Danfoss VLT Series Service Manual
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Danfoss VLT Series Service Manual

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Service Manual
MOTION CONTROLS
VLT® 4152 - 4652
VLT® 5122 - 5602
VLT® 6152 - 6652
VLT® 8152 - 8652

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Summary of Contents for Danfoss VLT Series

  • Page 1 Service Manual VLT® 4152 - 4652 VLT® 5122 - 5602 VLT® 6152 - 6652 MOTION CONTROLS VLT® 8152 - 8652...
  • Page 2 Division of Danfoss Inc. Danfoss can accept no responsibility for possible errors in catalogs, brochures and other printed materials. Danfoss reserves the right to alter its products 4401 North Bell School Road without notice. This also applies to products already on order provided that...

  • Page 3: Table Of Contents

    Table of Contents INTRODUCTION ..........................intro-1 PURPOSE ............................intro-1 VLT PRODUCT OVERVIEW ........................ intro-1 FOR YOUR SAFETY .......................... intro-1 ELECTROSTATIC DISCHARGE (ESD) ....................intro-1 TOOLS REQUIRED ..........................intro-3 Additional Tools Recommended for Testing ................intro-3 SECTION 1 OPERATOR INTERFACE AND DRIVE CONTROL ............. 1-1 INTRODUCTION ............................
  • Page 4 Table of Contents (continued) 3.3 WARNING AND ALARM MESSAGES ....................3-6 3.4 AFTER REPAIR TESTS ........................3-13 SECTION 4 DRIVE AND MOTOR APPLICATIONS ................4-1 Torque Limit, Current Limit, and Unstable Motor Operation ............. 4-1 Overvoltage Trips ......................... 4-2 Mains Phase Loss Trips ........................ 4-2 Control Logic Problems .........................
  • Page 5 Table of Contents (continued) 5.2.14 Input Terminal Signal Tests ....................5-27 5.2.15 Control Card Test ......................5-28 5.3 INITIAL START UP OR AFTER REPAIR DRIVE TESTS ..............5-29 SECTION 6 D-FRAME SIZES DISASSEMBLY AND ASSEMBLY INSTRUCTIONS ......6-1 ELECTROSTATIC DISCHARGE (ESD) ....................6-1 6.0 INSTRUCTIONS ..........................
  • Page 6 List of Figures Figure Title Page Exploded View D1 Frame Size ....................Intro-4 Exploded View D2 Frame Size ....................Intro-5 Exploded View E Frame Size ....................Intro-6 1-1. Control Terminals ......................... 1-8 1-2. Control Terminals Electrical Diagram ....................1-10 1-3. Grounding Shielded Cables ......................1-11 2-1.
  • Page 7 List of Figures (continued) Figure Title Page 6-12. Current Sensor ...........................6-18 6-13. FanAssembly ..........................6-19 6-14. AC Input Terminals ........................6-21 6-15. D2 IGBT Modules ........................6-22 6-16. D1 IGBT Modules ........................6-25 7-1. Control Card Cassette ........................7-1 7-2. Interface Card, Power Card, and Mounting Plate ................

  • Page 9: Introduction

    Drives contain dangerous voltages when connected to line voltage. Only a competent technician to identify faults and perform repairs on VLT series adjustable frequency drives of 125/150 hp to 550/600 hp. technician should carry out service.
  • Page 10 HP @460 VAC kW @400 VAC 8062 8152 8072 8202 8102 8252 8122 8302 8152 8352 8202 8452 8252 8502 8302 8602 550 (600)* 8352 8652 8402 *unit can attain 600 hp 8502 8602 8652 Intro-2 VLT is a registered Danfoss trademark...

  • Page 11: Tools Required

    TOOLS REQUIRED Instruction manual for the VLT series drive Metric socket set......7 - 19mm Socket extensions......4 in. and 6 in. (100mm - 150mm) Torx driver set.......T10 - T50 Torque wrench......6 - 170 in-lbs (0.675 - 19 Nm) Needle nose pliers...

  • Page 12: Exploded View D1 Frame Size

    IGBT module IGBT 1 Fan assembly F1 + C1 +CBL11 SCR/Diode module SCR 1, 2, 3 IGBT output bus bar Current sensor L2, L3, L4 Output motor terminals Exploded View D1 Frame Size Intro-4 VLT is a registered Danfoss trademark...

  • Page 13: Exploded View D2 Frame Size

    IGBT module SCR/Diode module IGBT1, 2 SCR1, 2, 3 Fan assembly F1 + C1 + CBL11 IGBT output bus bar Current sensor L2, L3, L4 Output motor terminals Exploded View D2 Frame Size Intro-5 VLT is a registered Danfoss trademark...

