 5042 5052 5062 5075 5100 5125 5150 5200 5250

6002 6003 6004 6005 6006 6008 6011 6016 6022 6027 6032 6042 6052 6062 6072 6100 6125 6150 6175 6225 6275

8002 8003 8004 8005 8006 8008 8011 8016 8022 8027 8032 8042 8052 8062 8072 8100 8125 8150 8200 8250 8300

Model

Min Volt

4006 4008 4011 4016 4022 4027 4032 4042 4052 4062 4072 4100 4125 4150 4200 4250 4300

ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO ISO

The VLT 4000, 6000 and 8000 AQLIA units are avaiI8IDIe in the standard version only The VLT SOOO has three hardware configurations available for all sizes of drives: Standard (ST), Standard with Brake (SB), and Extended with Brake (EB). The SB and EB units contain all logic and hardware necessary to connect an ex1ernal resistor to provide dynamic braking. The EB configuration offers connection terminals for load sharing capabilities between multiple VLT SOOO units plus input terminals for a remote 24 VDC power supply to maintain control logic during removal of the AC input power. Options are available for synchronizing and positioning.

RFI Filters

In the VLT SOOO Series, RFI filtering is standard on all 1 - 10 HP, 380- 500V and 1 - 5 H , 200-240V configurations and is available as a built-in option on all larger

models.

Servicing

Because of the design of the lower power drives (5 HP and below, 200V, and 10 HP and below, 380-600V) it is not practical to perform repairs on these units in the field. The typical service transection in this case would be to exchange the entire unit. Servicing for the larger models can De performed by replacing defective modules. It is recommended, due to the physical design, that the unit be removed from the installation or and placed on a suitable workbench prior to disassembly of the unit.

Description of Operation Logic Section

The control ccrd contains most of the logic section. A microprocessor on the control card supervises 8IIl functions of the unit's oper8ltion. In addition, BI separate PROM contains the parameters which provide settings to meet application requirements. This definable data is then stored in an EE ROM which provides security during power-down and also allows flexibility for future changes. A custom integrated circuit generates a Pulse Width lVloclulction (PWM) waveform which is sent to the interface circuitry located on the power card. This PWM waveform is created using an improved control scheme called VVC"' ", which is a further development of the VoItcQ‹3 Vector Control (VVC) system used in the VLT 3000 Series. \/VCº vides a variable frequency and voltage to the motor

to match the requirements of the motor. The dynamic response of the drive corresponds to the changing motor requirements. Part of the logic section is the Local Control (L). This is c removable keypa6display mounted on the front of the unit. The keypad provides the interface between the and the digital logic. Programming is accomplished through

the use of nine keys cvaJable on the keypad. Five additional keys provide local control and displdy monitoring functions. The L can be removed during operation to prevent undesired prc›gram changes. With the addition of a remote mounting kit, the L can be mounted in a remote location of up to three meters cway. The Liquid Crystal Display(LCD) on the L has four clpha- numeric display lines providing a plain-language menu selection, drive status and fault

diagnostic information. Terminals are provided for the input of such commands as run, stop forward, reverse and speed reference. Terminals are also provided to supply output signals to peripheral devices for monitoring the control. The control card provides two voltage supplies from the terminal stnp. The 24VDC is used for switching functions such as stcrt, stop end forwcrd/reverse. A 10VDC supply is also available for use with speed reference circuitry The analog and digital output sign8IIs cre powered through a third supply. All three supplies ccn De isolatecl to eliminate ground loop problems in the control input circuitry. In addition, the control card is capable of communicating via serial link with outside devices such cs personal computers or progrcmmcble logic controllers. Provisions have Deen mcde on the control ccrd assembly for the future addition of option modules such as synchronizing control, special communication options or custom operating software.

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. This is accomplished on the power card. All communication between the control lc›gic end the rest of the unit es through the power card. This communication includes DC bus voltage monitonng, line voltage monitonng, output current monitonng, temperature sensing and the gate drive firing signals. The power card clso contains c Switch lVlode Power Supply (SMPS) which provides the unit with 24VDC, +13VDC, —13VDC and SVDC operating supplies. All logic and interface circuitry is powered by the SMPS. Normally the SMPS is fed by the DC bus voltage, however, in the extended version of the drive, it is possible to power it with an external 24VDC power supply. This enables operation of the logic circuitry without the power section being energized. Power supplies for the cooling fans cre 6iISo provided on the power card.

In units with dynamic brake options, the logic and firing circuitry for the brcke

operation are also contained on the power card. In addition to ing the communication pertaining to output current to the control logic, the power card provides much of the fault processing of output short circuit end ground fault conditions. A custom IC called an Application Specific Integrated Circuit (ASIC) continually monitors output current conditions with respect to peak amplitude, rate of rise (di/dt) and leakage current (ground fault).

At the point that any of these conditions are considered critical, the gate drive Sl¶DdIS Bfe imfTiédiately shut-off and an clcrm signal is sent to the control logic for displaying the fault information.

The power section contains the rectifier, the DC bus f !ter circuitry, inrush current limiting circuit, and the output IGBT (Isolated Gcte Bipolar Transistor) power components. These components process the high voltage, high current output signals to the motor.

Power Section

When power is applied, the rectifier module converts the AC line voltage into a pulsating DC voltage. The rectified voltage is fed to the DC bus filter circuit which smooths the DC pulsating voltage to provide a fixed DC voltage at the peak voltage value of the AC input line. DC bus inductors cre also used in the circuit to reduce harmonic current distortion on the AC line. To limit the inrush current present on the DC bus capacitors when charging, a Positive Temperature Coefficient (PTC) resistor is added in series with the output of the rectifier module. When the DC capacitors are sufficiently charged a relcy closes across the PTC resistor and byes it. At this time the SMPS turns on, illuminating the display.

The DC bus voltage is connected to six output lGBTs which switch on and off alternately in a manner that coverts the DC voltage into en AC PWM w8lveform. These IGBTs are arranged into three modules with two IGBTs in each module. Output current is measured by three Hall effect current transducers, one in each phase of the output. Signals from these transducers are sent to the interface

circuitry on the power ccrd. Dynamic braking is accomplished by in IGBT which, when gated, connects one end of the brake resistor to the (-) DC bus. The other end of the resistor is connected to the (+) DC bus, thereby placing the resistor across the DC bus.

Intermediate Voltage Limits

[voC] Nominal voltage SMPS undervoltage disable/enable Inrush circuit disable

Inverter undervoltage disable Control card undervoltage warning Inverter undervoltage enable Power down enable Overvoltage warning (without brake) Brake enable voltage Brake maximum voltage Inverter overvoltage enable Overvoltage warning (with brake) Overvoltage inverter stop

200 - 240V 170 208 211 222 227 232 384 390 397 400 405 425

380 - SOOV 310 400 402 423 442 443 801 808 823 830 840 855

SEO - 600V 310 640 557 613 631 613 943 943 958 958 965 975

Voltage and Current Values [Amps]

The following contains information on overcurrent and ground fault trip po›nts for thO v8lrious size drives along with over and under voIt8I§e IevelS.

Voltage Range

HP

200-240

1 1.5

[ |

10.5 15 2

[ |

1.3 19

2 3 4 5

[

22 30 35.2 43

(

2.8 24 2.8 34

7.5 10

]

|

|

15 20

| 380-440/460-500

| | |

25 1 1.5 2 3 4 5 7.5 10 15 20 25 30 40 50 1 1.5 2

550-600 V

|

3 4 5 7.5 10 15 20 25

|

30 40

50 60

14

Peak Current

[

70.7 90 5 ] 130. 1 | 173. 1 ] 206.5 6. 2/5.4 ] 8.0/7.4 11.6/9.6 ] 15.8/13.6 | 20.4/17.8 ] 28.3/23.2 36.8/31.1 ] 45.3/41.0 [ 67. 9/61.4 ] 90.5/78.9 106. 1/96.2 ] 124.5/117.1 172.5/152. 7 ] 206.5/183.8 7.35/6.79 ] 8.20/7.64 11.60/11.03 ] 14.71/13.86 18.10/17.25 ] 26.87/25.46 32.53/31.11 ] 32.53/31.11 [ 50.91/48.08 ] 79.20/76.37 96.1 7/90.51 ] 121.62/115.97 152.74/147.08 ] 183.85/175.36 229.10/217. 79

Ground Current - Peak

(

[

8.8 11 3

[ |

16.3 21 6

[

25.8 0.8/0 7 1.0/0.9 1.5/1 2 1.3/1. 1 1.6/1 4 2.3/1.9 2.9/2 5 3.6/3.3 8.5/7 7 11.3/9.9 13.3/12.0 10.0/9.4 13.8/12.2 16.5/14.7 0. 92/0 85 1.03/0.95 1.45/1 38 1.18/1. 11 1.45/1 38 2.15/2.04 2.60/2 49 2.60/2.49 6.36/6 00 9.90/9.55 12.02/11.31 9.73/9.28 12.22/11. 77 14.70/14.03 45.82/43.56

[ [ | [ [ [ [

[ [

[ [ ( [ [ [

[

Inrush

relay Rectifier

+DC Invener

choke

Mains

...........-

L1

TC CE1

CR MOV

Motor

Rs R C› D

S1

Surge Protection

Rs Rz

L3

CT

x3 I - transducer —DC

x6 UDC— UDC+ External 24V

Inrush Relay

Ext 24 V SJep-up

Fan driver

+24V

List of Warnings and Alarms

No. 1

2 3 4 5

6 7 8

9 10 11

13 14 15 17

2 2 23 2 27 29 30 31

32 34 35 36 7 39 4 41

4 43

60 62 63 64 66

67 68

69 99

Description

Warning

Under 10 Volts(10 VOLT LOw) Live zero fault (LIVE ZERO ERROR) No Ivlotor (NO IvlOTOR) Ivlains failure(ktA INS PHASE LOSS) Voltage warning high (DC LINK VOLTAGE HIGH) Voltage warning low(DC LINK VOLTAGE LOw) Overvoltage (DC LINK OVERVOLT) Undervoltage (DC LINK UNDERVOLT) inverter overloaded (INVERTER TIIvlE) kbtor overloaded (IvIOTOR TIIvIE) Motor Ihermistor(lvIOTOR THERIvlIST0R) Current limit (CURRENT LIMIT) Overcurrent (OVERCURRENT) Ground fault (EARTH FAULT) Sfitch mode fault(SWITCH JvlODE FAULT) Short circuit (CURR SHORT CIRCUIT) Serial communication timeout(STD BUSTIMEOUT) HP feld bus timeout(HPFBTIMEOUT) Fault in EEPROIvI on power card (EE ERROR POWER) Fault in EEPROIvI on control card (EE ERROR CONTROL) Auto-optimization OK(AUTO MOTOR ADAPT OK)

