BENSHAW SG Series Service Manual
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BENSHAW SG Series Service Manual

Variable frequency drive
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Pub # 890046-10-00
Dec. 2015
SG Series Variable Frequency Drive
Service Manual

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Summary of Contents for BENSHAW SG Series

  • Page 1 Pub # 890046-10-00 Dec. 2015 SG Series Variable Frequency Drive Service Manual...
  • Page 3 Pub # 890046-10-00 Dec. 2015 Index Section 1 – Spare Parts List Section 2 – Drive Component Layouts Section 3 – PC Board Descriptions Section 4 – Troubleshooting...
  • Page 5 Pub. # 890046-10-00 Dec. 2015 Section 1 Section 1 Section 1 Section 1 Spare Parts List Spare Parts List Spare Parts List Spare Parts List Section 1, Page 1 of 8...
  • Page 6 Dec. 2015 SG SPARE PARTS LIST - 230V (7.5 - 40 HP) Horsepower Description Part Number Specification CONTROL PCB assembly PC-100062-00 PCB ASS'Y,CONTROL,SV-IP5 (New) - for Benshaw PC-100006-00 PCB ASS'Y,POWER,SV-IP5,055-2 POWER PCB assembly PC-100007-00 PCB ASS'Y,POWER,SV-IP5,075-2 PC-100009-00 PCB ASS'Y,POWER,SV-IP5,110-2 SMPS (CTRL) PCB assembly...
  • Page 7 Dec. 2015 SG SPARE PARTS LIST - 460V (7.5 - 40 HP) Horsepower Description Part Number Specification CONTROL PCB assembly PC-100062-00 PCB ASS'Y,CONTROL,SV-IP5 (New) - for Benshaw PC-100034-00 PCB ASS'Y,POWER,SV-IP5,055-4 POWER PCB assembly PC-100008-00 PCB ASS'Y,POWER,SV-IP5,075-4 PC-100010-00 PCB ASS'Y,POWER,SV-IP5,110-4 SMPS (CTRL) PCB assembly...
  • Page 8 Charging Resistor RES-100181-00 RES,METAL CLAD,MCRBC60W40J,60W,40,J,B,Fullohm RES-100179-00 RES,METAL CLAD,MCRBC150W30J,150W,30,J,B,Fullohm Keypad/Display LCD-100000-00 Assy,Loader(LCD) BENSHAW, SV-IP5A Bezel, Keypad mount VFD-KEYPAD-SG-BEZEL COVER,LOADER BRK,SV-iP5A Terminal Block, Control Bd. TE-100883-01 Terminal Block, SG Ctrl Board, 5P, SG (new style after Aug 2008) Terminal Block, Control Bd.
  • Page 9 SG SPARE PARTS LIST - 460V (150 - 400 HP) Horsepower Description Part Number Specification Control PCB assembly PC-100064-00 PCB ASS'Y,CONTROL,IP5A,1100~4500-4 (New) - for Benshaw PC-100053-01 PCB ASS'Y,MAIN SMPS,IP5A,1100-4 PC-100053-02 PCB ASS'Y,MAIN SMPS,IP5A,1320-4 Main SMPS PCB assembly PC-100053-03 PCB ASS'Y,MAIN SMPS,IP5A,1600-4...
  • Page 10 SG SPARE PARTS LIST - 460V (500 - 700 HP) Horsepower Description Part Number Specification Control PCB assembly PC-100064-00 PCB ASS'Y,CONTROL,IP5A,1100~4500-4 (New) - for Benshaw PC-100053-08 PCB ASS'Y,MAIN SMPS,IP5A,3150-4 Main SMPS PCB assembly PC-100053-09 PCB ASS'Y,MAIN SMPS,IP5A,3750-4 FAN SMPS PCB assembly...
  • Page 11 Dec. 2015 SG SPARE PARTS LIST - 575V (7.5 - 40 HP) Horsepower Description Part Number Specification Control PCB assembly PC-100062-00 PCB ASS'Y,CONTROL,SV-IP5 (New) - for Benshaw PC-100074-00 PCB ASS'Y,POWER,SV-IP5A,0055-6 PC-100074-01 PCB ASS'Y,POWER,SV-IP5A,0075-6 PC-100074-02 PCB ASS'Y,POWER,SV-IP5A,0110-6 POWER PCB assembly PC-100074-03...
  • Page 12 SG SPARE PARTS LIST - 575V (50 - 125 HP) Horsepower Description Part Number Specification Control PCB assembly PC-100063-00 PCB ASS'Y,CONTROL,IP5A,370~900-4 (New) - for Benshaw PC-100076-00 PCB ASS'Y,MAIN SMPS,SV-IP5A,0370-6 Main SMPS PCB assembly PC-100076-01 PCB ASS'Y,MAIN SMPS,SV-IP5A,0750-6 PC-100076-02 PCB ASS'Y,MAIN SMPS,SV-IP5A,0900-6...
  • Page 13 Pub # 890046-10-00 Dec. 2015 Section 2 Drive Component Layouts Section 2, Page 1 of 50...
  • Page 14 Pub # 890046-10-00 Dec. 2015 Section 2, Page 2 of 50...

