Danfoss VLT Series Service Manual
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Also See for VLT Series:
- Programming manual (390 pages) ,
- Design manual (179 pages) ,
- Service manual (158 pages)
Table of Contents
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Section Six
Appendix
Safety Precautions
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Required Tools
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Description of Operation
Sequence of Operation
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Fault Indicators and Messages
Troubleshooting Tips
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Troubleshooting Flowchart
Symptom/Cause Chart
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Static Test Procedures
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Dynamic Test Procedures
Component Replacement Procedures
Current Limit Trips
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Table of Contents
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Table of Contents
Related Manuals for Danfoss VLT Series
Summary of Contents for Danfoss VLT Series
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Page 1: Table Of Contents
Table of Contents Introduction Safety Precautions 0 - 2 ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Required Tools 0 - 3 ○... -
Page 2: Introduction
Series Service Manual INTRODUCTION The purpose of this manual is to provide technical information and instructions that will enable the user to identify faults and affect repairs on the following Danfoss Series 3000 and 3500 Adjustable Frequency Drives: VLT 3002-3022, 230V... - Page 3 ® Series Service Manual The Adjustable Frequency Drive (AFD) contains dangerous voltages when connected to the line voltage. Only a competent technician should carry out the service. WARNING: 1) DO NOT touch the electrical parts of the AFD when the AC line is FOR YOUR SAFETY: connected.
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Page 4: Section One
Section One Refer to the overall schematic in the Appendix. DESCRIPTION OF OPERATION This manual in not intended to give a detailed description of the unit's operation. It is intended to provide the reader a general overview of the function of each of the unit's main assemblies. - Page 5 Section One LOGIC SECTION A 10VDC supply is also available for use as a speed reference when connected to an appropriate potentiometer. These two voltage references are limited in the amount of available current they can provide (see specifications in Instruction Manual).
- Page 6 Section One The logic to power interface isolates the high voltage components of the power LOGIC TO POWER section from the low voltage signals of the logic section. This is accomplished by INTERFACE use of the Interface/ILD Card*. All communication between the control logic and the rest of the unit passes through the Interface/ILD Card.
- Page 7 Section One VLT 3002-3004, 230V, VLT 3502-3504, 230V SEQUENCE OF VLT 3002-3008, 380V/460V VLT 3502-3508, 380V/460V OPERATION When input power is first applied, the Rectifier Module converts the line voltage into a DC voltage. The rectified output is then connected to the DC Bus filter establishing a fixed DC Bus voltage.
- Page 8 Section One SEQUENCE OF PTC resistors are placed in series with the inputs of the Rectifier Module to limit the initial charge current of the DC Bus capacitors. The rectified line voltage is OPERATION then applied to the DC Bus filter. As the DC Bus voltage increases, the Interface Card power supplies energize.
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Page 9: Section Two
Section Two A variety of messages are displayed by the control card. Some messages indicate FAULT INDICATORS the operational status of the unit while others provide warnings of an impending AND MESSAGES fault. In addition, there are the alarm messages which indicate that the unit's operation has stopped due to a fault condition. - Page 10 SMPS stop SMPS start Undervoltage trip, inverter stopped inverter enabled Control Card undervoltage warning Control Card overvoltage warning (brake applied*, parameter 300) (395) (705) (845) Overvoltage trip, inverter stopped inverter enabled * Only on VLT Series 3000 units. 2 - 2...
- Page 11 Section Two ALARM MESSAGES Alarm messages will be indicated by the following messages appearing in the display and the red Alarm LED will flash on the unit keypad. All alarm messages result in the unit's operation being interrupted and require a Manual or Automatic reset.
- Page 12 Section Two ALARM MESSAGES GROUND FAULT (5) This message indicates a leakage to ground on the output of the inverter. To remedy this fault, check the output wiring and motor for ground faults. It is also necessary to ensure that the VLT has been properly grounded. This fault returns a "Trip Locked".
- Page 13 Section Two Prior to diving into a repair, here a few tips that if followed will make the job easier GENERAL 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 14 Section Two VLT 3002-3022, 230V VLT 3502-3532, 230V VLT 3002-3052, 400/500V VLT 3502-3562, 400/500V Symptom Is the output phase to phase voltage and current balanced? Motor operation unstable Test the inverter Verify correct settings have section, page 3-4 been entered in Group 1 "Load &...
- Page 15 Section Two Symptom Is the correct line voltage present on the input terminals? No information in display L1/R (91), L2/S (92), L3/T (93) Check Input Disconnect and fusing. If fuses are blown, check for a short circuit in the Power Section. Disconnect all control signal plugs on the control card.