X X X X

Auto motor adaptation fault(AMA FAULT)

Brake test failed (BRAKE TEST FAILED) Brake resistor short cicuit (BRAKE RESISTOR FAULT) Brake resistor power 100% (BRAKE POWER 100%) Brake transistor short circuit (BRAKE IGBT FAULT) Heat-sink temperature too high (HEAT SINK OVERTEMP.) Motor phase U missing (MISSING MOT PHASE U) Motor phase V missing (MISSING MOT PHASE V) Motor phase W missing (MISSING MOT PHASE W) Quick discharge NOT OK (QUICK DISCHARGE FAIL) HPFB communication fault(HPFB COMM. FAULT) Out of frequency range (OUT FREQ RNC/ROT LIM) Main AC input power faJ (MAINS FAILURE) Inverter fault (GATE DRIVE FAULT) Check parameters 104 and 106 (CHECK P104 & P106) Check parameters 103 ard 105 (CHECK P103 & P106) Motor too large(MOTOR TOO BIG) I\totor too small(MOTOR TOO SMALL) Brake fault (BRAKE FAULT) Safety stop (EXTERNAL FAULT) Output frequency low (FOUT < FLOW) Output frequency high (FOUT > FHIGH) Output current low(I MOTOR < I LOW) Output current high (I MOTOR > I HIGH) low ( < FDB LOW) high ( > FDB HIGH) Reference low (REF < REF. LOw) Reference high (REF > REF HIGH) Temperature auto derate (TEMP.AUTO DERATE) Unknown fault (UNKNOWN ALARM)

X X X X

Alarm

Trip Locked

The table lists the warnings and alcrms end indicates whether the f8iult lochs up the drive. After Trip Locked AC line power must be removed and the fault corrected. Reapply AC line power and reset the drive. When a warning and an alarm are both indicated, the warning precedes the

alarm. In some cases it is possible to program whether a fault results in a warning or on alarm. After a trip, an alarm and warning will flash. When the fault is removed, only the alarm flashes. After resetting the drive, the alarm goes away and the drive is ready to restart operation.

Warnings

Alarms

The display flashes between normal state and warning. A warning appears on the first and second line of the

The clarm comes up in lines 2 and 3 of the display. A trip lock is indicated in line 1 .

display.

t 6 \/ 0LT LOIJ

TRIP

line 1

(RESET)

line 2

TORQUE

line 3

LIMIT

A manual reset is carried out by pressing the Stop/Reset key on the L or by activating one of the Digital Inputs that has been programmed for Reset. The following pages explain the more common clarms end their causes.

Alarm/Warning Limits VLT Series

3 x 200 - 240 V |VDC]

3 x 380 - SOO V |VDC]

21 1

402

557

222 384 no brake / 405 w/brake 425

423 801 no brake / 840 w/brake 855

613 943 no brake / 965 w/brake 975

Undervoltage

Voltage warning low Voltage warning high Overvoltage

3 x SSO - 600 V [VDC]

The voltages stated are the intermediate circuit voltage of the dr‹ ve w‹ th a tolerance of +5º8 The corresponding AC line voltage is the ntermed‹ate circuit voltage divided by V

WARNING 1 Under 10 Volts (10 VOLT LOW):

The 10 Volts voltage from terminal 50 on the control ccrd is below 10 Volts.

WARNING/ALARM 2 Live zero fault (LIVE ZERO ERROR):

The current signal on termina! 60 is less than 50% of the value set in |O8IrBmeter 315 Terminal 60, min. sc iling

WARNING/ALARM 3

No motor (NO MOTOR):

The motor check function (see VLT SOOO parameter 122) indicates that no motor has been connected to the output of the drive.

WARNING/ALARM 4 Mains imbalance (AC LINE PHASE

One of the three AC line phases is missing. Check the supply voltage to the drive.

Remove some of the load from terminal 50, cs the 10V supply is overloaded. Max. 1 7 mAmin. 59011

LOSS): WARNING 5

Voltage warning high (DC LINK VOLTAGE HIGH): WARNING 6

Voltage warning low (DC LINK VOLTAGE LOW):

The intermediate circuit voltage (DC) is above the upper voltage limit of the controls (refer to the tcble). the drive is still active.

The intermediate circuit voltage /DC) is below the lower voltage limit of the controls (refer to the tcble). The drive is still active.

WARNING/ALARM 7 Overvoltage (DC LINK OVERVOLT):

If the intermediate circuit voltage (DC) exceeds the inverter overvoltage limit (refer to the table). ”he drive will trip after the time set in parameter 410 (or

412) has ed. The voltage › s shown in the display. The fault can be eliminated Dy connecting c brake resistor (if the drive hcs in integrBl brake chopper, EB or SB) or by extending the time chosen in parameter 410 (or 412). In addition, Brake function/overvoltage control ccn be activated in VL” SOOO pcrcmeter 400.

WARNING/ALARM 8 Undervoltage (DC LINK UNDERVOLT):

WARNING/ALARM 9

Inverter overload (INVERTER TIME):

WARNING /ALARM 10

Motor overtemperature (MOTOR TIME):

If the intermediate circuit voltage (DC) drops below the inverter lower voltage limit (refer to tcble), it will be checked whether 24V power supply is

connected. If no 24V power supply is connected, the drive will trip after a given time that depends on the unit. The voltage is shown in the display. Check whether the supply voltage matches the drive, see technical data. On EB units with an external power supply connected, this warning will be present continuously while the AC power supply is disconnected. The electronic thermal inverter protection reports that the drive is cbout to cut out because of an overload (high current for too long). The counter for electronic thermal inverter protection gives a warning at 98% and trips at 100%, giving en clcrm. ”he drive cannot be reset until the counter is below 90%.The the drive is overloaded by more than 100 /o for too long. According to the electronic thermal protection (ETR), the motor is too hot. Parameter 128 (11 7) allows a choice of whether the drive gives a warning or

an alarm when the counter reaches 100%. The is overloaded by more than 100% for too long. Check that motor parameters 102 106 have been set correctly.

WARNING/ALARM 11 Motor thermistor (MOTORTHERMISTOR):

The thermistor or the thermistor connection has been disconnected. Parameter 128 (117) allows a choice of whether the drive is to give a warning

WARNING/ALARM 12 Torque limit (TORQUE LIMIT):

The torque is higher than the value in parameter 221(in motor operation) or the torque is higher than the value in parameter 222 (in regenerative

WARNING/ALARM 13 Overcurrent(OVERCURRENT):

ALARM: 14 Earth fault (Sự cố chạm đất):

ALARM: 15 Switch mode fault (SWITCH MODE FAULT):

ALARM: 16 Short-circuiting (CURR.SHORT CIRCUIT): 18

or an alarm. Check that the thermistor has been correctly connected between terminal 53 or 54 (Analog voltage input) and termin0l 50 (+10V supply).

operation). The inverter peck current limit (approximately 200% of the rated current) has been exceeded. The warning will last approx. 1 -2 seconds, following which the drive will trip, giving an alarm. Remove power to the drive and check whether the motor shaft can be turned and whether the motor size matches the drive. Giới hạn cao điểm hiện tại của biến tần _ (gần 200% giá trị hiện tại) đã bị vượt quá. Cảnh báo sẽ kéo dài khoảng. 1 -2 giây, sau đó lái sẽ đi, đưa ra một báo động. Gỡ bỏ điện vào thúc và kiểm tra xem các trục động cơ có thể quay và có kích thước động cơ phù hợp với lái. There is a discharge from the output phases to earth, either in the cable between the drive and the motor or in the motor itself. Remove power to the drive and clear the ground fault. Có 1 sự phóng điện từ ngõ ra đến mặt đất, hoặc trong các cáp nối giữa thúc và động cơ hoặc trong bản thân động cơ. Gỡ bỏ điện từ thúc và xóa lỗi mặt đất. Fault in the switch mode power supply (internal ±15 V supply). your Danfoss supplier. Short circuit on the motor terminals or in the motor itself. Remove power from

the drive end remove the short circuit.

WARNING/ALARM 17 Standard bus timeout (STD BUSTIMEOUT):

There is no communication to the drive. The warning will only be active when VLT SOOO parameter 514 has been set to another value than OFF. If VLT SOOO parameter 514 has been set to stop and trip, it will first give a warning and then ramp down until it trips, giving an alarm. VLT SOOO parameter 513 Bus time interval could possibly be increased.

WARNING/ALARM 18

There is no communication with the drive. The warning will only be active when parameter 804 has been set to another value than OFF. If parameter 804 has been set to Stop and trip, it will first give a warning and then ramp down until it tnps, giving an alarm. Parameter 803

HPFB bus timeout (HPFB BUS TIMEOUT)

Bus time interval could possibly be increased. Fault on the power card EEPROIVI. The drive will continue to function, but is likely to fail ct the next power-up. your Danfoss supplier.

WARNING 19 Fault in the EEprom on the power card (EE ERROR POWER CARD) WARNING 20 Fault in the EEprom on the control card (EE ERROR CTRL CARD)

There is a fault in the EEPROM on the control card. The drive will continue to function, but is likely to fail at the next power-up. your Danfoss supplier.

ALARM: 21

The automatic motor tuning is OK and the drive is now ready for operation.

AMA OK (AUTO MOTOR ADAPT OK)

A fault has been found during automatic motor adaptation. The text shown in the display indicates c f8iult message. The figure after the text is the error code, which can be seen in the fault parameter 615.

ALARM: 22

AMA not OK (AUTO MOT ADAPT FAIL)

®arameter 102, 103 or 105 has a wrong setting. Correct the setting and start AMA all over.