  • Page 14: Exploded View E Frame Size

    SCR1, SCR2, SCR3 and D1, D2, D3 Fan inductor (not on all units) Soft charge resistor assy Output motor terminals IGBT output bus bar Fan assembly F1 + C1 Exploded View E1 Frame Size Intro-6 VLT is a registered Danfoss trademark...
  • Page 15 Fan On Low Speed Temperature Degrees C Fan On High Sped Temperature Degrees C Fan Off Temperature Degrees C <30 <30 <30 <30 <30 Fan Voltage Low Speed Fan VAC Fan Voltage High Speed Fan VAC Intro-7 VLT is a registered Danfoss trademark...
  • Page 16 Fan On Low Speed Temperature Degrees C Fan On High Sped Temperature Degrees C Fan Off Temperature Degrees C <30 <30 <30 <30 Fan Voltage Low Speed Fan VAC Fan Voltage High Speed Fan VAC Intro-8 VLT is a registered Danfoss trademark...
  • Page 17 Fan On Low Speed Temperature Degrees C Fan On High Sped Temperature Degrees C Fan Off Temperature Degrees C <30 <30 <30 <30 <30 <30 Fan Voltage Low Speed Fan VAC Fan Voltage High Speed Fan VAC Intro-9 VLT is a registered Danfoss trademark...
  • Page 18 Fan On Low Speed Temperature Degrees C Fan On High Sped Temperature Degrees C Fan Off Temperature Degrees C <30 <30 <30 Fan Voltage Low Speed Fan VAC Fan Voltage High Speed Fan VAC Intro-10 VLT is a registered Danfoss trademark...
  • Page 19 Fan On High Sped Temperature Degrees C Fan Off Temperature Degrees C <30 <30 <30 <30 <30 Fan Voltage Low Speed Fan VAC Fan Voltage High Speed Fan VAC NA* use existing 525 - 600 V drive Intro-11 VLT is a registered Danfoss trademark...

  • Page 21: Section 1 Operator Interface And Drive Control

    The values displayed in lines 1 and 2 can be programmed system functions are identified and their values from a list of options. See programming in the operator's shown in real-time. manual for details. VLT is a registered Danfoss trademark...

  • Page 22: Status Display

    VLT 4000/6000/8000 series have different display status indications, the definitions appear in separate tables. Familiarity with the status display provides information regarding the operational mode of the drive. The status line displays are not programmable. VLT is a registered Danfoss trademark...
  • Page 23 Local control selected and motor is running and speed corresponds to reference. LOCAL/STOP Local control selected and drive stopped via control panel, digital input or serial communication. LOCAL/UNIT Local control selected and 0 V on terminal 27. READY VLT is a registered Danfoss trademark...
  • Page 24 512. UNIT NOT READY Drive not ready for operation because of a trip or because OFF1, OFF2 or OFF3 is a logic ‘0.’ (Only on units with external 24 VDC supply.) VLT is a registered Danfoss trademark...
  • Page 25 Unit ready for operation but digital input terminal 27 is logic ‘0’ and/or a Coasting Command received via serial communication. XXXX Control microprocessor stopped for unknown cause and drive not operating. Cause may be noise on the power line, motor leads or control wires. VLT is a registered Danfoss trademark...

  • Page 26: Warnings And Alarms

    Use the [+] and [-] keys on the LCP keypad to – scroll through parameters. See the operator's manual for detailed information on accessing and displaying parameters and for descriptions and procedures for service information available in the 600s parameter group. VLT is a registered Danfoss trademark...

  • Page 27: Fault Message Table

    Output current high (I MOTOR > I HIGH) Feedback low (FEEDBACK < FDB LOW) Feedback high (FEEDBACK > FDB HIGH) Reference low (REF. < REF. LOW) Reference high (REF. > REF. HIGH) Temperature auto derate (TEMP.AUTO DERATE) Unknown fault (UNKNOWN ALARM) VLT is a registered Danfoss trademark...

  • Page 28: Drive Inputs And Outputs

    12 or 13, or from a customer supplied external 24 VDC power source. Improperly connected control wiring is a common service issue for a motor not operating or the drive not responding to a remote input. VLT is a registered Danfoss trademark...

  • Page 29: Control Terminals

    Control terminals must be programmed. Each terminal has specific functions it is capable of performing and a numbered parameter associated with it. The setting selected in the parameter enables the function of the terminal. See the Operator's Manual for details. VLT is a registered Danfoss trademark...
  • Page 30 Programmable 0 to 20 mA or 4 to 20 mA, analog current input, Resistance = approx. 200 Ω. Used for reference or feedback signals. RS-485 common. 68, 69 RS-485 interface and serial communication. Figure 1-2. Control Terminals Electrical Diagram 1-10 VLT is a registered Danfoss trademark...

  • Page 31: Grounding Shielded Cables

    61. This terminal connects to ground through an internal RC link. It is recommended to use twisted-pair cables to reduce the differential mode interference between condutors. Figure 1-3. Grounding Shielded Cables 1-11 VLT is a registered Danfoss trademark...

  • Page 33: Section 2 Internal Drive Operation

    The VLT series drives covered in this manual are very similar in design and construction. For the purpose of troubleshooting, Logic Section two main differences exist.

  • Page 34: Logic To Power Interface

    1 Amp. The logic circuitry on the control card allow for the addition of option modules for synchronizing control, serial communications, additional relays, the cascade pump controller, or custom operating software. VLT is a registered Danfoss trademark...

  • Page 35: Power Section

    The DC bus capacitors are arranged into a capacitor bank along with bleeder and balancing circuitry. Due to the requirement for higher power capacity, some drives have two capacitor banks connected in parallel. Figure 2-3. Typical Power Section VLT is a registered Danfoss trademark...

  • Page 36: Sequence Of Operation

    After a short delay, an inrush enable signal is sent from the control card to the power card SCR gating circuit. The SCRs are automatically gated when forward biased, acting, as a result, similar to an uncontrolled rectifier. VLT is a registered Danfoss trademark...
  • Page 37 No RFI relay on 525 - 690V units. E1 units have 2 RFI cards. Figure 2-4. Rectifier Circuit VLT is a registered Danfoss trademark...

  • Page 38: Intermediate Section

    RFI/HF switch on the interface card, which can be manually switched off. This disconnects the ground references to all filters should unbalanced phase-to-ground voltages create nuisance overvoltage conditions. For 525-600/690 V drives, there are no relay contacts that disconnect to ground. VLT is a registered Danfoss trademark...
  • Page 39 E1 units have 2 door fans. No RFI relay on 525 - 690V units Figure 2-5. Intermediate Section VLT is a registered Danfoss trademark...

