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1. J37 BIk Red J20 S1 Gate Red IGBT Module Red A Grn S4 Gate J36 Wht Wht 5 J22 S3 Gate G Red o IGBT Module B Re 2 ues S6 Gate oO 335 Yel o Blu Blu Y E J24 S5 Gate Red IGBT Module i Red J25 S2 Gate Vio Power Board J34 Red Red Braking Red IGBT Module J26 gt DB Gile Blu J26_1 Figure 86 Gate Driver Board Connections on IGBT Modules 6 Using needle nose pliers carefully disconnect J26_1 J26_2 and J34 at the termination points located on the braking IGBT module see Figure 86 on page 155 1996 Square D All Rights Reserved 155 Cnapter 4 rquipment Cnange Out ATV66D33N4 and ATV66D46N4 Installing the Gate Driver Board 156 Bulletin NO VDUCUOS U1 December 1996 7 Using needle nose pliers depress the tabs on the six plastic fixing pins and unsnap the gate driver board from the fixing pins Do not attempt to remove the gate driver board until all the connectors have been disconnected 8 Lift the boa
2. 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Using a drive socket loosen and remove the two screws which hold the plexiglass shield in place see Figure 139 on page 283 3 Remove the plexiglass shield 4 Using a hex key wrench loosen and remove the two bus capacitor fuse screws Remove the bus capacitor fuse see Figure 140 on page 285 5 Using a hex key wrench loosen and remove the two bolts which hold the DCB and DCB power cables see Figure 139 on page 283 6 Using a hex key wrench remove the positive bus connector bolt see Figure 139 on page 283 7 Using a hex key wrench loosen and remove the four or six capacitor bus bar screws which hold the laminated bus assembly in place Remove the two DCB and one DCB control cables see Figure 139 on page 283 Bus mounting bolt sA Bus connector bolt O y 5 Capacitor bus A E iE Bus connector lip bar screws 6 dl n Bus capacitor fuse oe gt O j PU C E Capacitor jumper screws 3 T Plexiglass shield screws Jl He s Capacitor bus bar Le i Capacitor bus bar if fj DCB control cables 6 RE vo v DCB control cable DO 4 DCB power cable lt RB cable pr Circuit protector ER
3. 67 Cnapter 3 Correcting tne Problem Bulletin NO VDUCUOS UT Dynamic Brake Resistor Overtemperature December 1996 Dynamic Brake Resistor The resistor temperature rise is calculated continuously using the value of the Overtemperature resistor programmed in the Fault Management menu the DC bus voltage measurement and the braking time measurement minimum 1 msec The power is calculated according to the conduction time of the DB Resistor The resistance value is set in the Fault Management menu and the thermal time con stant is factory set in the controller There is no early warning for this fault The temperature rise state cannot be dis played on the keypad display Figure 35 illustrates the troubleshooting procedure when a dynamic brake over temperature fault is present DB RESISTOR Fault Displayed OVERTEMPERATURE DB Resistor has DB Resistor parameters DB switch damaged insufficient thermal rating incorrectly programmed in Possible for application controller cause The DB Resistor or its The DB Resistor is The DB Resistor is cold ARRA associated enclosure is warm but not excessively 9 d ied operating at excessive hot omen temperature Result Cycle too harsh Compatibility of Refer to chapter 4 to Sizing of resistor installed vs programmed change the Soluti resistor Control basket
4. 247 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Metric hex key set 2 to 14 mm e 4 Needle nose pliers With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Using a flat blade screw driver loosen the two screws holding the hinged assembly in place Swing the hinged assembly out to the right see Figure 124 on page 244 This allows access to the snubber boards Snubber Boards Snubber Boards Figure 126 View of Snubber Boards 3 Using needle nose pliers carefully disconnect the J1 J2 J3 and J4 connectors on the snubber board to be replaced see Figure 127 on page 249 4 Using a hex