CHECK P.103, 105

LOW P. 105

[1]

The motor is too smell for AMA to be carried out. if AMA is to be enabled, the rated motor current (parameter 105) must be higher than 35% of the rated output current of the drive.

ASYMMETRICAL IMPEDANCE

[2]

AMA has detected an asymmetrical impedance in the motor connected to the system. The motor could be defective. The motor connected to the system is too big for AMA to be carried out. the setting in parameter 102 does not match the motor used.

MOTOR TOO BIG

MOTOR TOO SMALL

TIME OUT

[4]

The motor connected to the system is too small for AMA to be carried out. The setting in parameter 102 does not mctch the motor used. AlVlA fails because of noisy measuring signals. Try to start AMA all over a number of times, until AMA is carried out. Please note that repeated AMA runs may heat the motor to a level where the stator resistance Rd is

increased. In most cases, however, this is not critical. INTERRUPTED BY

AlVlA has been interrupted Dy the .

INTERNAL FAULT

An interndl fault h8ls Occurred in the drive. your Danfoss supplier.

LIMIT VALUE FAULT

The parameter values found for the motor are outside the acceptable range within which the drive is able to work.

MOTOR ROTATES

[9]

NOTE:

WARNING/ALARM 23 Fault during brake test (BRAKE TEST FAILED):

The motor shaft rotates. Mcke sure th8l t the load is not able to mcke the motor shaft rotcte. Then start AMA all over. AMA can only be carried out if there are no alarms during tuning. The VLT SOOO brake test is only run after power up. If Warning has been selected in parameter 404, the warning will come when the DF8Ike test spots a fault. If ”rap has been selected in parameter 404, the dnve will trip when the brake test finds a fault. The brake test may fail for the following reasons:

No brake resistor connected or f0ult in the connections; defective brake resistor or defective brake transistor. A warning or clarm will mean that the brake function is still active. WARNING 25 Brake resistor fault (BRAKE RESISTOR FAULT):

WARNING 26 Brake resistor power 100º/» (BRK PWR WRN 100º/ )

WARNING 27

Brake transistor fault (BRAKE IGBT FAULT):

The VLT SOOO brake resistor is monitored during operation and if it shortcircuits, the brake function is disconnected and the warning comes up. The drive will still be able to work, although without the brake

The power transmitted to the VLT SOOO brcke resistor is calculated as a percentage, cs a mean value over the last 120 sec., on the basis of the

resistance value of the brake resistor (parameter 401) and the intermediate circuit voltage. The wcming is active when the dissipated braking power is higher than 100 If Trip [2] has been selected in parameter 403, the drive will cut out while giving this alarm The VLT SOOO brake transistor is monitored during operation and if it shortcircuits, the brake function is disconnected and the warning comes up. The drive will still be able to run, but since the brake transistor has shon circuited, subst8lntial power will be transmitted to the brake resistor, even if it is inactive. Remove power to the drive and remove the brake resistor. Note: Proper Brake Resistor installation should include the ability to disconnect AC power from the drive automatically if a fault should occur. If not, this condition ccn c8luse damage tO the brake resistor. It is important to discontinue use of the inverter if this indication appears.

WARNING 29 Heat sink temperature too high

(HEAT SINK OVER TEMP.):

If the enclosure is Chassis (IPOO or 1 20), the cut-out temperature of the

heatsink is 90O C. If NEMA 12 (I 54) is used, the cut out temperature is 80“C. The tolerance is +5“C. The temperature fault cannot be reset until the temperature of the heatsink is below 60”C. The fault could be the following: - Ambient temperature too high. - Too long motor cable. Too high switching frequency.

ALARM: 30 Motor phase U missing (MISSING MOT. PHASE U):

the drive end check motor phase U.

ALARM: 31 Motor phase V missing (MISSING MOT. PHASE V):

Motor phase V between the drive and the motor is missing. Remove power to the drive end check motor phcse V.

ALARM: 32 Motor phase W missing (MISSING MOT. PHASE W):

Motor phase W between the drive and the motor is missing. Remove power to the drive and check motor phase W.

Motor phase U between the drive and the motor is missing. Remove power to

ALARM: 33 Quick discharge not OK (QUICK DISCHARGE NOT OK):

Check whether VLT SOOO 24 Volts external DC supply has been connected and check that an external brake/discharge resistor also has been

WARNING/ALARM: 34 HPFB communication fault (HPFB COMM. FAULT):

The sericl communication on the communication option card is not working.

WARNING: 35

This warning is active if the output frequency has reached its Output frequency low limit (parameter 201) or Output frequency high limit (parameter

Out of frequency range (OUT OF FREQ. RANGE):

WARNING/ALARM: 36

Mains failure (MAINS FAILURE):

connected.

202). If the drive is in Process regulation, closed loop /parcmeter 100), the warning will be cctive in the display. This war ning/alarm is only active if the supply voltage to the VLT SOOO is lost and if parameter 407 Mains fault has been set to another value than OFF. If parameter 407 has been set to Contr. ramp-down trip [2], the drive will first give a warning and then ramp down and trip, while giving an alarm. Check the fuses to the drive.

ALARM: 37 Inverter fault (INVERTER FAULT):

IGBT or power card is defective. your Danfoss supplier.

Warnings 39, 40, 41 and 42: AMA

Automatic motor adaptation has stopped, since some parameters have prob8lbly been set wrongly, or the motor used on too biQsmaII for AMA to be carried out. A choice must be made by pressing [CHANGE DATA] and choosing "Continue" + [OK] or "Stop” + [OK].

WARNING 39 CHECK P.104, 106

The setting of parameter 102, 104 or 106 is probably wrong. Correct the setting and run AMA 8l§Bin.

WARNING 40 CHECK P.103, 105

The setting of parameter 102, 103 or 105 is probably wrong. Correct the setting and run AMA again.

WARNING 41 MOTOR TOO BIG

The motor used is probably too big for AMA to be carried out. The setting in Q8lrBmeter 102 mcy not match the motor. Correct the setting and run AMA again

WARNING 42 MOTOR TOO SMALL

The motor used is probably too smell for AMA to be carried out. The setting in parameter 102 may not match the motor. Correct the setting and run AMA

again.

ALARM 43 Brake fault (BRAKE FAULT)

A fault on the VLT SOOO brake. ”he text shown in the display indicates a fault message. The figure after the text is the f0ult code that ccn be seen in the fault log, parameter 615

Brake check failed (BRAKE CHECK FAILED)

The brake check carried out during power-up indicates that the brake has

Brake resistor short-circuited (BRAKE RESISTOR FAULT)

been disconnected. Chink whether the brake has been connected correctly and that it has not been disconnected. The broke output has short - circuited. Replace the brake resistor [1]

Brake IGBT short-circuited (BRAKE IGBT FAULT)

The brake IGBT has short - circuited. This fault means that the unit is not able to stop the Drcke end that, consequently, the resistor is constantly Deing

energized

Alarms 60-69 are indicated on the VLT 4000, 6000, and 8000 AQUA only. ALARM 60 External Fault (EXTERNAL FAULT)

Terminal 27, parameter 304, Oipi/a/ /nou/s, has been programmed for a Sa/e/y /n/er/oc/‹ and is a logic '0‟.

WARNING 61 Output frequency low (FOUT < FLOW)

The output frequency is lower than parameter 223, Warning. Low Frequency.

WARNING 62 Output frequency high (FOUT > FHIGH)

The output frequency is higher than parameter 224, harming. High Frequency.

WARNING/ALARM 63 Output current low (I MOTOR < ILOW)

The output current is lower than parameter 221 , Warning. Low Current.

WARNING 64 Output current high (I MOTOR > IHIGH)

The output current is higher than parameter 222, Warning. High Current.

WARNING 65 low ( < FDB LOW)

The resulting value is lower than parameter 227, Warning. Low .

WARNING 66

The resulting value is higher than parameter 228, Swnmp. hgh

high ( > FDB HIGH)

7eedDac/‹.

WARNING 67

Reference low (REF. < REF LOW)

The remote controlled reference is lower than parameter 225, Warning.„ for Peference

WARNING 68 Reference high (REF. > REF HIGH)

The remote controlled reference is higher than parameter 226, Warning. High Peference.

WARNING 69 Temperature automatic derate

The hOBt Sink temp6›F itUre has exceeded the maximum value and the auto deleting function in parameter 411, func/ on a/ Ov6'r 7‹3/T/ D, is active.

(TEMP.AUTO DERATE)

WARNING 99 Unknown alarm (UNKNOWN ALARM)

22

Select the required function in parameter 409, *unc//on n Case o/ /Vo Load.

An unknown fault has occurred which the software is not able to handle.

Danfoss service department.

Ground Fault Trips

Ground fault trips are usually the result of short circuits to earth ground either in the motor or the wiring to the motor. The VLT adJUSt8IDle frequency drive detects ground faults by monitoring the sum of the currents on all three phases of the output. In a three phase system operating correctly, the sum of the three currents should equal zero. If the sum is other than zero there is leakage current present in the system, presumably to ground. If the leakage current is great enough, a ground fault will appear. When this occurs, measure the resistance between the motor windings (or motor leads) and earth ground. Normally a megohmmeter is used for this purpose. Mcny times these readings are taken with c common ohmmeter, which is actually incapable of detecting any shorts other than those that cre virtually direct. A megohmmeter has the capability of supplying higher voltages, typically SOO volts or more, which enables the megohmmeter to detect breakdowns in insulation or higher resistance shorts which cannot be picked up through the use of an ohmmeter. When using a megohmmeter, it is necessary to disconnect the motor leads from the output of the drive. ”ake the measurements so that the motor and all

associated wiring and connections are captured in the test. When reading the results of a megohmmeter test, the rule of thumb is that any reading less then SOOK Ohms is 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 drive could give a false ground fault indication. Tests can be made of this circuitry to isolate the possibilities. Refer to the section Current Sensors testing in this manual.