  • Page 40: Inverter Section

    AC sine wave. plus This waveform, as generated by the Danfoss VVC principle at the control card, provides optimal performance and minimal losses in the motor. Hall effect current sensors monitor the output current and deliver proportional signals to the power card where they are buffered and delivered to the control card.
  • Page 41 Figure 2-7. Inverter Section VLT is a registered Danfoss trademark...

  • Page 42: Brake Option

    DC bus. This occurs, for example, when the load drives the motor causing the voltage to return to the DC bus circuit. Figure 2-8. Brake Option 2-10 VLT is a registered Danfoss trademark...

  • Page 43: Cooling Fans

    Regardless of the heatsink temperature, the fans are started without first consulting Danfoss Application Engineering. shortly after main input power is applied to the drive. If the heatsink temperature is below 86°F (30°C), the fans will turn off In the second method, the drive is powered exclusively from after a short interval.
  • Page 44 Terminal positions on the power card labeled MK400, MK103, and FK101 are reserved for future use. 2-12 VLT is a registered Danfoss trademark...

  • Page 45: Section 3 Troubleshooting

    3.1 Display 3.1.1 No Display 3.1.2 Intermittent Display 3.1.3 Display Line 2 Flashing 3.1.4 WRONG Displayed 3.2 Motor 3.2.1 Motor Will Not Run 3.2.2 Incorrect Motor Operation 3.3 Warnings and Alarms 3.4 After Repair Tests VLT is a registered Danfoss trademark...

  • Page 46: Visual Inspection

    Vibration Though somewhat subjective look for an unusual amount of vibration that the drive may be subjected to. The drive should be mounted solidly or the use of shock mounts employed. VLT is a registered Danfoss trademark...

  • Page 47: Fault Symptoms

    (external to the drive). All control wiring should be checked for shorts or incorrect connections. If the display continues to cut out, follow the procedure for No Display as though the display were not lit at all. VLT is a registered Danfoss trademark...

  • Page 48: Motor

    Check control wiring to ensure that the proper reference signal is present at the drive input terminals and that the unit is properly programmed to accept the signal provided. Refer to the Input Terminal Signal Test in Section 5. VLT is a registered Danfoss trademark...

  • Page 49: Incorrect Motor Operation

    Alarm 13. Check setting of all motor parameters. Perform Output Phase Imbalance Test in section 5. If output voltage is unbalanced, perform Gate Drive Signal Test in section 5. VLT is a registered Danfoss trademark...

  • Page 50: Warning And Alarm Messages

    Refer to section 5, Dynamic Test Procedures, Input Voltage Test, Input Phase Imbalance Test, Output Phase Imbalance See Input Voltage Test in Section 5. Test. See Mains Phase Loss Trips in Section 4 for more details. VLT is a registered Danfoss trademark...
  • Page 51 Check for overheated motor (if Thermistor function is being See Internal Drive Problems in Section 5. used). Check for open connection by measuring voltage between corresponding terminal and terminal 55. A reading of less than 8 VDC indicates an open connection. VLT is a registered Danfoss trademark...
  • Page 52 Note: the motor nameplate current, and the value entered in on serial communication cable. parameter 105, must be greater than 35% of the nominal rating of the drive in order to carry out AMA. VLT is a registered Danfoss trademark...
  • Page 53 The motor shaft rotated during the tuning process due to an reduced or drive and resistor must be resized. overhauling load. Ensure the load is not capable of rotating the shaft, and restart AMA. VLT is a registered Danfoss trademark...
  • Page 54 See Output Phase Imbalance Test (5.2.8) in Section 5. Check connections in feedback circuit. Check process operation. Note: Some applications may be designed to operate normally in this mode. No action is necessary in this case. 3-10 VLT is a registered Danfoss trademark...
  • Page 55 It may be possible to run the drive with the brake resistor 102 is incorrect. disconnected, however the braking function will be inoperative. Check the motor and setting and choose “Continue” or “Stop”. If stop is selected AMA will have to be started over. 3-11 VLT is a registered Danfoss trademark...
  • Page 56 This may be due to noise interference, or a faulty Control Card. No corrective action needed. Cycle power and or reinitialize the VLT to clear the fault. Possible replacement of control card is needed. 3-12 VLT is a registered Danfoss trademark...

  • Page 57: After Repair Tests

    10. Using a clamp-on style ammeter, measure output current on each output phase. All currents should be balanced. If unbalanced current is measured, refer to Current Sensor Test (5.2.12). 3-13 VLT is a registered Danfoss trademark...

  • Page 59: Section 4 Drive And Motor Applications

    Enter the motor data required as listed on the motor nameplate. For effective and efficient load control, the drive relies on this information for calculating the output waveform in response to the changing demands of the application. VLT is a registered Danfoss trademark...

  • Page 60: Overvoltage Trips

    Otherwise, the speed could continue to rise to potentially unsafe levels. In applications with very high inertia, such as a centrifuge, it is recommended to use a VLT 5000 Flux drive. VLT is a registered Danfoss trademark...

  • Page 61: Control Logic Problems

    In such cases, setting the Perform the IGBT gate signal test (5.2.9). correct values to these parameters and performing the automatic motor adaptation (AMA) function will usually solve the problem. VLT is a registered Danfoss trademark...

  • Page 62: Internal Drive Problems

    A tolerance of +/- 15mv is acceptable. In a three phase system that is operating correctly, the sum of the three output currents should always be zero. VLT is a registered Danfoss trademark...