5. 79 Cnapter 3 Correcting the Problem Checking the Power Part of the Controller Checking the Keypad Display 80 Bulletin NO VDUCUOS U1 December 1996 To enter the keypad display self diagnostic routine press the following keys simultaneously with the drive powered up and NOT RUNNING F1 and 0 keys on V1 2 see note F1 and UP Arrow keys on V1 1 see note NOTE Keypad Version V is labeled on the reverse side of the keypad display WARNING The keys on the keypad do not function as normal during this test The STOP key will not stop the drive while the keypad display self diagnostic routine is in progress MAKE SURE THE DRIVE IS NOT RUNNING BEFORE INITIATING THIS PROCEDURE The following message will appear AUTOTEST CONSOLE SOFTWARE VERSION V1 2 ENTER TO CONTINUE If keypad display is V1 1 that number will appear Press ENT to continue The keypad will then proceed through 4 different tests of the screen pixels and characters Press ENT to scroll through each test The following message will appear MINI CONSOLE TEST TEST DISPLAY TEST MICRO amp RAM TEST KEYPAD TEST SWITCH TEST SERIAL LINK Pressing ENT starts the keypad test which generates a display like this COI LJ E E 1 Fey EE E ELE E COI OO Ez pz 1 E J IIT E Depressing each Keypad key should highlight it s corresponding box Depressing ENT twice
6. 207 Bulletin NO VDUCUOS UT1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D54N4 to D79N4 NOTE To ensure that the power board is mounted level make sure that each mounting pin has two washers mounted under it and that the red end of the pins are facing up Also the three pins with the stripe s are to be used for connecting the U V and W cables to the IGBT modules 6 Position the U cable over the mounting hole in the top IGBT Position the V cable over the mounting hole in the middle IGBT and the W cable over the mounting hole on the bottom IGBT 7 Usinga torque wrench with hex key attachment install the 12 hex head screws with the balancing resistors which connect the bus bar to the bus capacitors Tighten to 17 7 lb in 2 Nem Using a torque wrench with drive socket attachment install the nine mounting pins and washers which connect the bus bar or cables to the IGBT modules Tighten to 26 5 Ib in 3 Nem 8 Position the cable marked BR3 over the C1 terminal of the braking IGBT module Using a torque wrench and phillips head attachment install and tighten the two braking IGBT screws to 17 7 lb in 2 Nem 9 Replace the bus bar isolating screen 10 Remove static protective foam from IGBT module control terminals 11 Install the power board as described in the procedure on page 203 Removing the Braking This procedure explains how to remove the br
7. J20 3 320 res T st cate Red 920 2 IGBT Module Red J21 2 Q J21 E 1223 Ber ce Bs m Wht J22 1 aj 42 dH B ae E el y 7 IGBT Module 2 Red 229 o J23 w mM S6 Gate e MEN J24 3 a Blu 2410 gs gate Og Bm Gy Red Say E O IGBT Module i Red J25 2 j J5 OOX EEG Y Y Y Vio 5 PL S2 Gate p A Power Board Figure 66 Gate Driver Board Connections on IGBT Modules 11 Remove the gate driver board 12 If the gate driver board is to be replaced loosen the J3 cable connector and remove the J3 cable See Figure 62 on page 114 for instructions on loosening the J3 cable connector This cable will be needed during the installation of the new gate driver board 1996 Square D All Rights Reserved 119 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 Installing the Gate Driver Board 120 Bulletin NO VDUCUOS U1 December 1996 NOTE Be sure the J3 Ribbon has been released before pulling to avoid damage to the cable This procedure explains how to install the gate driver boards in the following drive controllers Drive Controller No Gate Driver Board No ATV66D16N4 VX5 A66103 ATV66D23N4 VX5 A66104 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the
8. 295 Cnapter 4 rquipment Change Out Bulletin NO VDUCUOS UT ATV66C10N4 to C19N4 tos f i CONTROL o POWER gt Ht TRANSFORMER n x X3 NN i Q 9 9 B A i 8 928 83 1 9 48 i 956 6 9768 i CIRCUIT Ss i PROTECTOR l TO DCB jo TO DCB R10 R8 R7 I Oaz B B p ae o o o n poo PRECHARGE A H Ea a H amp A i CONTACTOR GROUNDS 4 lt FAULTCT TORB ie gt TO RB I i I To pc Figure 144 Wiring Diagram for Control Power Transformer Precharge Contactor and Auxiliary Contact Block Precharge Resistors Discharge Resistors Circuit Protector and Ground Fault CT 6 Using a torque wrench and a hex key socket tighten the two discharge resistor mounting screws to 35 4 lb in 4 0 Nem 7 Install jumper between wire connection tabs R7 A bottom resistor and R8 B top resistor see Figure 144 on page 296 Using a torque wrench and flat blade screw driver socket tighten the wire connection screws to 8 9 Ib in 1 0 Nem 8 Install R7 B and R8 A wires see Figure 144 on page 296 Using a torque wrench with flat blade screw driver socket tig