23

Overcurrent Trips

Overcurrent trips cre usually caused by instantaneous high currents occurring so rapidly that the unit's current limit (torque limit) cannot respond. It is also possible that this type of fault can result from short circuits on the output of the drive. However, depending on the impedance of the motor leads, this type of fault is more likely to result in an output short circuit fault (Alarm 16). Incorrect motor settings are often the cause of the instantaneous high currents thct result in an overcurrent fault. It is recommended to check the settings of parameters 102 - 106 to ensure that they are set according to the n8Ime|DI6iti information on the motor, and that they have not been tampered with. Even with these set correctly, there cre other parameters that ccn cause the motor to draw excessive current if set wrong. For instance, parameters 108 and 109

(stator resistance and stator reactance, respectively) have this effect if set incorrectly. The most reliable method for ensuring thct these parameters are correct is to perform the AlVlA function in parameter 107. Instantaneous overcurrents ccn also be ccused by incorrectly switching on the output of the drive. If the drive is running it Speed at the instdnt that the or is switched in, the inrush current to the motor can be quite high. If the application requires switching of this noture, the drive must be properly sized to handle the inrush current. Another example of instantaneous overcurrent is experienced with windmilling loads. A Icrge fan that has not been commanded to run can rotate due to air currents moving across it. If this is occurring when a run command is given, the drive must first ramp the fan to zero speed and begin the acceleration process

from there. ”he current required to do this may be so great and the rise so rapid that the current limit function ccnnot control the process. This situation ccn be solved by the use of the drive's flying start feature.

Overvoltage Trips Unequal Phase to Ground Voltages on the Input Line

In some installations, three phase input power is fed from a transformer with a delta secondary configuration. Usually this is not a problem, although sometimes the phase to ground relationship is not equal on all three phases. When this occurs, frequent overvoltage trips can result due to the RFI filtering circuitry in the drive reacting to this inequality. In this event, the RFI filter capacitors must be disconnected from ground. This is done by opening the RFI Switch in the drive. Refer to the dnve instruction manual for location of this switch.

24

Overvoltage Trips Regenerative Applications

Regenerative energy is created when the locd overhauls the motor. This mecns that the motor is being forced by the inertia of the load to rOt8ltO at a speed greater than the command speed. When overhauling occurs the motor acts as a Qenerator. The voltage generated by the motor is returned to the DC capacitor bank, thus causing the DC bus voltage level to increase. Regeneration is most commonly found in applications with high inertia locds and medium to fast decel ramps. However, even an unloaded motor romped down fast enough can cause regeneration to occur. It is most common that regeneration is experienced during romping, although locds such as flywheels can cause some regeneration during normcl running. Since the drive can aDSorD approximately 1 5 percent of the motor's rated power in regenerated energy, this phenomena goes unnoticed in most applications. When the returned energy, combined with the DC bus voltage, exceeds the upper voltage limit the unit responds to limit the voltage rise.

If the amount of regeneration is sJght c Warning 5 message appears in the drive display during the ramp down or when overhauling occurs. As long as the regenerated energy does not increase, no action will take place.

If the regenerated energy increases, c Warning 7 appears in the display. This warning indicates that the DC bus voltage is approaching the level which ccn damcge components in the dnve power section. For this reason, the unit releases the control of the motor until the voltage decreases to a scfe level. If the motor is still coasting at that point, the drive will try to regcin control of the motor. This can often result in high amounts of inrush current causing the unit to trip. Warning 7 changes to en Alarm 7 and the unit will trip when the time set hds Ol0|DSC›d. To prevent a trip from occurring, lengthen the decel ramp or use the overvoltage control function. Another solution is to release the motor using the motor coast function.”he flying start function is normally employed when using this method. In applications where a short decel ramp is required, the dynamic brake function may be needed (SB or EB units only). The dynamic brcke function combines c power IGBT, the electronics for controlling it and a resistor bank of sufficient wattage to dissipate the unwanted energy. The dynamic brake monitors the level of the DC bus voltage. When the voltage level exceeds permissible limits, the IGBT is switched on connecting the resistor b8lnk across the Dus to dissipate the excess voltage. articular attention must be paid to the proper sizing of the resistor bcnk. Consult your local representative or the factory for assistance in selecting the appropriate dynamic brcke option and dynamic brake resistors.

25

AMA Faults

When the AMA function is performed as commanded in parameter 107, c stcrt comm6ind is initiated to begin the process. FOr safety reasons an aI8Irm message appears when the AMA process is complete. This ensures thct the motor will not run until the VLT adjustable frequency drive has been reset. The alarm message that is displayed depends upon whether the drive was successful in performing the AlVlA function. If AlVlA was carried out successfully an Alarm 21 messaQe appears.”his indicates that normal operation can resume after the unit has been reset. If the drive encounters a problem during the process, it will display an Alcrm 22 or one of several warning messages. The warning messages often indicate that one or more of the motor parameters in the drive (parameters 102 through 106) are set incorrectly. the A fv1A function ccn be stopped (or resumed) at this point by pressing the [Change Data] key followed by the [Stop] key (or the [OK] key to continue). Keep in mind that if

continue is chosen, the drive may not be able to carry out the AMA function correctly. To change an incorrect parameter, select [Stop]. Once the parameter has been corrected, restart the AlVlA function from the beginning.

If the error is great enough or if there is a problem in the output circuit, the drive will trip and display an Alarm 22 message. A text message also appears on the bottom line of the display indicating the nature of the fault detected. Refer to the

section on 4/arm arning Messages for description of fault messages. The AMA function checks fOr stator resistance Bind the stator reactance of the motor (R, - X,), and enters those values into parameters 108 and 109. Parameter 107 can also be set for Limited AMA to check only the stator resistance (Rd) for motors unable to run complete AMA or for motor with 6 or more poles. The preferred method is to check both values for the most accurate optimization. If a failure occurs when using this method, it is recommended to try the AMA agcin with parameter 107 set to Limited AlVlA.

26

Input Phase Loss Trips

The VLT adjustable frequency dnve monitors phase loss by monitonng the amount of ripple voltage on the DC bus. The VLT uses this method, although ripple voltage on the DC bus is c product of a phase loss, because the main concern is that ripple voltage causes overh‹3atinQ in the DC bus capacitors and the DC coil. Left unchecked, the lifetime of the capacitors and the DC coil would be drastically reduced. As the voltage becomes imbalanced, or should a phase disappear completely, the ripple voltage increases and the VLT will trip. Other than the obvious missing phase voltage, increased bus ripple can De the result of line disturDances or line imbalances. Line disturbances may be ccused by line notching, defective transformers or other loads that mcy effect the form factor of the AC waveform. Line imbalances that exceed 3% cause sufficient DC bus ripple to initiate a Mains Phase Loss ”rip. Severe phase imbalances, or phase losses, can easily be detected with a voltmeter. Line disturbances most likely have to be viewed on an oscilloscope.

Output Phase Loss Trips

Output Phase Loss trips occur when the output current in any phase falls below the calculated "no locd" current vclue for the motor. This is typically due to en open circuit condition in the motor, motor wiring, or switching devices in the

output circuit. In some cases, such as when multiple motors are being switched in an out, it can appear to the drive that this is occurring. In such cases, "nuisance" Output hase Loss tripping can result. If the control card software is of version 3.20 or higher, the output phase loss function can be disabled in VLT SOOO parameter 234 to correct for this. Caution must be taken when disabling this function as the motor can be damaQed

if a genuine loss of phase occurs.

27

Troubleshooting

Prior to repair, here a few tips that will make the job easier and may prevent damage to good components.

General Troubleshooting Tips

1

First and foremost, respect the voltages produced by the drive! Always check for the presence of line voltage and bus voltage before working on the unit.

Also, that some points in the drive are referenced to the negative Dus and cre 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 Sta/ic Test

Procedures. ”he static tests check all high voltage components for short circuits. The tests are relatively simple and can scve money and downtime. The safest method of conducting tests on the dnve is with the motor disconnected. In this way, 8i fDulty component that was overlooked or the unfortunate slip of a test probe will generally result in a unit trip instead of

further damage.

4

Following the replacement of parts, test run the unit with the motor disconnected. Start the unit at zero speed end slowly rcmp up until the speed is at least 40 Hz. Monitor the phase to phase output voltage on all three motor terminals to check balance (an analog voltmeter works best

here). If balanced, the unit is ready to be tested on a motor. If not, further investigation is necessary. Never attempt to defeat fcult protection devices within the drive. This will only result in unwanted component damage and may result in personal injury as well. 6. Always use faCto 8lpproved replacement parts. The unit h is been designed to operate within certain specifications. Incorrect parts may effect performance end result in further damage to the unit. 7. Read the instruction and service manuals. A thorough understanding of the unit is best. If ever in doubt, consult the factory or an authorized repair center for cssist8lnce.

28

Troubleshooting Recommendations

When approaching a machine or system that is not functioning properly, observe the message in the drive display. With the diagnostic information available in the unit, direction can be indicated for the cause of the problem. With this information, one can determine whether the problem is, for instance, in the motor wiring, a defective brake resistor, and so on. The absence of display lTt‹3SS iges can indicate a problem in the incoming AC line voltage. The absence of a fault message ccn indicate for example that the relcy which closes to provide a run command to the drive is not functioninQ, and no fault condition is sensed by the drive. It has simply not rmeived a run command.

When troubleshooting, that the control logic only responds to the commands it re›0eives. The possibility exists that, due to a f8IiIure in the control card, commands are not reaching the U to be processed. For this recson, it is necessary to isolate the fault to control commands, programming or the drive itself. Check the control commands first. This includes confirming that the closures end analog signals cre present at the proper terminals of the drive. Never assume that a signal is present because it is supposed to be. Use a meter to confirm the presence of signals at the drive terminals. Secondly, confirm that the drive programming for the terminals are set correctly

for the signals connected. Each digital and anaput terminal can be programmed to respond in very different ways. When concerned whether remote controls are functioning correctly, it is possible to control the drive from the keypad to confirm proper operation. A word of caution here: prior to taking control of the unit at the keypad, in8ure that all other equipment associated with the drive is prepared to operate. In many cases, safety interlocks to prevent inadvertent operation are ignored through local or hand control start.