  • Page 63: Signal And Power Wiring Considerations For Drive Electromagnetic Compatibility

    Filter reactor AC Line Motor IGBT Filter capacitor Sine wave PWM waveform Figure 4-1. Adjustable Frequency Drive Functionality Diagram The high rate of voltage change caused by the IGBT switching creates high frequency EMI. VLT is a registered Danfoss trademark...

  • Page 64: Emi Propagation

    Motor cable Stray capacitance Signal wiring to BMS Figure 4-3. Signal Conductor Currents Unprotected or poorly routed signal conductors located close to or in parallel to motor and AC line conductors are susceptible to EMI. VLT is a registered Danfoss trademark...

  • Page 65: Preventative Measures

    If parallel routing is unavoidable, try to maintain a separation of 6 - 8 inches between the cables or separate them with a grounded conductive partition. Avoid routing cables through free air. VLT is a registered Danfoss trademark...

  • Page 66: Proper Emc Installation

    This technique will not be as effective alleviate such problems. as shielded cable due to the unavoidable contact of the conduit with various points within the equipment. Figure 4-5. Proper EMC Installation VLT is a registered Danfoss trademark...

  • Page 67: Section 5 Test Procedures

    Differences in the procedures are noted, as required. However, the Soft Charge and Rectifier Circuit Test, Soft Charge Rectifier Test, and Fan Continuity Test sections Test Cable Connector and SCR Shorting Plug are independent for D-frame and E-frame drives. VLT is a registered Danfoss trademark...

  • Page 68: Test Procedures

    Current scaling card MK104 MK102 MK111 MK105(A) +DC Interface Card MK105(B) -DC FK100 MK110 MK400 FK100 FK101 FK102 MK109 MK100 MK106 FK103 MK107 Power Card Figure 5-1. Interface PCA and Power PCA Connector Identification VLT is a registered Danfoss trademark...

  • Page 69: Soft Charge And Rectifier Circuits Test: D-Frame Size

    MK106 pin 6 on power card. A measurement of 0 ohms indicates good continuity. Replace any open fuse (infinite resistance). To replace a soft charge fuse, follow the soft charge disassembly instructions in Section 6. VLT is a registered Danfoss trademark...
  • Page 70 A short circuit reading indicates either one or more of the upper soft charge rectifier diodes are shorted or the SCRs are shorted in the SCR/Diode module. To isolate between SCRs or the soft charge rectifier, perform the Soft Charge Rectifier Test. VLT is a registered Danfoss trademark...

  • Page 71: Soft Charge Rectifier Test: D-Frame Size

    Section 6. 5. Reverse meter leads with positive (+) meter lead to positive (+) MK3 (A). Connect negative (-) lead to MK1 terminals R, S, and T in turn. Each reading should show open. VLT is a registered Danfoss trademark...

  • Page 72: Soft Charge And Rectifier Circuits Test: E-Frame Sizes

    2. Measure F2 across fuse. Open reading indicates open (blown) fuse. 3. Measure F3 across fuse. Open reading indicates open (blown) fuse. A measurement of 0 ohms indicates good continuity. Replace any open fuse (infinite resistance). VLT is a registered Danfoss trademark...
  • Page 73 With the Part III test connection, the diodes in the main rectifier diode modules are forward biased. The meter reads the diode drops. If a short circuit or an open circuit exists, the diode module is damaged. VLT is a registered Danfoss trademark...

  • Page 74: Soft Charge Rectifier Test: E-Frame Size

    3. Reverse meter leads with positive (+) meter lead to positive (+) MK3 (A). Connect negative (-) lead to MK1 terminals R, S, and T in turn. Each reading should show open. Figure 5-5. Soft Charge Card Connectors VLT is a registered Danfoss trademark...

  • Page 75: Inverter Section Tests

    V, and W in turn. Each reading should show a wires, or if the resistors are defective, the entire IGBT module diode drop. assembly requires replacement. Replace the IGBT module in accordance with the disassembly procedures in Section 6 or 7. VLT is a registered Danfoss trademark...

  • Page 76: Brake Igbt Test

    1. Test for short circuits with ohmmeter set on 10K ohms equals 25°C and 787 ohms equals 95°C. The higher Rx100 scale or, for a digital meter, select diode. the temperature, the lower the resistance. 5-10 VLT is a registered Danfoss trademark...

  • Page 77: Fan Continuity Tests: D-Frame Size

    Approximately 20 ohms should be read. 2. Measure between CN2 terminals 1 and 2. Approximately 8 ohms should be read. 3. Measure between CN2 terminals 2 and 3. Approximately 12 ohms should be read. 5-11 VLT is a registered Danfoss trademark...

  • Page 78: Fan Continuity Tests: E-Frame Sizes

    5502, 4602, 6552, 8602 380-500 5552, 4652, 6602, 8652 525-690 5402, 4502, 6502, 8502 525-690 5502, 4602, MK107 6602, 8602 525-690 5602, 4652, Figure 5-7. Fan and DC Bus Fuse Locations 6652, 8652 5-12 VLT is a registered Danfoss trademark...

  • Page 79: Dynamic Test Procedures

    Take all necessary safety precautions for system necessary. start up prior to applying power to drive. Main 3-phase AC power to drive 3-phase output to motor DC bus/loadsharing connections Brake resistor connection Figure 5-8. Drive Power Terminals (D-size Frames) 5-13 VLT is a registered Danfoss trademark...

  • Page 80: No Display Test

    3%. 2. Measure 10 V DC control voltage at terminal 50 Danfoss calculates line imbalance per an IEC specification. with respect to terminal 55. Meter should read Imbalance = 0.67 X (Vmax – Vmin) / Vavg between 9.2 and 11.2 VDC.