9. Release Position Release Position White Cable Clasps Blue Cable Clasps Figure 55 Cable Connector Secure and Release Positions 102 s 019 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Control Basket Cnapter 4 Equipment Cnange Out ATV66U90N4 and ATV66D12N4 8 Using a phillips screw driver loosen the two screws at the bottom of the control basket see Figure 54 on page 102 Pull down on the control basket and remove it from the drive controller As the control basket is removed pull the three ribbon cables out of the guides on the back of the control basket This procedure explains how to install the control basket in the following drive controllers Drive Controller No Control Kit No ATV66U90N4 ATV66D12N4 VX4 A66CK1 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Aset of magnetized phillips sc
10. 0 000 eee ttt esee 221 Removing the Main Fan 0 0 cette 223 Installing the Main Fan i ze pr A e RUE eee ee 225 Replacing the Precharge Resistor 2 0 cee eee eee eee 226 Replacing the Discharge Resistor 0 cece eee ees 227 Replacing the Auto Transformer 0 0 cece eee 230 ATV66C10N4 TO C1I9N4 ooo 233 Replacing the Keypad Display 0 cece eect tees 236 Removing the Control Basket oooccococcccococ tenes 237 Installing the Control Basket sssllleleeseeee 240 Replacing Control Terminal Blocks 00 0 cece eese 241 Removing the Power Board o oocccccooc eee 243 Installing the Power Board oooocccccoo tet eee 246 Removing the Snubber Board coooccccocccc se 247 Installing the Snubber Board cocccoccccco ee 249 Removing the Gate Driver Board 1 0 0 0 cece eee 250 Installing the Gate Driver Board 0 0 ects 252 Removing the IGBT Module 00 cece tte eae 253 Installing the IGBT Module sssesse RII 255 Removing the Diode Block lssleeleeee ee 257 Installing the Diode Block 0 cece IR 259 Removing the Current Sensor Assembly 00000 cece eee eee eee 261 Installing the Current Sensor Assembly oococcccccococ eese 263 Removing the Dynamic Braking DB Snubber Board ooooccoocoocoo o 264 Installing the Dynamic Braking DB Snubber Board oooocc
11. 93 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66U41N4 to ATV66U72N4 December 1996 8 Disconnect the J3 J4 and J5 cables at the connectors located on the power board see Figure 50 on page 94 See Figure 48 on page 89 for connector construction Figure 50 Power Board Connector Locations 9 Discard the old power board and chassis 10 Install the controller bottom cover Using a phillips screw driver install and tighten the three screws holding the bottom cover in place 11 Install the controller top cover Using a phillips screw driver install and tighten the two screws holding the top cover in place 12 Install the IP20 protection cover saved from step 2 above 13 On the new power board and chassis connect J1 at the bottom of the power board See Figure 49 on page 92 14 Using a torque wrench and a flat blade screw driver socket install and tighten the field wiring at the termination points on connector J2 See Receiving Installation manual VDOCO65304 for torque specifications 15 Install the J3 J4 and J5 cables at the connectors located on the power board See Figure 50 on page 94 16 Install the control basket as described in the procedure on page 90 Removing the Fan This procedure explains how to remove the fan from the following drive controllers Drive Controller No Fan No ATV66U41N4 VZ3 V661 ATV66U54N4 VZ3 V661 ATV66U72N4 VZ3 V662 A DANGER HAZARDOUS VOLTAG
12. 1996 Square D All Rights Reserved L 127 Cnapter 4 Equipment Cnange vut ATV66D16N4 and ATV66D23N4 Installing the IGBT Module 128 Bulletin NO VDUCUOS U1 December 1996 There are three IGBT modules in this size of drive controller This procedure explains how to install the IGBT modules in the following drive controllers IGBT Module No VZ3 IM2050M 1 201 VZ3 IM2075M1201 Drive Controller No ATV66D16N4 ATV66D23N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm e Torque wrench set to 13 3 lb in 1 5 Nem or 17 7 lb in 2 Nem per procedure e Metric hex key sockets for torque wrench 2 to 14 mm e Set of open end wrenches 5 5 to 19 mm e Thermal grease Thermalloy Thermalcote M II Part No 349 or equivalent e Power board procedure tool list page 124 e Gate driver board procedure tool list page 120 e Control basket procedure tool list page 115 For the IGB