29

Troubleshooting Recommendations (continued)

It is clso Important to ensure th0t the programming is correct for the system. For instance, incorrect settings of one or more of the motor parameters can result in poor performance of the motor by drawing excess current or even causing the unit to trip when there is no reel fault condition. There may be situations where the control card displays unknown information or where performance be affected in an unusual mcnner, such as speed instability. In these cases, the first thought may be to replace the control card. However, this type of operation is usually due to electrical noise in the control signal wiring. Although the control card is designed to reject interference, noise of sufficient amplitude can affect the performance. In these situations, it is nmessary to investigate the winng practices. For example, control wiring should never be run in parallel with higher voltage wiring, including power, motor, and brcke resistor leads. Shielded C8IbIe Should De used when the control wiring runs long distances. Termination of the shield should be in according to the instcllction manual. This is especially i mportant in installations that require compliance with "CE" specifications. In the event that one or more of the customer supplied line fuses blow, it is not recommendecl to replace the fuse and reapply power without further investigation. Blown line fuses usually indicates a problem in the power section of the drive. Perform the Static Test Procedures outlined in this manual to check for shorted

power components.

1)

2)

Symptom

If the motor runs unevenly, but no fault report is given, this may be because the VLT adjustable frequency drive has been set wrongly. Adjust setting.

Motor runs unevenly

Danfoss if the new setting does not make the motor run evenly.

4)

Symptom

Is the display illuminated?

Motor does not run

6)

NO

YES

Are display messages shown? YES

Is the unit connected to the mains supply? YES

See: 19)

Is the L connected to

Refer to the section on Fault Messages.

the unit correctIy º

YES

See: 8)

NO

Check L connection.

8)

Symptom No fault report or light in display.

Have prefuses for the VLT adjustable frequency drive blown?

NO

YES

10)

Perform Static Test Procedure on power components.

11)

Is the control card overloaded? Disconnect all control signal wires on the control card. (Remove

control plugs). Does that remove the fault? NO

YES

Measure the DC Bus voltage at +UDC and —UDC. that they are approximately 1.4 x the AC line voltage. Is the DC Bus voltage within rangeº

14)

Test the Soft Charge Circuit Rectifier, and Bus Capacitors.

NO

YES

12)

Check that the previous points are in order: The fault may have been caused by a shortcircuiting of the control signals. Perhaps the 24V supply has short circuited

15)

Replace the Control Card. Does the problem disappear? NO

Replace the Power Card. Does the problem disappear?

17)

Replace the Relay Card.

Does the problem

NO

YES

disappear? NO

YES

Resume operation Consult factory

Resume operation

YES

Resume operation

19)

20)

Symptom

Start the VLT adjustable frequency drive by pressing "Start" on the control .

Motor stopped. Light in display, but no fault

report. 22) Has the display locked, i.e.

it cannot be changed or is illegible? NO

YES

24)

Put the adjustable frequency drive on local reference. Change the parameter setting as follows: Parameter 002 = Local operation. Parameter 003 = desired reference value. The reference is changed by means of the ”+” and ”—" keys. Is the motor running? NO

YES

Has the motor been

Consult YES

25)

Check whether the control signals to the control card are in order.

Replace the Control card. Does the problem disappear? YES

Resume operation

27)

Replace the Power Card. Does the problem disappear? NO

Consult factory

YES

YES

correctly connected and are all motor phases in order?

26)

NO

Check whether the following precautions have been taken: • Have shielded control cables been used? • Are the shielded cables connected correctly?

Resume

operation

factory

Symptom/Cause Charts

SymptoWCause Charts are directed toward more experienced technicians. The intent of these charts is to provide possible ccuses for a specific symptom. In doing so, the charts provide a direction, but with limited instruction.

Possible Causes 1. Control Ccrd Display is not fit

Incorrect or missing input voIt8I§i3 Incorrect or missing DC bus voltage

Remote control wiring loading the power supply Defective Control Card Defective Power Card

Defective Relay Ccrd Defective or disconnected ribbon cables 2. Blown Input Line Fuses

Shorted Rectifier module Shorted IGBT Shorted DC Bus Shorted brake IGBT Mis-wired Dynamic Brake Resistor

3. Motor operation unstable (speed fluctuating)

Incorrectly adjusted motor parameters Improper current PID Regulator or Auxiliary Reference mis-adjusted

Control signal noise 4. Motor draws high current but ccnnot stcrt (may shimmer)

Open winding in motor

Open connection to motor One inverter phase missing. ”est output ph8se balance.

Symptom/Cause Charts (continued)

Possible Causes Motor runs unloaded but stalls when loaded. (Motor may run rough and VLT may trip.)

Unbalanced Input Phase Currents

Torque Limit set too low One half of one inverter phase missing. ”est output phase balance.

Input line voltage unb6ilanced FOUIty connection on input wirinQ

Input Rectifier module faulty (open diode).

Unbalanced Motor hase Currents

Open motor winding

Note. Slight variations in phase currents are normal. Variations

Faulty motor connection

Will also display Alarm 30, 31 or 32.

Static Test ProcedUFéS

WARNING Allow sufficient time for the DC Bus Capacitors to fully discharge before beginning any testing. The presence of bus voltage can be tested by connecting a voltmeter set to read up to 1000VDC to the +UDC and —UDC terminals.

WARNING

Test Equipment Setup

Make all tests with a meter capable of testing diodes. Use a digital VOM set on the diode scale or an analog ohmmeter set on R x 100 sccle.

JkCAUTION Before making any checks, disconnect all input, motor and brake resistor connections.

36

Input Rectifier Testing

The purpose of making tests on the rectifier is to rule out failures from either

shoned or open diodes. Failure of the rectifier module will usually result in open input line fuses. Open line fuses can also be the result of shooted IGBT module(s) or damaged DC bus capacitor. See the section on mveter tes / ng. For measurements where an open circuit is expected, some initial continuity may be present as the DC bus capacitors charge up. This is normal. For VLT SOOO EB version, and at! VLT 8000 and VLT 6000 units, the input rectifier can be tested using DC terminals 88 (-) and 89 (+) on the DC terminal block. (The terminal block locations are illustrated in the unit instruction manual.) Test in accordance with the following procedure using terminals 88 and 89 rather than —UDC and +UDC bus lugs.

For VL” SOOO ST and SB versions: 1. . Remove front cover ond loccte +UDC and —UDP bus lugs on relcy card (see Figure 1). BUS l UQs on some units mcy only be accessible by disassembling in accordance with procedures in Peplacement of lG8 Modu/es in this manual. 2. Connect positive (+) meter lead to +UDC. Connect negative (—) meter feed to terminals 91 (LI ), 92 (L2), and 93 (L3) in turn. Each reading should be

open. 3. Reverse meter leads by connecting negative (—) meter to +UDC and

positive (=) meter lead to terminals 91 (LI), 92 (L2), and 93 (L3) in turn. Ecch reading should show a diode drop. 4. Connect positive (+) meter lead to —UDC. Connect negative (—) meter lead to terminals 91 (L1), 92 (L2), and 93 (L3) in turn. Each reading should

show a diode drop. 5. Reverse the meter leads by connecting the negative (—) meter lead to —UDC and the positive (+) meter lead to terminals 91 (L1), 92 (L2), and 93 (L3) in turn. Each reading should be open.

Readings that are incorrect could indicate a faulty rectifier module. Refer to Component Peplacement Procedures section on removing end replacing components. If an open reading is present where a diode drop is expected, refer to the section Soft Charge Circuit Testing.

+UDC and —UDC Bus Lugs

WheneVeF f6iUlty power components cre found, 8IIw8Iys check for other faulty components in surrounding circuitry Often a component failure can ccuse subsequent failures in other components.

Figure 1: Input Rectifier

37

Soft Charge Circuit Testing Soft Charge or

The soft charge circuit in these units consists of one or more Positive Thermal Coefficient (PTC) resistors with a or connected across them so that when the or pulls-in, it byes the PTC resistor(s). The soft charge or on some units may only De accessible by disassembling in accordance with procedures in Peplacement of IGBT lVlooules in this manual.

1. Locate soft charge or mounted next to IGBT modules. On most models, it is located above IGBTs (see Figure 2). 2. With ohmmeter set for R x 1 scale, measure resistance across open s. At room temperature, resistance reading should be about 30 Ohm6. (Note: on some units, soft charge or is located with difficult access to half of the terminals. On these units, the reading ccn be taken from the available three terminals of the or and the +UDC bus bar across the IGBT modules.) Readings thdt 8lre incorrect could indicate a dcma ed or, rel£l\ CBrd, vcnstor card or problems with the DC bus capacitor. Reading 0 ohms could indicate closed requiring a soft charge circuit replacement. An open reading could indicate a defective resistor on the vcristor ccrd requiring varistor

card replacement.

+UDC Bus Bar

Figure 2: Soft Charge Curcuit

38

The purpose for testing the inverter is to rule out failures › n the IGBT power

InverterTesting

modules. If c short circuit is discovered during testing, the particular module ccn be pinpointed Dy noting the output terminal indicating the short circuit. (IGBT phases U, V, and W can be seen by pcQing ahecd to FiQUré 11.) Before beginning the test, ensure that the input line voltage and the motor and brake resistor leads are disconnected. For VLT SOOO EB version, and all VLT 8000 and VLT 6000 units the inverter ccn be tested using DC terminals 88 (-) and 89 (+) on the DC terminal block. (The terminal block locations are illustrated in the unit instruction manual.) Test in accordance with the following procedure using terminals 88 and 89 rather than —UDC and +UDC Dus lugs. 1. Connect the positive (+) meter lead to +UDC. Connect the negative (—) meter lead to terminals 96 (U), 97 (V), and 98 (W) in turn. (See Figure 3.) (Bus lugs on some units may only be accessible by disassembli ng in accordance

with procedures in Peplacement of IGBT Modules in this manual.) 2. Reverse the meter leads connecting the negative (—) meter to +UDC and the positive (+) meter lead to terminals 96 (U), 97 (V), and 98 (W) in turn.

Each reading should show a diode drop. 3. Connect the positive (+) meter lead to —UDC. Connect the negative (—) meter lead to terminals 96 (U), 97 (V), and 98 (W) in turn. Each reading should

show c diode drop. 4. Reverse the meter leads connecting the negative (—) meter lead to —UDC and the positive (‹) meter lead to terminals 96 (U), 97 (V), and 98 (W) in turn.

Each reading should be open. Readings that are incorrect could indicate c damaged IGBT module(s). Refer to the section on Pep/acemenf of lGB Modules for repair.