  • Page 81: Switch Mode Power Supply (Smps) Test

    DC bus voltage was read at power card connector MK105 (A) and (B). Replace the power card in accordance with the disassembly procedures in Section 6 or 7. 5-15 VLT is a registered Danfoss trademark...

  • Page 82: Dc Under Voltage Test

    SCR gates. Further tests on the proper gating of the SCRs requires an oscilloscope equipped with current probes. Proceed to testing the input waveform and input SCR in accordance with their procedures. 5-16 VLT is a registered Danfoss trademark...

  • Page 83: Input Waveform Test

    40% load. The two positive and two negative jumps are typical of any 6 diode bridge. It is the same for drives with SCR/Diode modules. CONTINUED ON NEXT PAGE Figure 5-10. AC Input Current Waveform with Diode Bridge 5-17 VLT is a registered Danfoss trademark...
  • Page 84 Perform the static soft charge and rectifier tests and also the dynamic SCR/Diode module test. 5-18 VLT is a registered Danfoss trademark...

  • Page 85: Input Scr Test

    A distorted signal may be due to a defective gate on that signal is inactive and the SCRs are not gated. particular SCR that is loading down the supply. Replace the SCR module which corresponds to the incorrect gate signal reading. 5-19 VLT is a registered Danfoss trademark...

  • Page 86: Output Phase Imbalance Test

    At 30 Hz it is about half of that and so on for any other speed selected. The exact voltage reading is less important than balance between phases. 5-20 VLT is a registered Danfoss trademark...

  • Page 87: Igbt Gate Drive Signals Test

    CONTINUED ON NEXT PAGE into MK3. pin 1 MK850 MK250 MK350 MK650 MK750 (brake) MK450 MK550 MK105 MK102 (U) MK103 (V) MK104 (W) (brake option) Figure 5-13. Gate Drive Card Test Connectors 5-21 VLT is a registered Danfoss trademark...
  • Page 88 12. Insert signal test board into interface card connector MK104. 13. With scope probe ground connected to terminal 4 (common) of signal board, measure six gate signals at signal board terminals 25 through 30. CONTINUED ON NEXT PAGE 5-22 VLT is a registered Danfoss trademark...
  • Page 89 The control card would be suspect if all six signals are incorrect. Replace the corresponding card in accordance with the disassembly procedures in Section 6 or 7. 5-23 VLT is a registered Danfoss trademark...

  • Page 90: Igbt Switiching Test

    8. Leaving negative meter lead connected to cable determine whether the fault lies in the IGBT or the gate driver MK105, run drive at 30 Hz. card. See Gate Drive Signal Tests (5.2.9). 5-24 VLT is a registered Danfoss trademark...

  • Page 91: Current Sensors Test

    9. Install signal test board into interface card 525-600/690 5302, 4352, 6352, 8352 connector MK104. 525-600/690 5352, 4402, 6402, 8402 525-600/690 5402, 4502, 6502, 8502 525-600/690 5502, 4602, 6602, 8602 525-600/690 5602, 4652, 6652, 8652 5-25 VLT is a registered Danfoss trademark...

  • Page 92: Fan Tests

    Section 6 or 7. equal 66% of main AC supply voltage (48% for drives 525-600/690 VAC) applied to drive (or that of auxiliary supply). If voltage is incorrect, replace fan transformer. 5-26 VLT is a registered Danfoss trademark...

  • Page 93: Input Terminal Signal Tests

    A reading of 0 VDC indicates no Note that a (-) minus sign preceding any reading above indicates signal is present. a reversed polarity. In this case, reverse the wiring to the analog terminals. 5-27 VLT is a registered Danfoss trademark...

  • Page 94: Control Card Test

    Display will indicate a pass or fail mode. If a failure is indicated, replace control card in accordance with procedures in Section 6. 8. If tests pass successfully, press OK key and parameter 620 automatically returns to normal operation. 5-28 VLT is a registered Danfoss trademark...

  • Page 95: Initial Start Up Or After Repair Drive Tests

    10. Using a clamp-on style ammeter, measure output current on each output phase. All currents should be balanced. If unbalanced current is measured, refer to Current Sensor Test (5.2.12). 5-29 VLT is a registered Danfoss trademark...

  • Page 97: Section 6 D-Frame Sizes Disassembly And Assembly Instructions

    Control card cassette Ribbon cables (Step 4) LCP cable connector (Step 3) Control card Control terminals (Step 1) Captive screws (Step 5) Grounding clamps (Step 2) Figure 6-1. Control Card Cassette VLT is a registered Danfoss trademark...

  • Page 98: Interface Card

    Power card mounting s c r e w Interface card standoff MK105 Mounting plate Mounting plate standoff FK100 FK101 FK102 MK109 MK106 MK107 FK103 MK100 Figure 6-2. Interface Card, Power Card, and Mounting Plate VLT is a registered Danfoss trademark...

  • Page 99: Gate Drive Card

    Reinstall by aligning soft charge card with fastening clips on the side of the chassis. Reattach connectors. Slide into place and tighten mounting screws to 35 in-lbs (4 Nm). Figure 6-4. Soft Charge Card Assy VLT is a registered Danfoss trademark...

  • Page 100: Capacitor Bank(S)

    4. Note that weight of cap bank is approx. 20 lbs. (9 kg). Remove cap bank by pulling free from mounting studs. Reinstall in reverse order of this procedure. Tighten mounting screws to 35 in-lbs (4 Nm). VLT is a registered Danfoss trademark...

