Danfoss VLT 3032 Service Manual
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Danfoss VLT 3032 Service Manual

Danfoss VLT 3032 Service Manual

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Table of Contents

Section Two
Section Three Static
Test Procedures
Section Three Dynamic
Test Procedures
Section Four
Section Five
Appendix
Introduction
Safety
Flow Charts
Removing and Replacing Gate/Snubber/IGBT
Overtemperature Trips
Additional Fault Codes
Block Diagram VLT 3032
Block Diagram VLT 3042
Block Diagram VLT 3052
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35
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39
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II
III
IV
V

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Summary of Contents for Danfoss VLT 3032

  • Page 1: Table Of Contents

    Removing and Replacing Input Rectifiers Section Five Current Limit Trips Unstable Motor Operation Ground Fault Trips Overcurrent Trips Overvoltage Trips Overtemperature Trips Additional Fault Codes Appendix Spare Parts List Block Diagram VLT 3032 Block Diagram VLT 3042 Block Diagram VLT 3052...
  • Page 2 The purpose of this manual is to provide technical information and instructions that will enable the user to identify faults and affect repairs on Danfoss series 3000 Adjustable Frequency Drives, VLT 3032 through VLT 3052, 230 Volt models. The manual has been divided into five sections. The first section covers the description and sequence of operations.
  • Page 3 SAFETY WARNING: The Adjustable Frequency Drive (AFD) contains dangerous voltages when connected to the line voltage. Only a competent technician should carry out the service. FOR YOUR SAFETY: 1) DO NOT touch the electrical parts of the AFD when the AC line is connected.

  • Page 5: Section One

    SECTION ONE DESCRIPTION OF Refer to the overall schematic in the Appendix. OPERATION It is not the intention of this manual to enter into a detailed description of the unit's operation. Moreover, it is intended to provide the reader with a general view of the unit's main assemblies. With this information, the repair technician should have a better understanding of the unit's operation and therefore aid in the troubleshooting process.
  • Page 6 LOGIC SECTION A 10VDC supply is also available for use as a speed reference when connected to an appropriate potentiometer. These two voltage (continued) references are limited in the amount of available current they can provide (see specifications in Instruction Manual). Attempting to power devices which draw currents in excess of that available may result in an eventual failure of the power supply.
  • Page 7 LOGIC TO POWER The logic to power interface isolates the high voltage components of the power section from the low voltage signals of the logic. This is INTERFACE accomplished by use of the interface board. All communication between the control logic and the rest of the unit passes through the interface board.
  • Page 8 POWER SECTION The power section is made up of the SCR/Diode modules (input rectifiers), the soft charge circuit, the DC capacitor bank, the gate drive and snubber cards and the IGBT power devices. Also located in the power section are the DC Bus coil, the motor coils and, although not typically considered part of the power section, the output phase current sensors.

  • Page 9: Sequence Of Operation

    When input power is first applied, the SCR/Diode modules (input SEQUENCE OF rectifiers) are not gated so the incoming line voltage is rectified by the OPERATION soft charge rectifier (BR1). As the DC Bus capacitors charge, the inrush current is limited by the series soft charge resistors (R2 and R3). Following a time delay of approximately one second, the interface board monitors the DC Bus voltage and, providing it has reached an acceptable level, begins sending gate pulses to the SCR/Diode Modules.

  • Page 10: Status Messages

    SECTION TWO A variety of messages are displayed by the control card. Some of these indicate the operational status of the unit while others provide warnings of an impending fault. In addition, there are the alarm FAULT INDICATORS messages which indicate that the unit's operation has stopped due to AND MESSAGES a fault condition.

  • Page 11: Warning Messages

    WARNING MESSAGES VOLTAGE LOW This message will flash when the DC Bus voltage has fallen below the lower limit. This is an indication of low line voltage. This is only a warning message, however. If the condition persists, it will result in a unit trip on "Under Voltage".

  • Page 12: Alarm Messages

    ALARM MESSAGES Alarm messages will be indicated by the following messages appearing in the display and the red alarm LED being lit on the control panel. All alarm messages result in the unit's operation being interrupted and require a Manual or Automatic reset. Automatic reset can be selected in parameters 309 and 312.
  • Page 13 GROUND FAULT (5) ALARM MESSAGES This message indicates a leakage to ground on the output of the inverter. (continued) The "Ground Fault Trip" LED (D2) on the interface board will be illuminated and the "Inverter OK" LED on the interface board will be out.
  • Page 14 CURRENT LIMIT (9) ALARM MESSAGES This message will be displayed if the unit has run in current limit for a (continued) time which exceeds the setting in parameter 310. To remedy this fault, reduce the motor's load or verify that the correct settings have been entered in parameter 209 (Current Limit) and parameter 310 (Current Limit Trip Delay).
  • Page 15 EXTERNAL OVER TEMP ALARM MESSAGES EOT (D108-YELLOW) (continued) Indicates the external temperature sensor has detected an over temp condition. If used, the sensor is connected to MK15 on the interface board. The I0K LED will be off and the control card will indicate "Over Temp". POWER SUPPLY FAULT PSF (D1-RED) Indicates the low voltage power supplies are out of tolerance.