+UDC and -UDC Bus Lugs

Figure 3: Inverter

DYNAMIC TEST PROCEDURES

Output Phase Imbalance Testing

1. Perform a pre-test to isolate faults between the drive and motor. Connect the motor to the drive. Test phase-to-phase voltage and with a clamp on amp meter read the current. A balanced voltage reading with imbalanced current indiC it6›S that the motor is drawing uneven current. This could be ccused by a fcult in the motor windings or Dy the wiring connections between the drive and the motor. These f8iult conditions are external to the drive. 2. Test for an output phase imbalance. Disconnect motor and measure the

output phase—to phcse voltage. An output phase imbalance with no motor connected indicates an internal drive fault. When both voltage and current are imbalanced, it indicates c switching problem or faulty connection within the drive. This can be caused by improper gate drive

signals as a result of a faulty power card. Another cause may be a faulty IGBT or loose connection between the lGBTs and the power terminals. Note: When monitonng the output voltage, use an analog meter (for PWM output). Some digital meters are sensitive to the switching frequency and can give false readings. 1. Remove motor leads from output terminals 96, 97, end 98 of drive. 2. Conduct w eeder and /npu/ Pectitier tests as outlined earlier in this manual. 3. If inverter test indicates a good unit, apply power to unit. Initiate a run command with a speed reference greater then 40Hz. 4. Reed phase-to-phase output voltage on all three phases with analog meter. Actual vclue of output voltcQe is less important than the balance between phases. Balance should be within 8 volts per phase. 5. If imbalance is greater than 8 volts, measure gate drive firing signals in accordance with procedures in Oa/e Drive Firing Circuits Testing.

40

Gate Drive Firing Circuits Testing

t¶DANGER Gate firing signals are referenced to either the negative DC Bus or to the output of the drive. There is a large DC or AC potential to ground in these signals. Take extreme care to prevent personal injury or damage to equipment. Equip oscilloscopes, when used, with isolation devices.

The individual gcte drive firing pulses originate on the control card. These signals are then distributed to the individual IGBTs. Use an oscilloscope when observing gate drive signals. When an oscilloscope is not cvailcble, the test can be mcde with a DC voltmeter.

When using a voltmeter, compare the gcte pulse voltage readings between ph8ISC›S. A missing or incorrect gate pulse has c different average voltage when compared to the gcte pulse voltage in other phases. At very low frequencies (below 10Hz), the voltmeter reading will tend to be unstable. Above 10Hz the meter reading will stabilize. When using an oscilloscope, the signal can be read at any output frequency.

2t,WARNING These tests must be made with motor disconnected.The internal impedance of the measuring device can induce problems into the output circuit. Also, noise pulses produced by the connecting and disconnecting of scope/meter leads can cause an IGBT to fire at the wrong time. This can result in damage to one or more IGBT modules. It is recommended to disconnect the main input voltage between each connector reading.

1. . On power ccrd, locate connectors marked "MK1 ", "MK2" and "MK3". Two pairs of leads connect to each connector, consisting of a red and a blcck lead. Red leads connect to gate of each IGBT. Blcck leads connect to emitter of IGB”. (See Figure 4 and Figure 6 on the following page.)

Figure 4: MK Connector

2. Connect the scope or meter leads across the pcir of leads, plus (+) meter lead to red, minus (—) meter lead to bldCk. 3. Apply power and run unit at 20Hz. Reed voltage level if a meter is used or TBk aun: zsksrs

nvrrage ggjg,j

»

, „

waveform if a scope is used.

4. Disconnect power from unit before changing leads to c different set of gate wires. If a DVM is used for this reading, it will typically measure approximately +3.5VDC for each set of gate leads while the unit is running. When the drive is not running, the reading should be —8VDC. It is important that all six sets of gate signals give the same reading.

" i• v •••»•

” "”' "‟“

" '

scope used for this test, the waveform should appear similar to Figure 5. The waveform mcy vary slightly for different models of oscilloscopes. It is important that all six waveforms are identical.

Figure 5: Circuit Waveform 41

Gate Drive Firing Circuits Testing (continued)

00

Figure 6: Gate Pulse Pin-outs

42

Current Sensors Testing

When a current sensor f6iils it typically gives a false indication for the amount of current present in the circuit. It may clso indicate current flow when the actual current value is zero. Test the current sensor in accordance with the following

procedure. 1. Adjust parameters for small display readouts of L keypad with lJ, V, and W currents displayed. 2. Disconnect motor from output terminals 96, 97, and 98 of drive.

3. Apply a run and speed command to drive to produce an output of some level. 4. Observe current in the displays. The v6lues should be zero. Note: dnve will always display zero current with no run or speed command present. A defective current sensor typically indicates several amps of current flowing when the actual value is zero. On most VL”s, the current sensors cre located on the relcy card. If 6 f6ulty current sensor is found in one of thes6› units, replace the entire relay card assembly. On some older VLTs with higher horse power ratings, the current sensors cre mounted on a separate bracket and connected to the feIB CBrd via connectors MK1 , MK2, and MK3. For these units, individual defective current sensors ccn be replaced. Test the current sensor in accordance with the fOIIowinQ proCedure.

1. . Disconnect motor. 2. Measure voltage between pins 1 (black lead) and 3 (white lead) of connectors MK1, MK2, and MK3. 3. With no motor current flow (motor disconnected), voltage should read 14VDC. All three measurements should be equal (within 15mV). 4.

Replace any faulty current sensor.

43

COMPONENT REPLACEMENT PROCEDURES

2kDANGER

Touching electrical parts may be fatal — even after equipment has been disconnected from AC line. To be sure that capacitors have fully discharged, wait 14 minutes for 208 V and 460 V units and 30 minutes for 600 V units after power has been removed before touching any internal component.

Control Card Removal and Replacement Control Terminals

&CAUTION Many drive components are sensitive to Electrostatic Discharge.When removing modules from drive, use proper ESD equipment to prevent possible damage to circuitry. Disconnect power to unit and ensure that DC DuS c8lpacitors are fully discharged. 2.

Remove L keypad by pulling from top. Disconnect control wiring from control ccrd assembly by removing protective cover over control terminals end unplugging control terminal strips.

Control Card Assy.

4

Remove two control card retaining screws.

5.

Lift out bottom end of control card assembly far enough to remove the two ribbon cables from connectors on control ccrd. (Note: top side of assembly is hinged.)

5.

Swing control card assembly out until top of assembly releases.

7.

Remove L mounting cradle by gently depressing tabs at four corners of crcdle end pulling straight out. Remove three mounting screws from control card and disengage card from retaining slot.

L Mounting Cradl

g

Position replacement control card into retaining sIOt 8IIong side Of aluminum mounting bracket and position it so that screw holes align with

bracket. Replace three mounting screws. Tighten to 10 in. lbs. Carefully snap L mounting cradle back into place. 12.

Hook top end of control card assembly onto hinge flange at top of unit. Connect two ribbon cables before securing assembly into place.

Retaining Slot

Secure bottom end of assembly into place and tighten two mounting screws. 14. 15.

Control Card

44

ounting Scew Hole

Reinstall L keypad into crodle.

When reapplying power to drive, new control card must be initialized. On Keypcd, press and hold 3 keys (Display, Change DOtd end Menu) while applying power to unit. "Manual Initialize" will pear in bottom line of display. Release keys. When message disappears, initialization is

complete.

POWER COMPONENTS DISASSEMBLY NEMA 1 (IP20) Units

JtCAUTlON Many drive components are sensitive to Electrostatic Discharge. When removing modules from drive, use proper ESD equipment to prevent possible damage to circuitry. Note: It is rmommended that the unit be removed from the inst8lIIation or and pieced on a suitable workbench when performing major repairs such as power component replacement. Minor variations mcy occur in the following prc›cedures based upon configuration of the unit. Remove control ccrd in accordance with Control Card Pemoval and

Power Card Replacement

PC:Dlacement.

2

Remove seven (7) top cover mounting screws (see Figure 7).

Disconnect fan cable(s) from MKJ 0 and/or MK11 on power card. Remove top cover while threading fen cable(s) through opening in top bulkhead (see Figure 8).

4. Remove retaining screws from side (see Figure 9). Remove two (2) retaining screws from bottom . Disconnect two (2) ribbon cables from

power board. Remove two (2) ribbon cable retaining plate screws. Remove side pcnel with control channel and ribbon cable retainer att8lChed. Note correct location of each connector on power card to ensure proper reinstallation (see Figure 10). Unplug five (5) connectors (or 6 with brake) from power card. Remove three (3) mounting screws and two (2) ribbon cable retaining plate standoffs from power ccrd. Remove power card. Reverse this procedure to reinstall power card.

Power Card Mounting Plate Removal

Remove power card in accordance with Power Card Replacement.

2

Remove four (4) side mounting screws on remaining side . Remove six (6) mounting screws from power cord mounting plate. Remove plate end retain insulator with mounting plate.