  • Page 15: Section 1, Page 3 Of

    Pub # 890046-10-00 Dec. 2015 LCD-100000-00 Section 2, Page 3 of 50...

  • Page 16: Section 1, Page 4 Of

    Pub # 890046-10-00 Dec. 2015 PC-100004-00 SMPS Board PC-100062-00 Control Board TE-100883-00 Control Terminal Blocks Section 2, Page 4 of 50...
  • Page 17 Pub # 890046-10-00 Dec. 2015 PC-100002-00 CA-100132-00 DRV SMPS 3300uF Capacitors Board Qty 4 IGBT-100034-00 IGBT PC-100016-00 Snubber Board DI-100044-00 150A Input PC-100014-00 Diodes CT PCB Qty 1 Section 2, Page 5 of 50...
  • Page 18 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 FA-100021-00 Fans (Not Shown) Qty 2 Section 2, Page 6 of 50...
  • Page 19 Pub # 890046-10-00 Dec. 2015 PC-100065-00 Main SMPS Board PC-100023-00 Fan SMPS Board Control Terminal PC-100063-00 Blocks Control Board See Parts List Section 2, Page 7 of 50...
  • Page 20 Pub # 890046-10-00 Dec. 2015 FU-100476-00 FU-100472-00 PC-100023-00 Fuse Detector 160A Fuse Fan SMPS Board PC-100024-00 RES-100180-00 Drive SMPS Pre-charge Board Resistor DI-100045-00 Diode Rectifier IGBT-100042-00 Qty 3 IGBT PC-100026-00 SCR Snubber PC-100030-00 Board CT Board CA-100133-00 4700uF Capacitors Qty 4 Section 2, Page 8 of 50...
  • Page 21 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 FA-100021-00 Fans (Not Shown) Qty 2 Section 2, Page 9 of 50...
  • Page 22 Pub # 890046-10-00 Dec. 2015 PC-100066-00 Main SMPS Board PC-100023-00 Fan SMPS Board Control Terminal Blocks See Parts List PC-100063-00 Control Board Section 2, Page 10 of 50...
  • Page 23 Pub # 890046-10-00 Dec. 2015 FU-100476-00 FU-100472-00 PC-100023-00 Fuse Detector 160A Fuse Fan SMPS Board PC-100024-00 RES-100181-00 Drive SMPS Pre-charge Board Resistor DI-100047-00 Diode Rectifier IGBT-100042-00 Qty 3 IGBT PC-100026-00 SCR Snubber PC-100030-00 Board CT Board CA-100134-00 5600 uF Capacitors Qty 4 Section 2, Page 11 of 50...
  • Page 24 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 FA-100022-00 Fans (Not Shown) Qty 2 Section 2, Page 12 of 50...
  • Page 25 Pub # 890046-10-00 Dec. 2015 PC-100067-00 Main SMPS Board PC-100023-00 Fan SMPS Board Control Terminal Blocks See Parts List PC-100063-00 Control Board Section 2, Page 13 of 50...
  • Page 26 Pub # 890046-10-00 Dec. 2015 FU-100476-00 FU-100473-00 PC-100023-00 Fuse Detector 200A Fuse Fan SMPS Board PC-100024-00 RES-100181-00 Drive SMPS Pre-charge Board Resistor DI-100047-00 95A Diode IGBT-100042-00 Rectifier IGBT Qty 3 PC-100026-00 SCR Snubber PC-100031-00 Board CT Board CA-100135-00 6800 uF Capacitors Qty 4 Section 2, Page 14 of 50...
  • Page 27 Pub # 890046-10-00 Dec. 2015 Section 2, Page 15 of 50...
  • Page 28 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 RSi-100-SG-4B FA-100023-00 QTY 2 Section 2, Page 16 of 50...

  • Page 29: Fan Smps Board

    Pub # 890046-10-00 Dec. 2015 PC-100023-00 Fan SMPS Board PC-100063-00 Control Board PC-100068-00 Main SMPS Board Control Terminal Blocks See Parts List Section 2, Page 17 of 50...