- Page 16 Try to run the VLT in local. Refer to CAUTION at left. Local control parameters. On VLT Series 3000: CAUTION: 003 = Local Prior to running in Local, 004 = Frequency reference insure all other equipment change by means of + and –...
- Page 17 Section Two 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.
- Page 18 Section Two SYMPTOM/CAUSE CHARTS SYMPTOM POSSIBLE CAUSES 5. Motor Runs Unloaded But Stalls Current Limit set too low When Loaded. (Motor may run rough and VLT may trip.) One half of one inverter phase missing. Test output phase balance. 6. Unbalanced Input Phase Currents Input line voltage unbalanced Note: Slight variations in phase Faulty connection on input wiring...
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Page 19: Section Three
Section Three STATIC TEST PROCEDURES All tests will be made with a meter capable of testing diodes. Use a digital VOM set on diode scale or an analog ohmmeter set on R x 100 scale. Before making any checks disconnect all input power, motor and brake option connections. CAUTION: Allow sufficient time for the DC Bus to fully discharge before beginning testing. - Page 20 Section Three STATIC TEST PROCEDURES VLT 3006-3022, 230V VLT 3508-3532, 230V TESTING THE INPUT VLT 3011-3052, 380V/460V VLT 3516-3562, 380V/460V RECTIFIER 1. Remove any plastic shields covering the DC Bus Capacitors and locate the 18 gauge red and black leads connected to the Bus Capacitor bus bars as shown.
- Page 21 Section Three STATIC TEST PROCEDURES TESTING THE SOFT- The purpose of the soft-charge circuit is to provide an initial high impedance current path for building up a charge on the Bus Capacitors. The size of the unit CHARGE CIRCUIT determines whether NTC resistors or PTC/Contactor combination are used. VLT 3002-3004, 230V VLT 3502-3504, 230V VLT 3002-3008, 380V/460V...
- Page 22 Section Three STATIC TEST PROCEDURES TESTING THE The purpose of static testing the inverter section is to rule out failures in the IGBT power devices. If a short circuit is discovered during the testing, the particular INVERTER SECTION module can be pinpointed by noting the output terminal indicating the short circuit. When looking in units with multiple IGBT modules, the "U"...
- Page 23 Section Three STATIC TEST PROCEDURES TESTING THE INVERTER VLT 3006-3022, 230V VLT 3508-3532, 230V VLT 3011-3052, 380V/460V VLT 3516-3562, 380V/460V SECTION 1. Prior to making any measurements it is necessary to disconnect the motor leads from the unit. The low winding resistance within the motor will make it appear that there is a short circuit in the inverter section.
- Page 24 Section Three STATIC TEST PROCEDURES There are thermal switches included on all units covered by this manual. The TESTING THE HEATSINK smaller drives monitor the ambient temperature within the unit. The thermal switch THERMAL SWITCH is mounted on the ILD Card. All units with Interface Cards have a stand alone thermal switch mounted on the heatsink.
- Page 25 Section Three DYNAMIC TEST PROCEDURES A current sensor is in line with each phase of the output. These hall effect devices TESTING FOR CURRENT generate a current that is proportional to the current being drawn in each respective FEEDBACK motor phase. The VLT relies on this feedback for proper output waveform control and for providing fault protection.
- Page 26 Section Three TESTING GATE DRIVE CAUTION: The gate firing signals are referenced to the negative DC FIRING CIRCUITS Bus and are therefore at Bus potential. Extreme care must be taken to prevent personal injury or damage to equipment. Oscilloscopes, when used, should be equipped with isolation devices. The individual gate drive firing pulses originate on the Interface/ILD Card.
- Page 27 Section Three To Expose the Interface/ILD Card: Interface/ILD Card • Leaving the Ribbon Cables attached, remove the Control Card • Mount the card by snapping the right side (edge) of the Control Card into the two (2) mounting clips. Mounting Clips Gate pulses @ 20Hz, 10V/Div, 10mS/Div GATE PULSE...
- Page 28 Section Three 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%.
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Page 29: Section Four
Section Four COMPONENT NOTE: The Control Card comes mounted to a metal plate. When installed REPLACEMENT this plate sits in a slot provided on the left-hand side of the unit enclosure and PROCEDURES is secured by two press-fit mounting clips attached to the right-hand side of the enclosure. - Page 30 Section Four REMOVING & REPLACING VLT 3002-3004, 230V VLT 3502-3504, 230V VLT 3002-3008, 380V/460V VLT 3502-3511, 380V/460V THE ILD CARD, DC CARD, RECTIFIER CARD AND IGBT ILD Card: 1. Remove the ground screw(s) on the ILD Card. The screws are located at the bottom and possibly at the top right on the board.