45

Replacement of NEMA

1 (IP20)

IGBT Modules

1. Remove power card and power ccrd mounting plate in accordance with POw6'F Card Sep/acemen/ and Power Card Mounting Plate Removal. 2. Remove bottom plate from unit by removing attaching screws (see Figure 9). 3. Remove power terminal assembly plate by removing six (6) attaching screws. 4. Remove bus bar attaching screws from IGBT modules (see Figure 1 1) 5. Remove motor terminal attaching screw from IGBT. 6. Remove machine screw positioned on relcy card necr soft charge relcy from h6›8Itsink st indoff (see Figure 12). 7. Disconnect wiring from MOV and relay card by grasping connector and pulling to release locking tab. 8. Remove capacitor bank assembly. 9. Remove IGBT module by removing mounting screws (see Figure 12). 10. Clean away any remaining silicon compound from heatsink in location where

IGBT was removed. 11. Apply evenly light coating (3 mils) of silicon heatsink compound to entire base

of replacement IGBT module. 12. Position replacement IGB” module into place. Fasten with mounting screws to 8 10 in. lbs. 13. Assemble in reverse order. Hand tighten mounting screws of capacitor bank assembly before torquing screws into location. Tighten mounting screws to

22-30 in. lbs. Note: On some VLT models, the IGBT modules h0ve four mounting screws. For these

modules, use a cross-torque tightening pattern as shown

46

bp Cover Mounting

Top Cover Mounting

Figure 7: Top Cover Disassembly

47

Cable Access

Control Channel

End Mounting Screw

Fan

Fan Cable

Figure 8: Top Cover and Fan Removal

48

Side

Control Channel Mounting Screw

Side Mounting Screws

Bottom

Figure 9: Side Removal

49

Control Channel

Power Card Mounting Screws

Power Card

Ribbon Cable Retaining Plate Screws

Power Card

Mounting Screw

Power Card Connectors

Control Channel Mounting Screw

Figure 10: Contol Channel Assembly Removal

Bus Bar Attaching

Screws

IGBT (‹-) Bus Bar

Attaching Screw

Lock Tab Connector

Figure 11: IGBT Access

Soft Charge Relay

Heatsink Standoff

Outlet IGBT (V)

IGBT mounting screw Outlet IGBT (W)

Capacitor Bank Assy. Mounting Bracket (some models) Mounting Screws (some models)

Figure 12: IGBT Removal

REPLACEMENT OF POWER COMPONENTS (NEMA12)

¶LDANGER Touching electrical parts may be fatal - even after equipment has

been disconnected from AC line. To be sure that capacitors have fully discharged, wait 14 minutes for 208 V and 460 V units and 30 minutes for 600 V units after power has been removed before touching any internal component.

Power Card Replacement NEMA 12 (IP54) Units

Control Terminals

JtCAUTlON Many drive components are sensitive to Electrostatic Discharge.When removing modules from drive, use proper ESD equipment to prevent possible damage to circuitry.

Disconnect power to unit and ensure that DC bus capacitors are fully discharged.

2 Open front drive by loosening captured screws. Disconnect ribbon cable between Dack of keypad L and control C6ird

from control card connector (see Figure 13). Retaining Screw

4.

Disconnect two ribbon cables between control card and power card from power card connector. Disconnect control wiring from control ccrd assembly by unpluging control terminal strips. Remove two control card retaining screws.

Control Card Assy.

Remove control card assembly by lifting out Dottom end to disengage hinge at top of assembly.

8

Note carefully correct location of ecch power card connector to ensure

proper reinstallation of power card. Disconnect eight (8) power card cables from connectors MK1, MK2, MK3, MK7, MK8, MK10, MKJ I,and MK12 on power card. Units with Drake will hcve additional MK4 connector to remove.

9. Remove power card and insulator by removing five (5) mounting screws from power card (see Figures 1 4 and 15).

Reverse procedure to reinstall power ccrd.

Remove power card using procedure in Power Card Reo/acemen/ /VFMA 12 (IP54) Llni”ts.

Replacement of IGBT Modules NEMA 12 (IP54) Units 2

Unplug ccbles from MK1 and MK2 on fan control card. See Figures 14 (also shown on Figure 16). Disconnect fan cable from TP1 .

4

Remove five (5) mounting screws from power card mounting plate and remove plate (see Figure 15).

Remove two /2) bus bar and one (I) motor lead retaining screws from IGBT(s) to be removed (see Figure 17). 6.

Remove two (2) IGBT mounting screws. Note: some IGBT configurations have four (4) mounting screws.

7.

Remove IGBT Dy sliding component out from under Dus bcr.

8 Clean awcy any remaining silicon compound from heatsink in location where IGBT was removed.

9

Apply evenly light coating (3 mils) of silicon heatsink compound to entire base of replacement IGBT module. Position replacement IGBT module into place. Fasten with mounting screws to 8-10 in. lbs.

Assemble in reverse order. Tighten mounting screws to 22—30 in. lbs. Note: On some VLT models, the IGBT modules have four mounting screws. For these

modules, use a cross-torque tightening pattern as shown.

54

Control Card

Power Card

L Keypad

Ribbon Cable

Control Card Ribbon Cables

Cassette Retaining Screws

Figure 13: Ribbon Cable Removal

MK1 Connector MK2 Connector TP1 Connector Fan Control Card

5 Power Card Mounting Screws

Figure 14: Power Card Removal 56

Mounting Screws

owe Card

Mounting Plate

Power Card

Insulation

Figure 15: Power Card MountingPlate Removal 57

Bus Bar Retaining Screws

Fan Control Card

Motor Lead Retaining Screw

TP1 Connector

Power Card Mounting Plate

Figure 16: IGBT Bus Bar Removal 58

Brake IGBT IGBT (V) (W) IGBT IGBT(U) Retaining Screw

(+) Bus Bar

(-) Bus Bar

IGBT Retaining Screw

DC Bus Capacitors

Figure 17: IGBT Removal

Spare Parts Lists VLT 5008 - 5027 VLT 5008 - 5027 Flux VLT 8006 - 8032 Aqua VLT 6006 - 6032 VLT 4006 - 4032 VT

VLT SOOO Process VLT SOOO Flux VLT 4000 VT VLT 6000

VLT 6000 Aqua Descrtiption

200 - 240 V

5006

5011

5016

5022

5027

4006

4008

4011

4016

4022

4027

4032

b» n

soos

s«

s« s

sozz

go27

6032

8006

8008

6011

6016

8022

8027

6032

Power Card Power Card, Coated Control Card, Process Control Card, P rocess, Coated Control Card, Flux Control Card, HVAC Control Card, HVAC, Coated Control Card, 4000 VT

175Z2097 175Z2098 175Z4520 175Z2643 175Z2644 175Z2632 176F1400 176F1452 175Z3595 176F1405 176F 1405 176F1405 176F1453 176F 1453 176F1453 176F5591 176F5591 176F5591

175Z4521 175Z2633 176F1400 176F1452 175Z3595 176F1405 176F1453 176F5591

175Z4522 175Z2634 176F1400 176F1452 175Z3595 176F1405 176F1453 176F5591

175Z4523 175Z2635 176F1400 176F1452 175Z3595 176F 1405 176F 1453 176F5591

175Z4524 175Z2636 176F1400 176F1452 175Z3595 176F1405 176F1453 176F5591

Control Card, 4000 VT, Coated Control Card, Aqua Control Card, Aqua, Coated Dis play , Process Dis play, HVAC, Aqua Control Card Casette Cable, Control Card-Power Card Dis play Cradle, IP20 Term inal, 12 Pole Term inal, 9 Pole Term inal, 3 Pole Term inal, 6 Pole Rectifier IGBT Inwrter IGBT, Brake Clam p Capac itor DC Bus Capacitor Relay Card or Varistor PCB A s sem bly w/MOV MOV Fan, IP20 Fan IP54 Fan Assem bly, IP54 Fan Capacitor, IP54 Fan Control Card, IP54 Groin inet

176F5592 176F5580 176F5581 175Z0401 175Z7804 175Z1064 175Z1821 175Z1158 613X6358 613X6359 613X6360 175Z1988 175H0483 175Z1324 175Z1334 175H0810 175Z3513 175Z4507 175Z2012 175Z4510 612B 7099 175Z1378 175H0761 175Z2358 175Z1832 175Z1653 175Z1086

176F5592 176F5580 176F5581 175Z0401 175Z7804 175Z1064 175Z1821 175Z1 158 613X6358 613X6359 613X6360 175Z1988 175H0483 175Z1324 175Z1334 175H0810 175Z351 5 175Z4507 175Z2035 175Z4510 612B 7099 175Z1378 175H0761 175Z2358 175Z1832 175Z1653 175Z1086

176F5592 176F5580 176F5581 175Z0401 175Z7804 175Z1064 175Z1821 175Z1158 613X6358 613X6359 613X6360 175Z1988 175H0485 175Z1324 175Z1334 175H0810 175Z3517 175Z4507 175Z2001 175Z4510 612B 7099 175Z1378 175H0761 175Z2358 175Z1832 175Z1653 175Z1086

176F 5592 176F 5580 176F5581 175Z0401 175Z7804 175Z1064 175Z1821 175Z1158 613X6358 613X6359 613X6360 175Z1988 175H0485 175Z1339 175Z1339 175H0810 175Z3517 175Z4508 175Z2002 175Z4510 612B 7099 175Z1378 175H0761 175Z2358 175Z1832 175Z1653 175Z1086

176F5592 176F5580 176F5581 175Z0401 175Z7804 175Z1064 175Z1821 175Z1158 613X6358 613X6359 613X6360 175Z1988 175H0485 175Z1339 175Z1339 175H0810 175Z3515 175Z4508 175Z2002 175Z4510 612 B 7099 175Z1378 175H1807 175Z2358 175Z1832 175Z1654 175Z1086

60

176F 5592 176F 5580 176F 5581 175Z0401 175Z7804 175Z1064 175Z1821 175Z1158 613X6358 613X6359 613X6360 175Z1988 175H0483 175Z1324 175Z1334 175H0810 175Z3513 175Z4507 175Z2012 175Z4510 612B 7099 175Z1378 175H0761 175Z2358 175Z1832 175Z1653 175Z1086

176F5592 176F5580 176F5581 175Z0401 175Z7804 175Z1064 175Z1821 175Z1158 613X6358 613X6359 613X6360 175Z1988 175H0483 175Z1324 175Z1334 175H0810 175Z3513 175Z4507 175Z2012 175Z4510 612B 7099 175Z1378 175H0761 175Z2358 175Z1832 175Z1653 175Z1086

Spare Parts VLT 5016 - 5062 VLT 5016 - 5062 Flux VLT 8016 - 8072 Aqua VLT 6016 - 6072 VLT 4016 - 4072 VT

VLT SOOO Process VLT SOOO Flux VLT 4000 VT VLT 6000 VLT 8000 A ua Descrti tion Power Card, 4016,6016 8016 Power Card, VT, Coated Power Card Power Card, Coated Control Card, Process Control Card, Process, Coated Control Card, Flux Control Card, HVAC Control Card, HVAC, Coated Control Card, 4000 VT Control Card, 4000 VT, Coated Control Card, A ua Control Card, A ua, Coated Dis la , Process