  • Page 101: Single Capacitor Bank D1 Units

    Remove cap bank by pulling free from mounting studs. Reinstall in reverse order of this procedure. Tighten mounting screws to 35 in-lbs (4 Nm). Gate drive card (Step 3) Retaining nuts (Step 4) Figure 6-6. D1 Single Capacitor Bank Assembly VLT is a registered Danfoss trademark...

  • Page 102: Soft Charge (Sc) Resistors D2 Units

    20 in-lbs (2.25 Nm). Tighten 10mm mounting nuts to 35 in-lbs (4 Nm). Soft charge resistor Bus bars BB27 (do not remove) Retaining nut (loosen) (Step 3) Figure 6-7. D2 Soft Charge Resistor VLT is a registered Danfoss trademark...

  • Page 103: Soft Charge (Sc) Resistors D1 Units

    1 of each of 3 SCR/Diode modules and remove bus bar. CONTINUED ON NEXT PAGE Soft Charge Resistor Bus bar (BB2) (Step 3) Retaining screw (Step 3) Figure 6-8. D1 Soft Charge Resistor (1 of 3) VLT is a registered Danfoss trademark...

  • Page 104: D1 Soft Charge Resistor

    Remove DC input bus assembly. CONTINUED ON NEXT PAGE Retaining nuts Soft Charge Resistor (Step 5) DC input bus assembly BB3 (Step 5) Retaining screws (Step 4) Figure 6-8. D1 Soft Charge Resistor (2 of 3) VLT is a registered Danfoss trademark...
  • Page 105 Tighten T25 and 8mm mounting screws to 20 in-lbs (2.25 Nm) and T30 and 10 mm to 35 in-lbs (4 Nm). Soft Charge Resistor Mounting screws (Step 6) Figure 6-8. D1 Soft Charge Resistor (3 of 3) VLT is a registered Danfoss trademark...

  • Page 106: Input Terminal Mounting Plate Assy

    35 in-lbs (4Nm). Bus bar retaining nuts (shown removed) (Step 2) Input power connector (Step 1) Transformer connector (Step 3) Retaining nuts (Step 4) Figure 6-9. Input Terminal Mounting Plate Assy 6-10 VLT is a registered Danfoss trademark...

  • Page 107: Scr/Diode Module D2 Units

    BB21 or BB22 per drive power rating IGBT output bus bar retaining nut (Step 6) SCR/Diode terminal screw (Step 5) IGBT output bus bar BB32 (Step 6) Figure 6-10. D2 SCR/Diode Module (1 of 4) 6-11 VLT is a registered Danfoss trademark...
  • Page 108 (Step 9) IGBT output retaining screws (Step 7) Retaining screws (Step 9) Bus bar BB30 Intermediate IGBT output bus bar BB30 Bus bar BB31 (Step 8) Figure 6-10. D2 SCR/Diode Module (2 of 4) 6-12 VLT is a registered Danfoss trademark...
  • Page 109 CONTINUED NEXT PAGE Bus bar BB27 Bus bar BB28 Rectifier DC bus bars BB23 or BB24 per drive power rating (Step 10) Retaining screws (Step 10) Figure 6-10. D2 SCR/Diode Module (3 of 4) 6-13 VLT is a registered Danfoss trademark...

  • Page 110: D2 Scr/Diode Module

    (T30) and remove SCR/Diode instructions with spare part. modules. SCR/Diode module (Step 12) SCR gate lead connectors (Step 11) SCR/Diode module mounting screws (Step 12) Figure 6-10. D2 SCR/Diode Module (4 of 4) 6-14 VLT is a registered Danfoss trademark...

  • Page 111: Scr/Diode Module D1 Units

    CONTINUED ON NEXT PAGE Bus bar BB2 (Step 4) Retaining screw access (Step 3) Retaining nut (Step 4) Bus bar BB1 SCR/Diode module Figure 6-11. D1 SCR/Diode Module (1 of 3) 6-15 VLT is a registered Danfoss trademark...
  • Page 112 Remove DC input bus assembly. CONTINUED ON NEXT PAGE Retaining nuts Bus bar BB4 (Step 6) DC input bus assembly BB3 (Step 6) Retaining screws (Step 5) SCR/Diode module Figure 6-11. D1 SCR/Diode Module (2 of 3) 6-16 VLT is a registered Danfoss trademark...
  • Page 113 (2.25 Nm) and T30 and 10 mm to 35 in-lbs (4 Nm). 3. Reassemble remaining parts in reverse order of their removal. SCR/Diode module Mounting screws (Step 8) Figure 6-11. D1 SCR/Diode Module (3 of 3) 6-17 VLT is a registered Danfoss trademark...

  • Page 114: Current Sensor

    Reinstall in reverse order of this procedure. Tighten 8mm mounting nuts to 20 in-lbs (2.25 Nm). Current sensor Terminal mounting screw Terminal Current sensor mounting screws (2) Terminal mounting screws (2) Output motor cable connection screws (2) Figure 6-12. Current Sensors 6-18 VLT is a registered Danfoss trademark...

  • Page 115: Fan Assembly

    Intermediate SCR input bus bar (Step 3) Terminal (Step 3) Retaining nut (Step 4) Retaining nut (Step 2) IGBT output bus bar (Step 2) Retaining nut (Step 2) Figure 6-13. Fan Assembly (1 of 2) 6-19 VLT is a registered Danfoss trademark...
  • Page 116 18 lbs (8 kg). Reinstall in reverse order of this procedure. Tighten mounting nuts to 20 in-lbs (2.25 Nm). Inline molex connector (Step 6) Retaining nut (Step 7) Figure 6-13. Fan Assembly (2 of 2) 6-20 VLT is a registered Danfoss trademark...