  • Page 30: Qty 3

    Pub # 890046-10-00 Dec. 2015 FU-100476-00 Fuse Detector PC-100023-00 Fan SMPS Board FU-100474-00 250A Fuse IGBT-100043-00 DI-100047-00 450A IGBT 95A Diode Rectifier QTY 3 PC-100025-00 Drive SMPS Board Section 2, Page 18 of 50...
  • Page 31 Pub # 890046-10-00 Dec. 2015 PC-100032-00 CT Board PC-100027-00 SCR Snubber Board Section 2, Page 19 of 50...
  • Page 32 Pub # 890046-10-00 Dec. 2015 Section 2, Page 20 of 50...
  • Page 33 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 RSi-125-SG-4B FA-100023-00 Cooling Fan QTY 2 Section 2, Page 21 of 50...
  • Page 34 Pub # 890046-10-00 Dec. 2015 PC-100023-00 FAN SMPS Board PC-100069-00 Main SMPS PC-100063-00 Board Control Board Control Terminal Blocks See Parts List Section 2, Page 22 of 50...

  • Page 35: 315A Fuse

    Pub # 890046-10-00 Dec. 2015 PC-100023-00 FU-100476-00 Fan SMPS Fuse Detector Board FU-100475-00 315A Fuse IGBT-100043-00 IGBT DI-100047-00 95A Diodes QTY 6 PC-100025-00 Drive SMPS Board Section 2, Page 23 of 50...
  • Page 36 Pub # 890046-10-00 Dec. 2015 PC-100032-00 PC-100027-00 CT Board SCR Snubber Board Section 2, Page 24 of 50...

  • Page 37: Lcd-100000-00

    Pub # 890046-10-00 Dec. 2015 LCD-100000-00 Section 2, Page 25 of 50...
  • Page 38 Pub # 890046-10-00 Dec. 2015 PC-100053-06 PC-100053-07 Fan SMPS Board SCR Snubber Qty 2 Board PC-100053-01 PC-100064-00 Main SMPS Control Board Board Control Terminal Blocks See Parts List Section 2, Page 26 of 50...
  • Page 39 Pub # 890046-10-00 Dec. 2015 FA-100504-00 Cooling Fan DI-100057-00 FU-100476-00 Qty 3 130A Diode Fuse Detector Qty 3 FU-100473-00 PC-100053-14 200A Fuse IGBT Gate Qty 2 Board Qty 6 CA-100180-03 Snubber IGBT-100045-00* IGBT Qty 6 * Need to order with PC-100053-14 Section 2, Page 27 of 50...
  • Page 40 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 Section 2, Page 28 of 50...
  • Page 41 Pub # 890046-10-00 Dec. 2015 PC-100053-06 PC-100053-07 Fan SMPS Board SCR Snubber Qty 2 Board PC-100053-02 PC-100064-00 Main SMPS Control Board Board Control Terminal Blocks See Parts List Section 2, Page 29 of 50...

  • Page 42: Cooling Fan Qty

    Pub # 890046-10-00 Dec. 2015 FA-100504-00 Cooling Fan DI-100057-01 FU-100476-00 Qty 3 160A Diode Fuse Detector Qty 3 FU-100474-00 PC-100053-14 250A Fuse Gate Board Qty 2 Qty 6 CA-100180-03 Snubber Caps. IGBT-100045-00* IGBT Qty 6 * Need to order with PC-100053-14 Section 2, Page 30 of 50...