380 - 460 V

5016 5016

5022 5022

5027 5027

5032 5032

5042 5042

5052 5052

5062 5062

4016/4022

J027

4032

4042

4052

4062

4072

6016/6022 8016/8022

6027 8027

6032 8032

6042 8042

6052 8052

6062 8052

6072 8072

175Z2099 175Z2645 175Z4525 175Z2637 176F1400 176F1452 175Z3595 176F1405 176F1453 176F5591 176F5592 176F5580 176F5581 175Z0401

175Z4526 175Z2638 176F1400 176F1452 175Z3595 176F1405 176F1453 176F5591 176F5592 176F5580 176F5581 175Z0401

175Z4527 175Z2639 176F1400 176F1452 175Z3595 176F1405 176F1453 176F5591 176F5592 176F5580 176F5581 175Z0401

175Z4528 175Z2640 176F1400 176F1452 175Z3595 176F1405 176F1453 176F5591 176F5592 176F5580 176F5581 175Z0401

175Z4529 175Z2641 176F1400 176F1452 175Z3595 176F1405 176F1453 176F5591 176F5592 176F5580 176F5581 175Z0401

175Z4530 175Z2642 176F1400 176F1452 175Z3595 176F1405 176F1453 176F5591 176F5592 176F5580 176F5581 175Z0401

175Z3351 175Z33M 176F1400 176F1452 175Z3595 176F1405 176F1453 176F5591 176F5592 176F5580 176F5581 175Z0401

Dis la , HVAC, A ua

175Z7804 175Z7804 175Z7804 175Z7804 175Z7804 175Z7804 175Z7804

Control Card Casette

175Z1064 175Z1064 175Z1064 175Z1064 175Z1064 175Z1064 175Z1064

Cable, Control Card-Power Card 175Z1821 175Z1821 175Z1821 175Z1821 175Z1821 175Z1821 175Z1821

Dis la Cradle, IP20 Terminal, 12 Pole Terminal, 9 Pole Terminal, 3 Pole Terminal, 6 Pole Rectifier IGBT, Inverter IGBT, Brake Clam Ca acitor DC Bus Ca acitor

175Z1158 175Z1158 613X6358 613X6358 613X6359 613X6359 613X6360 613X6360 175Z1988 175Z1988 175H0483 175H0483 175Z1308 175Z1308 175Z1308 175Z1308 175H0810 175H0810 175Z3514 175Z3513

175Z1158 613X6358 613X6359 613X6360 175Z1988 175H0483 175Z1310 175Z1308 175H0810 175Z3515

175Z1158 613X6358 613X6359 613X6360 175Z1988 175H0485 175Z1310 175Z1308 175H0810 175Z3516

175Z1158 613X6358 613X6359 613X6360 175Z1988 175H0485 175Z1310 175Z1310 175H0810 175Z3517

175Z1158 613X6358 613X6359 613X6360 175Z1988 175H0485 175Z1310 175Z1310 175H0810 175Z3515

175Z1158 613X6358 613X6359 613X6360 175Z1988 175Z3353 175Z3303 175Z1310 175H0810 175Z3515

Rela Card

175Z4507 175Z4507 175Z4507 175Z4507 175Z4508 175Z4508 175Z3357

or aristor PCB Assembl w/MOV MOV Fan, IP20 Fan, IP54

175Z2012 175Z2012 175Z4509 175Z4509 612L6018 612L6018 175Z1378 175Z1378 175H0765 175H0765

Fan Assembl , IP54

175Z2358 175Z2358 175Z2358 175Z2358 175Z2358 175Z2358

Fan Ca acitor, IP54 Fan Control Card, IP54 Grommet

175Z1831 175Z1831 175Z1831 175Z1831 175Z1831 175Z1831 175Z1831 175Z1655 175Z1655 175Z1655 175Z1655 175Z1656 175Z1656 175Z3302 175Z1086 175Z1086 175Z1086 175Z1086 175Z1086 175Z1086

175Z2012 175Z4509 612L6018 175Z1378 175H0765

175Z2001 175Z4509 612L6018 175Z1378 175H0765

175Z2002 175Z4509 612L6018 175Z1378 175H0765

175Z2002 175Z4509 612L6018 175Z1378 175H1808

175Z3261 175Z4509 612L6018 175Z3382 175Z1378

Spare Parts VLT 5016 - 5062 VLT 5016 - 5062 Flux VLT 8016 - 8072 Aqua VLT 6016 - 6072 VLT 4016 - 4072 VT

SSO - 600 V

VLT SOOO Process VLT 4000 VT

5016 4016f4022

5022 4027

5027 4032

5032 4042

5042 4052

5052 4062

5062 4072

VLT 6000

6016/6022

6027

6032

6042

6052

6062

6072

VLT 8000 Aqua Descrtiption Power Card, 4016,6016,8016 Power Card, VT, Coated Power Card Power Card, Coated

8016/8022

8027

8032

8042

8062

8062

8072

Control Card, Process Control Card, Process, Coated Control Card, HVAC

176F1400 176F1400 176F1400 176F1400 176F1400 176F1400 176F1400 176F1452 176F1452 176F1452 176F1452 176F1452 176F1452 176F1452 176F1405 176F1405 176F1405 176F1405 176F1405 176F1405 176F1405

Control Card, HVAC, Coated

176F1453 176F1453 176F1453 176F1453 176F1453 176F1453 176F1453

Control Card, 4000 VT Control Card, 4000 VT, Coated

176F5591 176F5591 176F5591 176F5591 176F5591 176F5591 176F5591 176F5592 176F5592 176F5592 176F5592 176F5592 176F5592 176F5592

Control Card, A ua

176F5580 176F5580 176F5580 176F5580 176F5580 176F5580 176F5580

Control Card, A ua, Coated Dis la , Process Dis la , HVAC, A ua

176F5581 176F5581 176F5581 176F5581 176F5581 176F5581 176F5581 175Z0401 175Z0401 175Z0401 175Z0401 175Z0401 175Z0401 175Z0401 175Z7804 175Z7804 175Z7804 175Z7804 175Z7804 175Z7804 175Z7804

Control Card Casette

175Z1064 175Z1064 175Z1064 175Z1064 175Z1064 175Z1064 175Z1064

176F5514 176F5500 176F5501 176F5502 176F5503 176F5504 176F5505 176F5506

Cable, Control Card-Power Card 175Z1821 175Z1821 175Z1821 175Z1821 175Z1821 175Z1821 175Z1821 Dis la Cradle, IP20 175Z1158 175Z1158 175Z1158 175Z1158 175Z1158 175Z1158 175Z1158

Terminal, 12 Pole Terminal, 9 Pole Terminal, 3 Pole

613X6358 613X6358 613X6358 613X6358 613X6358 613X6358 613X6358 613X6359 613X6359 613X6359 613X6359 613X6359 613X6359 613X6359 613X6360 613X6360 613X6360 613X6360 613X6360 613X6360 613X6360

Terminal, 6 Pole Rectifier IGBT, Inverter IGBT, Brake

175Z1988 175H0483 176F2311 176F2311

Clam Ca acitor DC Bus Ca acitor

175H0810 175H0810 175H0810 175H0810 175H0810 175H0810 175H0810 176F2315 176F2315 176F2316 176F2317 176F2318 176F2317 176F2317

Rela Card or aristor PCB Assembl w/MOV Fan, IP20 Grommet

176F2307 175Z2012 176F2309 175Z1378 175Z1086

62

175Z1988 175H0483 176F2311 176F2311

176F2307 175Z2012 176F2309 175Z1378 175Z1086

175Z1988 175H0483 176F2312 176F2311

176F2307 175Z2035 176F2310 175Z1378 175Z1086

175Z1988 175H0485 176F2312 176F2311

176F2307 175Z2001 176F2310 175Z1378 175Z1086

175Z1988 175H0485 176F2313 176F2312

176F2307 175Z2002 176F2310 175Z1378 175Z1086

175Z1988 175H0485 176F2313 176F2312

176F2308 175Z2002 176F2310 175Z1378 175Z1086

175Z1988 175H0485 176F2313 176F2312

176F2308 175Z2002 176F2310 175Z3382 175Z1086

24VDC ‹8' Fan On

Control Card

ToDCBuTna

Red

Red

Blach

Black

Top Fan(s)

88 - 89 (E. B. o y) MK 9 MK10 MK1 1 MK 5

MK 6

MK 12

T“

Heat S› nk Thermal Switch

Power Card

ioxr› ‹0› Room Temp. MK 7 To Relay Card MK 4

MK 4

MK 8

To Bus or & Relay Card MK 8

To Brake IGBT MK 1

MK 2

MK 3

To U Phase IGBT Module

To V Phase IGBT Module

To W Phase IGBT Module

To Power Card 12VDC

Three Ouf oul I CBT Modules

Brake IGBT Module

To Power Card

Rectifier Module

BR

PTC

Varistor PCB Assy. .

TP2

DC BUS 6

To Power Card MK 8

x 1.4 AUX Relay

R + P—

Capac»or Balance C rcu4

oz 3

Brown

Relay Card

T2

E×ie , Brake Resistor

To Power Card 12VDC

Brake IGBT Module

²hree Output IGBT Modules

To Power Card MK 8

Gaie Signals

Rectifier Module

BR

Varistor PCB Assy. ;

P+ R—

DC Bus x 1.4

Relay

External Brake Resistor

02 03

Relay Card

T3

66

Danfoss cen eocept no responsibility for possible enors n catak›gs. brochures and otter printed mater?ls. Danfoss reserves tt›e r igtt to after ns produce without rotise. Th s also applies to o‹odust s already on order provided fhat suet› atteraéons can be ms6e ho‹n subseguemial ct›anges Eng necessary in specifications alree6y agreed upon.

Danfoss Drives

Danfoss Graham

Danfoss Water & Wastewater

Division of Danfoss Inc.

Division of Danfoss Inc.

Division of Danfo9s Inc.

4401 North Bell School Road Loves Park, Illinios 61 11 1 Phone: (800) 432-6367 Fax: (815) 639-8002

P.O. Box 245041 8800 West Bradley Road Milwaukee, Wisconsin 53224 Phone: (800) 621-8806

PO. Box 245041 8800 West Bradley Road Milwaukee, Wisconsin 53224 Phone: (800) 621-8806

Fax. (414) 355-61 17

Fax. (414) 355-61 1 7

© 2002 Danfoss Inc.

Part# 175R5389