  • Page 117: Ac Input Terminals

    Reinstall in reverse order of this procedure. Tighten mounting nuts per specifications in the unit's instruction manual. Retaining screw (Step 2) Retaining screws (Step 2) AC input cable connector (Step 1) AC input terminal Figure 6-14. AC Input Terminals 6-21 VLT is a registered Danfoss trademark...

  • Page 118: Igbt Modules D2 Units

    (Step 6) SCR/Diode terminal SCR/Diode input bus bar screw (Step 5) BB21 or BB22 per drive power rating IGBT output bus bar BB32 (Step 6) Figure 6-15. D2 IGBT Modules (1 of 3) 6-22 VLT is a registered Danfoss trademark...
  • Page 119 IGBT module Retaining screws (Step 11) Retaining nut (Step 7) Retaining nut (Step 12) IGBT module Intermediate IGBT output bus bar BB30 (Step 12) BB30 BB31 Figure 6-15. D2 IGBT Modules (2 of 3) 6-23 VLT is a registered Danfoss trademark...
  • Page 120 T25 and 8mm screws to 20 in-lbs (2.25 Nm) and T30 and 10 mm to 35 in-lbs (4 Nm). IGBT module Retaining screw (Step 13) Figure 6-15. D2 IGBT Modules (3 of 3) 6-24 VLT is a registered Danfoss trademark...

  • Page 121: Igbt Modules D1 Units

    Gate drive cable connectors (Steps 3 & 4) IGBT module IGBT output bus bar BB9 (Step 7) IGBT output bus bar retaining nut (Step 7) Figure 6-16. D1 IGBT Module (1 of 2) 6-25 VLT is a registered Danfoss trademark...
  • Page 122 Retaining nut solution. (Step 8) Snubber capacitor (Step 9) IGBT module Retaining screw (Step 9) Retaining nut (Step 11) Intermediate IGBT output bus bar (Step 11) Figure 6-16. D1 IGBT Module (2 of 2) 6-26 VLT is a registered Danfoss trademark...

  • Page 123: Section 7 E-Frame Sizes Disassembly And Assembly Instructions

    E1 frame size definitions. LCP (local control panel) Control card Control card cassette Control terminals Ribbon cables (Step 1) (Step 4) Captive screws (Step 5) Grounding clamps (Step 2) Figure 7-1. Control Card Cassette VLT is a registered Danfoss trademark...

  • Page 124: Interface Card

    PCA3 Ground connector MK102 MK104 MK110 Locking stud Interface card standoff MK105 Mounting plate Mounting plate standoff FK100 FK101 FK102 MK109 MK106 MK107 FK103 MK100 Figure 7-2. Interface Card, Power Card, and Mounting Plate VLT is a registered Danfoss trademark...

  • Page 125: Gate Drive Card

    Reinstall by mounting insulation onto standoffs. Mount soft charge card and tighten mounting screws to 20 in-lbs (2.3 Nm). Mounting screw (Step 2) Figure 7-4. Soft Charge Card Assy VLT is a registered Danfoss trademark...

  • Page 126: Capacitor Banks

    (Step 2) Lower cap bank assy electrical connection nuts Lower cap bank (Step 2) assy retaining nut (Step 3) Lower capacitor Soft charge card bank assy Figure 7-5. Upper and Lower Capacitor Bank Assemblies VLT is a registered Danfoss trademark...

  • Page 127: Input Terminal Mounting Plate Assy Option

    Fuse RFI filter assembly Retaining nut Connection nut (Step 2) (Step 3a) Input terminals (Step 1) Cooling fan (Step 4) Input terminal mounting plate Figure 7-6. Input Terminal Mounting Plate Assy (with RFI option) VLT is a registered Danfoss trademark...

  • Page 128: Soft Charge Resistor

    Reinstall in reverse order of this procedure. Tighten 8 mm retaining nuts to 20 in-lbs (2.3 Nm). MK4 connector (Step 2) Soft charge card Top retaining nut (Step 3) Soft charge resistor Bottom retaining nut (Step 4) Figure 7-7. Soft Charge Resistor VLT is a registered Danfoss trademark...

  • Page 129: Scr And Diode Modules

    (Step 7) Diode module Wire retaining nuts for output bus bars BB42 (Steps 5 & 6) Wire retaining nut on bus bar BB41 (Step 3) Figure 7-8. SCR and Diode Modules (1 of 3) VLT is a registered Danfoss trademark...
  • Page 130 Negative (-) output bus bar BB42 (Step 9) SCR and Diode Negative (-) output bus input bus bar BB41 bar connecting screw (Step 10) (Step 9) Figure 7-8. SCR and Diode Modules (2 of 3) VLT is a registered Danfoss trademark...
  • Page 131 Diode module D2 Diode module D3 SCR gate lead connection (Step 11) SCR module SCR1 SCR module SCR3 Retaining screw (Step 12) SCR module SCR2 Figure 7-8. SCR and Diode Modules (3 of 3) VLT is a registered Danfoss trademark...

  • Page 132: Current Sensor

    T50 screw to 170 in-lbs (19.2 Nm). IGBT terminal bus bar mounting screw Current sensor (Step 3) Current sensor mounting screws (2) (Step 5) Output motor terminal bus bar retaining nut (Step 2) Figure 7-9. Current Sensors 7-10 VLT is a registered Danfoss trademark...

  • Page 133: Fan Assembly

    Cut tie wrap to free wiring from frame. Retaining nut (Step 5) Retaining nut (Step 3) Fan housing Molex connector IGBT output bus bar (Step 4) BB49 Retaining nut (Step 2) Figure 7-10. Fan Assembly 7-11 VLT is a registered Danfoss trademark...