  • Page 43: R S I

    Pub # 890046-10-00 Dec. 2015 LCD-100000-00 Section 2, Page 31 of 50...
  • Page 44 Pub # 890046-10-00 Dec. 2015 PC-100053-06 PC-100053-07 Fan SMPS Board SCR Snubber Qty 2 Board PC-100053-03 PC-100064-00 Main SMPS Control Board Board Control Terminal Blocks See Parts List Section 2, Page 32 of 50...
  • Page 45 Pub # 890046-10-00 Dec. 2015 FA-100504-00 Cooling Fans DI-100057-02 FU-100476-00 Qty 3 253A Diodes Fuse Detector Qty 3 FU-100475-00 PC-100053-15 315A Fuses IGBT Gate Qty 2 Board Qty 6 CA-100180-03 Snubber Caps. Qty 6 IGBT-100045-01* IGBT Qty 6 CA-100137-00 8200uF Capacitors Qty 10 *Need to order with PC-100053-15 Section 2, Page 33 of 50...
  • Page 46 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 Section 2, Page 34 of 50...
  • Page 47 Pub # 890046-10-00 Dec. 2015 FA-100504-02 FA-100504-01 Cooling Fans Cooling Fans Qty 2 Qty 4 PC-100053-07 PC-100053-06 SCR Snubber Fan SMPS Board Board Qty 3 PC-100053-04 PC-100064-00 Main SMPS Control Board Board Control Terminal Blocks See Parts List Section 2, Page 35 of 50...
  • Page 48 Pub # 890046-10-00 Dec. 2015 FU-100474-00 DI-100057-02 250A E Fuse 253A Rectifier Qty 3 Qty 3 PC-100053-16 IGBT Interface Board Qty 3 IGBT-100045-03 900A IGBT Qty 3 CA-100136-00 6800uF Capacitor Qty 16 Section 2, Page 36 of 50...
  • Page 49 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 Section 2, Page 37 of 50...
  • Page 50 Pub # 890046-10-00 Dec. 2015 FA-100504-02 FA-100504-01 Cooling Fans Cooling Fans Qty 2 Qty 4 PC-100053-07 PC-100053-06 SCR Snubber Fan SMPS Board Board Qty 3 PC-100053-05 PC-100064-00 Main SMPS Control Board Board Control Terminal Blocks See Parts List Section 2, Page 38 of 50...
  • Page 51 Pub # 890046-10-00 Dec. 2015 FU-100475-00 DI-100057-03 315A E Fuse 330A Rectifier Qty 3 Qty 3 PC-100053-17 IGBT Interface Board Qty 3 IGBT-100045-02 1400A IGBT Qty 3 CA-100137-00 8200uF Capacitor Qty 16 Section 2, Page 39 of 50...
  • Page 52 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 Section 2, Page 40 of 50...
  • Page 53 Pub # 890046-10-00 Dec. 2015 PC-100053-06 Fan SMPS Board QTY 3 PC-100053-10 SCR Snubber Board PC-100053-08 PC-100064-00 Main SMPS Control Board Board FU-100532-00 800A Fuses Qty 3 FU-100535-00 Fuse Indicator Qty 3 Section 2, Page 41 of 50...
  • Page 54 Pub # 890046-10-00 Dec. 2015 FA-100504-03 RES-100286-02 Cooling Fans Precharge Qty 5 Resistor DI-100057-02 273A Diode/SCR IGBT-100045-02 Qty 6 1400A IGBT Qty 3 PC-100053-11 Diode/SCR Interface Board Qty 6 FU-100532-00 800A Fuse Qty 3 CA-100182-00 PC-100053-12 6800uF Capacitor IGBT Interface Qty 20 Board Qty 3 Section 2, Page 42 of 50...
  • Page 55 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 Section 2, Page 43 of 50...
  • Page 56 Pub # 890046-10-00 Dec. 2015 PC-100053-10 PC-100053-06 SCR Snubber Fan SMPS Board Board Qty 3 PC-100064-00 PC-100053-09 Control Board Main SMPS Board Terminal Blocks See Parts List Section 2, Page 44 of 50...
  • Page 57 Pub # 890046-10-00 Dec. 2015 RES-100286-03 Precharge Resistor DI-100057-03 330A Diode/SCR Qty 6 IGBT-100045-03 900A IGBT PC-100053-11 Qty 6 Diode/SCR Interface Board Qty 6 FU-100533-00 900A Fuse Qty 3 FU-100535-00 Fuse Indicator Qty 3 CA-100182-00 PC-100053-13 6800uF Capacitor IGBT Interface Board Qty 22 Qty 3 Section 2, Page 45 of 50...
  • Page 58 Pub # 890046-10-00 Dec. 2015 FA-100504-03 Cooling Fans Qty 6 Section 2, Page 46 of 50...
  • Page 59 Pub # 890046-10-00 Dec. 2015 LCD-100000-00 Section 2, Page 47 of 50...
  • Page 60 Pub # 890046-10-00 Dec. 2015 PC-100053-10 PC-100053-06 SCR Snubber Fan SMPS Board Board Qty 3 PC-100053-00 PC-100053-09 Control Board Main SMPS Board Terminal Blocks See Parts List Section 2, Page 48 of 50...
  • Page 61 Pub # 890046-10-00 Dec. 2015 RES-100286-04 Precharge Resistor DI-100057-05 330A Diode/SCR Qty 6 IGBT-100045-03 900A IGBT PC-100053-11 Qty 6 Diode/SCR Interface Board Qty 6 FU-100534-00 1000A Fuse Qty 3 FU-100535-00 Fuse Indicator Qty 3 CA-100182-00 PC-100053-13 6800uF Capacitor IGBT Gate Board Qty 24 Qty 3 Section 2, Page 49 of 50...
  • Page 62 Pub # 890046-10-00 Dec. 2015 FA-100504-03 Cooling Fans Qty 6 Section 2, Page 50 of 50...

  • Page 63: Pub. # 890046-10-00 Dec

    Pub. # 890046-10-00 Dec. 2015 Section Section 3 3 3 3 Section Section PC Board Descriptions PC Board Descriptions PC Board Descriptions PC Board Descriptions Section 3, Page 1 of 20...
  • Page 64 Pub. # 890046-10-00 Dec. 2015 Control Board Part # PC-100063-00 50 – 125 HP, 460V Keypad Cable, CN3 • • • • • +5 V, pins 1 & 3 • • • • • -15 V, pins 2 & 3 CN1 to Main SMPS Option Bd.
  • Page 65 Pub. # 890046-10-00 Dec. 2015 Part # HP Where Used Description Control Board PC-100063-00 50 - 125 Contains the 16 bit DSP for all signal processing including (2) 6 channel PWM modules for generating the IGBT firing signals, (4) 12 bit A/D converters, Serial Communications Interface, and memory for Software (program) and Data.
  • Page 66 Pub. # 890046-10-00 Dec. 2015 Section 3, Page 4 of 20...