  • Page 16: Troubleshooting Tips

    GENERAL Prior to diving into a repair here a few tips if followed will make the job easier and may prevent unnecessary damage to good components. TROUBLESHOOTING TIPS 1. First and foremost respect the voltages produced by the drive. Always verify the presence of line voltage and bus voltage before working on the unit.
  • Page 17 Symptom Is the output phase to phase voltage and current balanced? Motor runs unevenly See "Testing the Inverter" Section page 26. Verify correct settings have been entered in Group 1 "Load & Motor" Also see Section "Applications" pg. 35 Symptom Is the display illuminated? Motor does not run Are fault messages shown...
  • Page 18 Symptom Have prefuses for the VLT adjustable frequency drive blown, F1, F2, F3 or F4, No fault report or light in F5, 56? display. If one or more of the fuses F1, F2 or F3 have blown, test the input rectifiers and the inverter section, pages 25 and 26.
  • Page 19 Replace the Control Card, Symptom Start the VLT adjustable see page 31. If this does frequency drive by not help, the fault might be pressing "Start" on the Motor stopped. Light in electrical noise. Check control panel. display, but no fault report. whether the following precautions have been taken:...

  • Page 20: Symptom/Cause Charts

    SYMPTOM/CAUSE CHARTS SYMPTOM/CAUSE charts are generally directed towards the more experienced technician. The intent of these charts is to provide a range of possible causes for a specific symptom. In doing so, these charts provide a direction, but with limited instruction. SYMPTOM POSSIBLE CAUSES 1.
  • Page 21 SYMPTOM/CAUSE CHARTS SYMPTOM/CAUSE charts are generally directed towards the more experienced technician. The intent of these charts is to provide a range of possible causes for a specific symptom. In doing so, these charts provide a direction, but with limited instruction. SYMPTOM POSSIBLE CAUSES 7.

  • Page 22: Testing The Soft Charge Circuit

    SECTION THREE All tests will be made with an ohmmeter capable of testing diodes. Use a digital VOM set on diode scale or an analog ohm meter set on RX100 scale. Before making any checks disconnect all input power, motor STATIC TEST and brake option connections.
  • Page 23 TESTING THE 1. Prior to making the test, it is necessary to verify that the three soft charge fuses (F4, F5, and F6) are good. If they are not, they must be SOFT CHARGE CIRCUIT replaced before proceeding. 2. Remove the plug on spade connectors from the plus and minus terminals of the rectifier bridge (BR1).

  • Page 24: Testing The Input Rectifiers

    TESTING THE INPUT RECTIFIERS The purpose of statically testing the input rectifiers is to rule out failures in these devices. Typically a failure of an input rectifier will have caused the input line fuses to blow. It should also be noted that blown input line fuses can also be a result of a shorted IGBT.

  • Page 25: Testing The Inverter Section

    TESTING THE INVERTER SECTION The purpose of statically testing the inverter section is to rule out failures of the IGBT power devices and the snubber diodes. If a short circuit is discovered during the testing, the particular devices can be pinpointed by noting the output terminal indicating the short circuit. The output terminals are designated with a letter corresponding to the phase that feeds that terminal.

  • Page 26: Testing The Heatsink Temperature Sensor

    The heatsink temperature sensor is a NTC (negative temperature TESTING THE HEATSINK coefficient) resistor rated for 10K ohm at 25°C. As the temperature TEMPERATURE SENSOR rises, the resistance decreases. Conversely, as the temperature falls, the resistance increases. The interface board monitors this resistance and initiates a fault when the resistance is less than 787 ohms.