  • Page 134: Ac Input, Motor, Load Sharing Or Regen Terminals

    170 in-lbs (19.2 Nm) and 13 mm or T40 Torx screw to 85 in-lbs (9.6 Nm). Retaining nut (Step 2) Terminal block insullation (Step 4 or 5) Retaining nuts (Step 3) Figure 7-11. Terminal Blocks 7-12 VLT is a registered Danfoss trademark...

  • Page 135: Igbt Modules

    IGBT board Retaining nuts (Step 7) Wire retaining nuts for output bus bars BB42 (Steps 5 & 6) Wire retaining nut on bus bar BB41 (Step 3) Figure 7-12. IGBT Modules (1 of 4) 7-13 VLT is a registered Danfoss trademark...
  • Page 136 Negative (-) output bus bar BB42 (Step 9) SCR and Diode Negative (-) output bus input bus bar BB41 bar connecting screw (Step 10) (Step 9) Figure 7-12. IGBT Modules (2 of 4) 7-14 VLT is a registered Danfoss trademark...
  • Page 137 Retaining screw (Step 11) Retaining nut (Step 14) Output bus bar Retaining nut (Step 14) Retaining nut (Step 12) Over-fan bus bar Retaining nut (Step 13) Figure 7-12. IGBT Modules (3 of 4) 7-15 VLT is a registered Danfoss trademark...
  • Page 138 Retaining screw (Step 18) Snubber capacitor Retaining nut (Step 16) Retaining screw (Step 15) IGBT-Cap bus bar BB47 IGBT board IGBT retaining screw (Step 22) Figure 7-12. IGBT Modules (4 of 4) 7-16 VLT is a registered Danfoss trademark...

  • Page 139: Section 8 Special Test Equipment

    The cable is connected between the soft charge card and the power card. The SCR shorting plug shorts the gates of the SCRs to ensure they do not fire and add a charge to the DC bus. VLT is a registered Danfoss trademark...

  • Page 140: Signal Test Board (P/N 176F8437)

    Following is a description of the signals available on the signal test board. Section 5 of this manual describes when these tests would be called for and what the signal should be at that given test point. VLT is a registered Danfoss trademark...
  • Page 141 +16.5 to 19.5 +16.5 to 19.5 VNEG -18 VDC Red LED indicates voltage is present between VPOS and -18 VDC regulated regulated supply VNEG terminals. supply -16.5 to 19.5 -16.5 to 19.5 VDC VLT is a registered Danfoss trademark...
  • Page 142 Yellow LED indicates voltage is present. +24 VDC regulated supply supply +23 to 25 VDC +5.0 VDC Green LED indicates voltage is present. +5.0 VDC regulated regulated supply. supply +4.75 to 5.25 +4.75-5.25 VDC VLT is a registered Danfoss trademark...
  • Page 143 Signal originates on Control Card. 2v/div 100us/div Run@10Hz GVN_T IGBT gate 2.2 - 2.5 VDC signal, buffered, Equal on all phases V phase, neg- TP25-TP30 ative. Signal originates on Control Card. 2v/div 100us/div Run@10Hz VLT is a registered Danfoss trademark...
  • Page 144 Signal originates on Control Card. 2v/div 100us/div Run@10Hz GWN_T IGBT gate 2.2 - 2.5 VDC signal, buffered, Equal on all phases W phase, TP25-TP30 negative. Signal originates on Control Card. 2v/div 100us/div Run@10Hz VLT is a registered Danfoss trademark...
  • Page 153 MK103 MK104 MK103 MK101 TMP_P TMP_N TEST CONNECTOR MK104 MK105 MK102 MK110 MK104 MK111 MK100 BAL CKT AUX_S AUX_T AUX_S TMP+ AUX_T MK105 TMP- CURRENT SENSORS GATE...
  • Page 154 NTC2 NTC1 ELO3 EUP3 GLO3 GUP3 ELO2 EUP2 GLO2 GUP2 ELO1 EUP1 GLO1 GUP1 ELO3 EUP3 GLO3 GUP3 ELO2 EUP2 GLO2 GUP2 ELO1 EUP1 GLO1 GUP1 NTC2 NTC1...
  • Page 155 MK103 MK104 MK103 MK101 TMP_P TMP_N TEST CONNECTOR MK104 MK105 MK102 MK110 MK104 MK111 MK100 BAL CKT AUX_S AUX_T AUX_S TMP+ AUX_T MK105 TMP- CURRENT SENSORS GATE...
  • Page 156 NTC2 NTC1 ELO3 EUP3 GLO3 GUP3 ELO2 EUP2 GLO2 GUP2 ELO1 EUP1 GLO1 GUP1 ELO3 EUP3 GLO3 GUP3 ELO2 EUP2 GLO2 GUP2 ELO1 EUP1 GLO1 GUP1 NTC2 NTC1...
  • Page 157 MK103 MK104 MK103 MK101 TMP_P TMP_N TEST CONNECTOR MK104 MK105 MK102 LOAD SHARE WIRES MK110 MK104 MK111 REGEN WIRES MK100 BAL CKT BAL CKT AUX_S AUX_T AUX_S AUX_T CURRENT SENSORS MK105 TMP+ TMP- 1 2 6 GATE GATE...
  • Page 158 NTC2 NTC1 ELO1 EUP1 GLO1 GUP1 NTC2 NTC1 ELO1 EUP1 GLO1 GUP1 NTC2 NTC1 ELO1 EUP1 GLO1 GUP1...

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