- Page 31 Section Four Six-Pack IGBT Module: 1. Remove all wire leads connected to the Six-Pack module. 2. Remove the mounting hardware and remove from the unit. 3. Clean the remaining heatsink compound from the enclosure heatsink and the Six-Pack module. 4. Apply silicon grease 3 mils thick to the entire base of the Six-Pack module. 5.
- Page 32 Section Four REMOVING & REPLACING VLT 3006-3022, 230V VLT 3508-3532, 230V VLT 3011-3052, 380V/460V VLT 3516-3562, 380V/460V THE INTERFACE CARD, RELAY CARD, RECTIFIER, To gain access to some assemblies remove the Control Card (page 4-2). It may AND IGBT also be necessary to remove one of the enclosure cross support braces to gain access to components on some units.
- Page 33 Section Four Rectifier Module: 1. Remove the five terminal screws from the module. Note the wire orientation and disconnect all wire leads. 2. Remove the two mounting screws securing the rectifier module to the heatsink and remove the module. 3. Clean the thermal grease from the enclosure heatsink and from underneath the Rectifier Module.
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Page 34: Section Five
(VT) load. If a VT mode of operation has been selected for a CT load, sufficient starting torque will not be available. When a VLT Series 3000 unit is set for one of the variable torque modes, adjustments to parameters 109-113 will have no effect. The various VT modes have direct control over these parameters. - Page 35 The best rule of thumb is to start at the factory setting and make changes in small increments. Start and stop the unit to test the results. PARAMETER 110 (VLT SERIES 3000 ONLY) Start compensation is factory set based on the motor power entered in Parameter 103.
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Page 36: Ground Fault Trips
Section Five "GROUND FAULT" TRIPS Trips occurring from ground faults are usually the result of short circuits to earth ground either in the motor or the wiring to the motor. The VLT detects ground faults by monitoring all three phases of output current and looking for severe imbalances in those currents. -
Page 37: Overvoltage Trips
Section Five "OVERCURRENT" TRIPS Instantaneous overcurrent trips are caused by the current rising so fast on the output that the unit cannot respond. One example of this situation is in applications where the unit is running at speed and an output contactor is closed between the unit and the motor. - Page 38 Start" function is usually employed when using this method. In very high inertia applications where a short decel time is required, the only solution may be that of adding a Dynamic Brake Option (only VLT Series 3000 units only). The Dynamic Brake option combines a power IGBT, the electronics for controlling it and a resistor bank of sufficient wattage to dissipate the unwanted energy.
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Page 39: Fault Memory
Section Five FAULT MEMORY The VLT stores faults which have occurred in its fault memory register. The register stores the last 8 occurrences on a first in first out basis. You can access the fault memory by calling up parameter 602. In doing so you can then scroll through the register using the Data key to view each fault code stored. -
Page 40: Spare Parts Tables
Section Six SPARE PARTS VLT 3002-3004, 230V VLT 3002 VLT 3003 VLT 3004 VLT 3502-3504, 230V VLT 3502 VLT 3504 Control Card (VLT 3000) 175H7086 175H7086 175H7086 Control Card (VLT 3500) 175H4539 175H4539 ILD Card 175H7064 175H7065 175H7066 DC Bus Card 175H7018 175H7018 175H7019 Six Pack IGBT 175H7017 175H7017 175H7017 Recifier... - Page 41 Section Six SPARE PARTS VLT 3006-3022, 230V VLT 3006 VLT 3008 VLT 3011 VLT 3016 VLT 3022 VLT 3508-3532, 230V VLT 3508 VLT 3511 VLT 3516 VLT 3522 VLT 3532 Control Card (VLT 3000) 175H7086 175H7086 175H7086 175H7086 175H7086 Control Card (VLT 3500) 175H4539 175H4539 175H4539 175H4539 175H4539 Interface...
- Page 42 Section Six SPARE PARTS VLT 3002-3008, 380V VLT 3002 VLT 3003 VLT 3004 VLT 3006 VLT 3008 VLT 3502 VLT 3504 VLT 3508 VLT 3511 VLT 3502-3511, 380V VLT 3505 Control Card (VLT 3000) 175H7086 175H7086 175H7086 175H7086 175H7086 Control Card (VLT 3500) 175H4539 175H4539 175H4539 175H4539 175H4539 ILD Card...