  • Page 67: Section 1, Page 5 Of

    Pub. # 890046-10-00 Dec. 2015 I/O Terminal Details Part # PC-100063-00 Control Board 50 – 125 HP, 460V Terminal Description Ratings Default Setting Related Parameters 3A, 3C, Dedicated Fault Relay, Form C 250 Vac, 1A None 3A-3C NO, 3C-3B NC 30 VDC, 1A A1 - C1 Output Relays, Programmable...

  • Page 68: Section 1, Page 6 Of

    Pub. # 890046-10-00 Dec. 2015 Fan SMPS Board Part # PC-100023-00 50 – 125 HP, 460V LED1 Fuse, 1A, 600V Power from CN2 (P6-G6) Part # FU-603 DC Bus 6 VDC output CN5 CN4 CN3 CN1 (DCP-DCN) 24P-24P1 24 VDC ~650VDC input 24N –...
  • Page 69 Pub. # 890046-10-00 Dec. 2015 Part # HP Where Used Description Receives DC Bus voltage from the capacitor bank. Creates 2 power Fan SMPS Board PC-100023-00 50 - 125 supplies, 6 VDC and 24 VDC. The 6 VDC is sent to the Main SMPS board for SCR gate power.
  • Page 70 Pub. # 890046-10-00 Dec. 2015 Section 3, Page 8 of 20...
  • Page 71 Pub. # 890046-10-00 Dec. 2015 Fan Board Circuit, PC-100023-00 50 – 125 HP, 460V Fan Bd. SMPS Bd. 24P1 (2) (1) 24P1 • CN40 RLY2 24P (1) (2) 24P • Fan Control Relay 24P (3) 24N (1) 24P (3) 24N (1) 24P (3) 24N (1) Description...
  • Page 72 Pub. # 890046-10-00 Dec. 2015 Main SMPS Board Part # PC-100065-00 50 – 125 HP, 460V PC-100066-00 PC-100067-00 PC-100068-00 PC-100069-00 Supply to Control Board 24P1 – 24P Fan Control 24V (pins 1&2) Relay, RLY2 +/- 15V (pins 4&5) Description 24G is CM CN40 LED2 Control Board...
  • Page 73 Pub. # 890046-10-00 Dec. 2015 Part # HP Where Used Description Main SMPS Board PC-100065-00 The board contains circuits for Fan control, Input SCR control, IGBT Gate Firing signals, Current PC-100066-00 Transformer Feedback, DC Bus Voltage/DC Bus Fuse monitoring and IGBT temperature monitoring. PC-100067-00 Receives DC Bus voltage from capacitor bank.
  • Page 74 Pub. # 890046-10-00 Dec. 2015 Control Board Part # PC-100064-00 150 – 700 HP, 460V Keypad Cable, CN3 +5 V, pins 1 & 3 • • • • • -15 V, pins 2 & 3 • • • • • CN1 to Main SMPS...
  • Page 75 Pub. # 890046-10-00 Dec. 2015 Part # HP Where Used Description Control Board PC-100064-00 150 - 700 Contains the 16 bit DSP for all signal processing including (2) 6 channel PWM modules for generating the IGBT firing signals, (4) 12 bit A/D converters, Serial Communications Interface, and memory for Software (program) and Data.
  • Page 76 Pub. # 890046-10-00 Dec. 2015 Fan SMPS Board Part # PC-100053-06 150 – 700 HP, 460V CN3, CN4 24 VDC 24P, 24P1 CN1 (DCP-DCN) 24N – 24P ~650VDC input Pins 1 & 3* Description Fuse, 1A, 600V LED 1 CN2 (P6-G6) CN7 Fan Lock Part # FU-603 Power from DC Bus...
  • Page 77 Pub. # 890046-10-00 Dec. 2015 Part # HP Where Used Description Fan SMPS Board PC-100053-06 150 - 700 Receives DC Bus voltage from the capacitor bank. Creates 2 power supplies, 6 VDC and 24 VDC. The 6 VDC is sent to the Main SMPS board for SCR gate power.
  • Page 78 Pub. # 890046-10-00 Dec. 2015 SMPS Bd. Fan Board #1 24P1 (2) (1) 24P1 • 24P (1) (2) 24P • RLY2 (1) 24P1 • Board #2 (2) 24P • RLY3 24P (3) (1) 24P1 • 24N (1) CN16 Board #3 (2) 24P •...
  • Page 79 Pub. # 890046-10-00 Dec. 2015 Description 24 VDC The fan boards generate 24 VDC from a switch mode power supply on the fan board. This 24 VDC is sent to the Main SMPS board as 24P1. At the Main SMPS board, the 24P1 is passed through contacts of the fan control relays (RLY2, RLY3, &...
  • Page 80 Pub. # 890046-10-00 Dec. 2015 Main SMPS Board Part # PC-100053-01 thru -05, 150 – 700 HP, 460V -08 and -09 Fan Control Relays CT’s Fan Fault Fan Control DC Bus Power DC Bus & Fuse Ind. LED’s 2, 5 & 6 CN1 CN2 CN3 CN18 J1 CN15 CN8 CN9 CN5 CN6 CN16...
  • Page 81 Pub. # 890046-10-00 Dec. 2015 Part # HP Where Used Description The board contains circuits for Fan control, Input SCR control, IGBT Gate Firing signals, Main SMPS Board PC-100053-01 Current Transformer Feedback, DC Bus Voltage/DC Bus Fuse monitoring and IGBT PC-100053-02 temperature monitoring.