  • Page 27: Testing Gate Drive Firing Circuits

    TESTING GATE DRIVE FIRING CIRCUITS CAUTION: The gate firing signals are referenced to the negative DC Bus and are therefore at Bus potential. Extreme care must be taken to prevent personal injury or damage to equipment. Oscillo- scopes, when used, should be equipped with isolation devices. The individual gate drive firing pulses originate on the interface board.
  • Page 28 TESTING AT THE CAUTION: Allow sufficient time for the DC Bus to fully discharge before beginning testing. The presence of bus voltage can be GATE CARD OUTPUT tested by setting your voltmeter for 500VDC and reading the terminals labeled 88 (–) and 89 (+). Never power up the unit with any of the IGBT gate leads disconnected from the Gate Drive Card.

  • Page 29: Testing Input Rectifiers

    TESTING INPUT RECTIFIERS Theoretically, the input current drawn on each of the three input phases should be equal. These currents will vary, however, due to variations in phase-to-phase input voltage and due to some single phase loads within the drive. Given that the input phase voltages are equal, the input currents phase- to-phase should not vary more than 5%.

  • Page 30: Removing And Replacing The Control Card

    SECTION FOUR REMOVAL 1. Remove the two ribbon cables from plugs MK200 and REMOVING AND REPLACING MK201. THE CONTROL CARD 2. Insert a screwdriver at the points indicated on the right side of the control card cassette and pry upward. PRYING POINT 3.
  • Page 31 REMOVING AND REPLACING 1. To gain access to these assemblies remove the Control Card/ Interface Board Carrier. This is done by loosening the two captive GATE CARD, SNUBBER BOARD screws on the left side of the Carrier. Slide the carrier towards the AND IGBT top of the unit and lift out.

  • Page 32: Removing And Replacing Input Rectifiers

    REMOVING AND REPLACING INPUT RECTIFIERS REMOVAL 1. Remove the line side Phillips screw from the rectifier to be replaced. 2. Remove the two Phillips screws from the bus bar connections of the rectifier being replaced. Loosen but do not remove the remaining bus bar screws on the other rectifiers.

  • Page 33: Current Limit Trips

    SECTION FIVE APPLICATIONS CURRENT LIMIT TRIPS Excessive loading of the VLT may result in "CURRENT LIMIT" trips. This is not a concern if the unit has been properly sized and intermittent load conditions cause anticipated operation in current limit. Nuisance UNSTABLE current limiting and unstable motor operation can, however, be caused MOTOR OPERATION...
  • Page 34 Parameter 108 Motor Magnetization Current is the current required to maintain the magnetic field in the motor. Magnetization Current is factory set based on the motor power entered in parameter 103. This current value can also be found by running the motor without anything connected to the shaft and recording the current.

  • Page 35: Ground Fault Trips

    Trips occurring from ground faults are usually the result of short circuits "GROUND FAULT" TRIPS to earth ground either in the motor or the wiring to the motor. The VLT detects ground faults by monitoring all three phases of output current and looking for severe imbalances in those currents.

  • Page 36: Overvoltage Trips

    Instantaneous overcurrent trips are caused by the current rising so fast "OVERCURRENT" TRIPS on the output that the unit cannot respond. One example of this situation (CONTINUED) is in applications where the unit is running at speed and an output contactor is closed between the unit and the motor.
  • Page 37 When the energy returned, combined with the DC Bus voltage, exceeds "OVERVOLTAGE" TRIPS DUE TO the upper voltage limit, the unit responds in different ways to limit the REGENERATIVE APPLICATIONS voltage rise. If the returned energy is occurring during ramp down (to (CONTINUED) stop or to a lower speed), the unit will automatically adjust the decel ramp in an attempt to limit the voltage.
  • Page 38 A terminal connection MK15 is supplied on the Interface Board to provide "OVERTEMP" TRIPS for the connection of an external temperature sensor. The sensor is (CONTINUED) customer supplied and may be used for such things as monitoring the temperature of external brake resistors. By selecting the terminal connections the MK15 input can accept a normally open or closed input.
  • Page 39 The VLT stores faults which have occurred in its fault memory register. Fault Memory The register stores the last 8 occurrences on a first in first out basis. You can access the fault memory by calling up parameter 602. In doing so you can then scroll through the register using the Data key to view each fault code stored.

  • Page 40: Spare Parts List

    Spare Parts List Control Card 175H7086 Interface Board 175L3821 Gate Drive Board 175L3822 IGBT Snubber Board 175L3823 Input Fuse 175L3830 Soft Charge Fuse 175L3829 Soft Charge Rectifier 175L3832 Input Rectifier 175L3831 Soft Charge Resistor Assembly 175L3833 IGBT Module 3032 175L3836 IGBT Module 3042/52 175L3837 Power Supply Fuse...

This manual is also suitable for:

3000 seriesVlt 3052Vlt 3042

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