- Page 43 Section Six SPARE PARTS VLT 3011-3032, 380 VLT 3011 VLT 3016 VLT 3022 VLT 3032 VLT 3516-3542, 380 VLT 3516 VLT 3522 VLT 3532 VLT 3542 Control Card (VLT 3000) 175H7086 175H7086 175H7086 175H7086 Control Card (VLT 3500) 175H4539 175H4539 175H4539 175H4539 Interface Card (VLT 3000) 175H5386 175H5387 175H5388 175H5389...
- Page 44 Section Six SPARE PARTS VLT 3042-3052, 380V VLT 3042 VLT 3052 VLT 3552-3562, 380V VLT 3552 VLT 3562 Control Card (VLT 3000) 175H7086 175H7086 Control Card (VLT 3500) 175H4539 175H4539 Interface Card (VLT 3000) 175H5390 175H5391 Interface Card (VLT 3500) 175H5396 175H5397 IGBT Module 175H0268 175H4100...
- Page 45 Section Six SPARE PARTS VLT 3002-3008, 460V VLT 3002 VLT 3003 VLT 3004 VLT 3006 VLT 3008 VLT 3502-3511, 460V VLT 3502 VLT 3504 VLT 3506 VLT 3508 VLT 3511 Control Card (VLT 3000) 175H7086 175H7086 175H7086 175H7086 175H7086 Control Card (VLT 3500) 175H4539 175H4539 175H4539 175H4539 175H4539 ILD Card...
- Page 46 Section Six SPARE PARTS VLT 3011-3032, 460V VLT 3011 VLT 3016 VLT 3022 VLT 3032 VLT 3516-3542, 460V VLT 3516 VLT 3522 VLT 3532 VLT 3542 Control Card (VLT 3000) 175H7086 175H7086 175H7086 175H7086 Control Card (VLT 3500) 175H4539 175H4539 175H4539 175H4539 Interface Card 175H5378 175H5380 175H5381 175H5383...
- Page 47 Section Six SPARE PARTS VLT 3042 VLT 3052 VLT 3042-3052, 460V VLT 3552 VLT 3562 VLT 3552-3562, 460V Control Card (VLT 3000) 175H7086 175H7086 Control Card (VLT 3500) 175H4539 175H4539 Interface Card 175H5384 175H5385 IGBT Module 175H6251 175H1371 IGBT Snubber Cap 175H0831 175H0831 Recifier 612L9476 612L9477...
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Page 48: Component Locations
COMPONENT LOCATION Appendix VLT 3002-3004, 230V VLT 3502-3504, 230V VLT 3002-3008, 380/460V VLT 3502-3511, 380/460V 1. Top Cover 2. DC Coil 3. DC Bus Capacitor 4. DC Card 5. ILD Insulator Foil 6. Input Line Driver (ILD) Card 7. Control Card 8. -
Page 49: Block Diagrams
Appendix Appendix BLOCK DIAGRAM (for reference only) VLT 3002-3004, 230V VLT 3502-3504, 230V VLT 3002-3006, 460V VLT 3502-3506, 460V 7 - 2... - Page 50 BLOCK DIAGRAM Appendix Appendix (for reference only) VLT 3008, 3508, 460V 7 - 3...
- Page 51 Appendix BLOCK DIAGRAM (for reference only) VLT 3511, 460V 7 - 4...
- Page 52 COMPONENT LOCATION Appendix VLT 3006-3022, 230V VLT 3508-3532, 230V VLT 3011-3052, 380/460V VLT 3516-3562, 380/460V 1. Top fan 2. Top Cover 3. Heat Sink Thermal Switch 4. Interface Insulator Foil (not on 230V) 5. Interface Card 6. Brake Control Card Support (not on VLT 3500) 7.
- Page 53 Appendix BLOCK DIAGRAM (for reference only) VLT 3006-3011, 230V VLT 3506-3522, 230V 7 - 6...
- Page 54 BLOCK DIAGRAM Appendix Appendix (for reference only) VLT 3011-3022, 230V 7 - 7...
- Page 55 Appendix BLOCK DIAGRAM (for reference only) VLT 3011-3022, 460V VLT 3516-3532, 460V 7 - 8...
- Page 56 BLOCK DIAGRAM Appendix Appendix (for reference only) VLT 3032-3052, 460V 7 - 9...
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