  • Page 82 Pub. # 890046-10-00 Dec. 2015 Connector ID Terminals Description CN11 (pins 1 & 2) Main SMPS Board P6 - G6 6 VDC from Fan Board, CN2. Used to power Input SCR's gate circuit. CN13 (pin 1 - 5) DCN - DCP DC Bus Voltage into board continued CN13 (pin 2 - 3)
  • Page 83 Pub # 890046-10-00 Dec. 2015 Section 4   Troubleshooting  4.1 Over Voltage Fault  4.2 Over Current Faults  4.3 Overload Faults  4.4 Ground Fault  4.5 Speed Reference Inputs/Transducer Wiring  4.6 Output Phase Fault/No Motor Trip  4.7 Inverter Capacity Setting  4.8 Power Component Check  Section 4, Page 1 of 32...
  • Page 84 Pub # 890046-10-00 Dec. 2015 Section 4, Page 2 of 32...
  • Page 85 Pub # 890046-10-00 Dec. 2015 Over Voltage Fault    Fault Display: Over Voltage Auto Resettable: Yes Background - What is the DC Bus Voltage? The line voltage (input) to the drive gets rectified with a 3 phase full bridge rectifier. This DC voltage is filtered with the capacitor bank within the drive.
  • Page 86 Pub # 890046-10-00 Dec. 2015 Check Fault History: At parameter AFN-01 (most recent fault), hit the program button, then up arrow to view data captured at time of fault (Hz, Volts, Amps, Status). AFN-02 through AFN-05 are previous faults. Fault  Causes Solutions ...
  • Page 87 Pub.# 890046-10-00 Dec. 2015 Fault  Causes Solutions  Over Voltage  Regenerative Load ‐ Feeders,  Enable Stall Mode (FUN‐70) ‐  This function  during running  Crushers, Stamping Press.  attempts to regulate the DC Bus below the trip  level by increasing the speed of the motor  (forcing the regen power back out to the motor).  Add Dynamic Braking Module and Resistor.  Sudden change in speed  Increase Accel and Decel times (DRV‐01 and  reference signal.  DRV‐02)  Changes in load from full  Avoid rapid changes in load.  load to no load.  Over Voltage  Decel Time too short  Increase Decel time (DRV‐02).  during  Change stop mode (FUN‐23) to Coast to Stop  Deceleration  (Free Run).  Regenerative Load.  Enable Stall Mode (FUN‐70) ‐  This function  attempts to regulate the DC Bus below the trip  level by increasing the speed of the motor  (forcing the regen power back out to the motor).  Add Dynamic Braking Module and Resistor.  Section 4, Page 5 of 32...
  • Page 88 Pub # 890046-10-00 Dec. 2015 Over Current Faults    Fault Display: Over Curr-1 Auto Resettable: Yes Description: Over Curr-1 ~ 200% drive rated current (standard duty rating) Check Fault History: At parameter AFN-01 (most recent fault), hit the program button, then up arrow to view data captured at time of fault (Hz, Volts, Amps, Status).
  • Page 89 Pub.# 890046-10-00 Dec. 2015 Fault Display: Over Curr-2 Auto Resettable: No Description: Over Curr-2 ~ instantaneous at ~300% drive rated current (standard duty rating) Check Fault History: At parameter AFN-01 (most recent fault), hit the program button, then up arrow to view data captured at time of fault (Hz, Volts, Amps, Status). AFN-02 through AFN-05 are previous faults.
  • Page 90 Pub # 890046-10-00 Dec. 2015 4.3 Overload Faults  The model SG drives have two different motor overload protection settings along with drive overload protection. Each is described below. A. E-Thermal B. Overload C. Inverter Overload A. E-Thermal Fault Display: E-THERMAL Auto Resettable: No DRV-05 –...
  • Page 91 Pub.# 890046-10-00 Dec. 2015 Fault  Causes  Solutions  E‐Thermal  The internal electronic  Check fault history. DRV‐13 if still tripped,  (Electronic  thermal overload protection  AFN‐01 if reset.  Thermal  of the drive has determined  Note the amps and frequency recorded  Overload, ETH)  that the motor is overloaded  when the trip occurred.  Inspect load and  and/or over heated.  motor for causes of high current draw.  ETH settings too low.  Check/Adjust motor settings and ETH levels:  DRV‐05 through DRV‐08  AFN‐40 motor capacity.  Motor was operated at low  If low speed operation is normal, options  speeds for extended period  are:  of time.  Turn off low speed ETH (FUN‐09 to forced  cool) and add separate motor cooling fan.  Turn of ETH completely (FUN‐06, No) and  use FUN‐66, 67 and 68.   Incorrect motor capacity  Select correct motor capacity (AFN‐40,  selected.  Motor select).  Incorrect drive capacity  Select correct drive capacity (MAK‐01,  selected. ...
  • Page 92 Pub # 890046-10-00 Dec. 2015 B. Overload Fault Display: Overload Auto Resettable: No Related Parameters: DRV-05 Motor rated current FUN-66 Overload Trip Selection Yes/No FUN-67 Overload Trip Level FUN-68 Overload Trip Time Description: General overload protection for the drive and the motor. The Overload Trip function is activated with FUN-66 (set to Yes).
  • Page 93 Pub.# 890046-10-00 Dec. 2015 C. Inverter Overload Fault Display: Inv. OLT Auto Resettable: No Description: The Inverter Overload trip level is an electronic overload (I²t) calculation for protection of the drive. The trip settings are fixed at 110% of the drive Std. Duty rating for 60 seconds.
  • Page 94 Pub # 890046-10-00 Dec. 2015 4.4 Ground Fault  Fault Display: Ground Fault Auto Resettable: No Related parameters: DRV-05, DRV-30, MAK-26 Description: The drive has detected a level of ground current higher than the programmed ground fault setting in the drive. Parameter MAK-26 is set as a percentage of motor amps (DRV-05).
  • Page 95 Pub.# 890046-10-00 Dec. 2015 Fault  Causes  Solutions   Ground Fault  Type of Cable  Insulation Rating? Higher rating may be  (continued)  required for PWM type signals as leakage  (parasitic capacitance) can cause drive to  sense and trip on ground fault.  Long motor lead length.  Add output reactor or long lead filter (dV/dT).   Distance between drive  and motor is too long.  Type of Cable  Shielded or Non‐Shielded? Shielded is not  necessarily required unless there are sensitive  devices (sensors, weight scales, comms.  network, computers, etc.) that could be  affected by the Noise (EMI/RFI) emitted from  the drive and the output cables.  If specs refer  to EMC standards, cable should be shielded.  1. Adjust the ground fault setting. Access to the hidden group of parameters is required. Accessing the MAK group a) Push the Mode button twice to get to the AFN Group.
  • Page 96 Pub # 890046-10-00 Dec. 2015 2. Check PC Board Connections a) Power Down. b) Remove upper cover of VFD. c) Below is a picture of the internal PC Boards (Control Bd. And Main SMPS). d) LEM Feedback / DC Power connectors are in the upper left of the Main SMPS board.
  • Page 97 Pub.# 890046-10-00 Dec. 2015 4.5 Speed Reference Inputs / Transducer Wiring  Problem: Drive does not respond to the 4-20mA input source. Description: The output frequency (speed) of the drive can be controlled with a 4-20mA input source. Input terminals on the control board are designated “I” and “CM” (or 5G). There are a number of input wiring schemes that could be used.
  • Page 98 Pub # 890046-10-00 Dec. 2015 Section 4, Page 16 of 32...
  • Page 99 Pub.# 890046-10-00 Dec. 2015 Section 4, Page 17 of 32...
  • Page 100 Pub # 890046-10-00 Dec. 2015 SG Analog Input Calibration Procedure This procedure defines how to calibrate the analog input signals of the SG VFD. Required equipment: A calibrated current/voltage source (4–20 mA, 0–10 VDC and/or 0 to +/-12 VDC). Using a calibrated source, input the analog signal (max then min) to the appropriate drive terminals.
  • Page 101 Pub.# 890046-10-00 Dec. 2015 C. For 0 to 12 VDC and 0 to -12 VDC 1) Input a 12 VDC signal at Terminals V1 and CM of the VFD. 2) Using the arrow buttons, go to parameter MAK-32 (V1S 12V cal). 3) Program to YES, push enter.
  • Page 102 Pub # 890046-10-00 Dec. 2015 4.6 Output Phase Open Fault / No Motor Trip  Faults: Output Phase Open and No Motor Trip Fault Display: Out Phase Open and/or No motor Trip Auto Resettable: Yes Related Parameters: Output Phase Open parameters DRV-05 Motor rated Current AFN-40 Rated motor selection (motor HP) AFN-44 No Load motor current FUN-57 No Motor Selection FUN-58 Trip Current Level...
  • Page 103 Pub.# 890046-10-00 Dec. 2015 Fault  Causes  Solutions  Out Phase  Open Output ‐ either wiring or  Check output wiring and connections.  Check output  Open  contactor/switch on output of  contactor/switch if applicable.  drive.  Low Current ‐ Drive has  Parameter checks:  detected low current or no  AFN‐40 Motor Capacity.  current flow out of drive.  AFN‐44 No Load Current (if not know ~ 33% of motor  amps).  FUN‐57, if yes,   FUN‐58 current level (percentage of motor amps,  DRV‐05).  FUN‐59 trip time.  Single Phase output from drive.  Measure phase‐phase voltage output at 60 Hz. with  no motor connected.  Change FUN‐57 to "No" for  this test.  Poor connections at Main  Perform check of PC Board connections per 1) below.  SMPS PC Board (>150 HP)  No Motor  Same as Output Phase Open  Parameter checks: FUN‐57, if yes,   Trip  except specifically related to  FUN‐58 current level (percentage of motor amps,  parameters FUN‐57, FUN‐58  DRV‐05).  and FUN‐59 ...
  • Page 104 Pub # 890046-10-00 Dec. 2015 4.7 Inverter Capacity Setting  Fault: Initialize Inverter Capacity Fault Display: Flashing Message “Init. Inv Cap” Auto Resettable: No Description: When installing a new Control Board, you will get a message “Init. Inv Cap” which is interpreted as Initialize Inverter Capacity. You have to assign the VFD Horse Power and Voltage ratings.
  • Page 105 Pub.# 890046-10-00 Dec. 2015 Table 1: SG VFD Maker Group Selection MAK 01 Display Equivalent Std. Duty HP Voltage 280.0 kW-6 220.0 kW-6 160.0 kW-6 132.0 kW-6 110.0 kW-6 90.0 kW-6 75.0 kW-6 55.0 kW-6 45.0 kW-6 37.0 kW-6 30.0 kW-6 22.0 kW-6 18.5 kW-6 15.0 kW-6...
  • Page 106 Pub # 890046-10-00 Dec. 2015 Section 4, Page 24 of 32...
  • Page 107 Pub # 890046-10-00 Dec. 2015 4.8 Power Component Check 50 - 125 HP Configuration/Description <125HP Input rectifier circuit arrangement consists of 3 diode/SCR modules. 125 HP has 6 diode/SCR modules. All SCR's have a snubber circuit across them. Pre-charge resistor circuit between R and P1/P2 (jumper) parallel with the snubber circuit. One DC Bus fuse in the Positive DC Bus rail.
  • Page 108 Pub # 890046-10-00 Dec. 2015 Section 4, Page 26 of 32...
  • Page 109 Pub.# 890046-10-00 Dec. 2015 150 - 250 HP Configuration/Description Input rectifier circuit arrangement consists of 3 Diode/SCR modules. Pre-Charge resistor/diode circuit between R and P1/P2 (jumper). No P1 terminal due to a DC Link Reactor in the Positive DC Bus rail. Two DC Bus fuses in the DC Positive Bus Rail.
  • Page 110 Pub # 890046-10-00 Dec. 2015 Section 4, Page 28 of 32...
  • Page 111 Pub.# 890046-10-00 Dec. 2015 350 - 400 HP Configuration/Description Input rectifier circuit arrangement consists of 3 Diode/SCR modules. Pre-Charge resistor/diode circuit between T phase to P2. No P1 terminal due to a DC Link Reactor in the Positive DC Bus rail. Three DC Bus fuses in the DC Negative Bus rail.
  • Page 112 Pub # 890046-10-00 Dec. 2015 Section 4, Page 30 of 32...
  • Page 113 Pub.# 890046-10-00 Dec. 2015 500 - 700 HP Configuration/Description Input rectifier circuit arrangement consists of 6 Diode/SCR modules. Pre-Charge circuit resistor/diode circuit between T phase to P1. Pre-Charge Resistors 500 HP 8 ohms 600 HP 10 ohms 700 HP 12 ohms (2 - 24 ohms parallel) Three internal inline fuses, no DC Bus fusing.
  • Page 114 Pub # 890046-10-00 Dec. 2015 Section 4, Page 32 of 32...
  • Page 115 Revision History Manual # Rev. Date Changes ECO# 890027-14-00 Jan. 2, 2008 First Release None 890027-14-01 May 28, 2009 Added Section 3 and General Updates None 890046-10-00 Dec. 15, 2015 New Manual # to group with other SG Manuals E4954 Added Trouble Shooting, Updated Parts List...
  • Page 116 BENSHAW 615 Alpha Drive Pittsburgh PA, 15238 Phone: (412) 968-0100 Fax: (412) 968-5415 BENSHAW Canada 550 Bright Street Listowel, Ontario N4W 3W3 Phone: (519) 291-5112 Fax: (519) 291-2592...

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