13. ooocoococcccccc ee 141 Installing the Bus Capacitors 0 cece B 143 ATV66D33N4 AND D46N4 0 0 0 0 mh 145 Replacing the Keypad Display o oooooooooccorrr I 146 Removing the Control Basket 147 Installing the Control Basket oococcoococccococo 149 Replacing Control Terminal Blocks ococoooccccocccnoc eene 150 Replacing the Board Fan ooooccccccoc e 152 Removing the Gate Driver Board 0 0 cece eee eae 154 Installing the Gate Driver Board 0 0 cece 156 Removing the Power Board 0 c eect tet ee 157 Installing the Power Board 0 cece tees 159 Removing the IGBT Module 0 0 0 e cece tte eee 161 Installing the IGBT Module 2 0 0c eect eee 163 Removing the Braking IGBT Module 000 c cece eee 165 Installing the Braking IGBT Module 0c cece eee 166 Removing the Bus Capacitors 0 0c ee ete 167 Installing the Bus Capacitors ooocococcocccc B 169 Removing the Filter Board 0 2 eee IR 171 Installing the Filter Board 0 ee IM 173 Removing the Diode Block oo oooooocoooccorrr 175 Installing the Diode Block o oooooooocorororrr IR 177 Replacing the Current Sensor 0 00 c cece eee 178 Removing the Fan x cti DRE eR bee A Re hae ME 181 Installing the Fans ess Ste heed RI RE Bae ed bed ae RY 182 Replacing the Discharge Resistor o oooooooococcor eee 183 Replacing t
14. Correct wiring mode Correct load side wiring Figure 10 Cannot Start Motor 32 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cannot Start Motor continued 2 of 5 No power output from controller run fwd or run rev signal present keypad start depressed or auto run signal present Possible cause Check that correct command mode selected for run signals present Switching of command mode with run signals present Stop function activated Check state of auto manual function e State of LI1 menu 2 Check for presence of Speed reference command Check state of Controlled Stop function Check sequence input if using Bypass function Check to be performed Incorrect command mode selected Controller requires removal and re application of run signal If the stop function of the command mode not selected is actuated the controller requires removal and re application of run signal Auto manual not set to receive available start signal e Run permissive not present Speed reference command not present Controlled Stop active Sequence input inactive in Bypass mode Result Set Command mode per VD0CO06S305 Cycle run signal once correct command mode is selected Cycle run signal after determining reason for stop actuation Solution available start signal VD0CO6S3
15. Possible cause Check controller settings Brake sequence settings Check under menus 1 7 11 7 12 menu 7 11 to be and 7 13 Mechanical brake performed hardware and wiring Brake not being commanded to release Braking system hardware Controller improperly tuned Henn damaged or misconfigured Referto VDoCo6s305_ Y Refer to VDOCO6S305_ to choose correct settings t0 choose correct settings Correct braking system Solution hardware operation O 1996 Square D All Rights Reserved Brake hardware damaged Wiring damaged or missing Bulletin NO VDUCUOS U1 December 1996 Replace damaged equipment or wiring Bulletin NO VDUCUOS U1 December 1996 Cannot Stop Motor Cnapter 3 Correcting tne Problem Cannot Stop Motor Figure 11 illustrates the troubleshooting procedure when the motor cannot be stopped or has the appearance of not stopping Operating Condition Motor coasting windmilling or turbining Possible from previous stop cause Type of stop method selected DC injection time and magnitude at end of deceleration Action of stopping or holding brake if used Check to be performed Stop method not appropriate for application e DC injection time and magnitude incorrect for desired performance Result Select a more appropriate stopping method Refer to VDO0CO06S305 Adjust DC injection time and mag
16. 6 Carefully insert the three ribbon cables into the cable clasp at the J3 seven connector cable J4 six connector cable and J5 18 connector cable connectors Ensure the silver leads of the cables are facing outwards from the controller 7 Push the three ribbon cable connectors to their secure position 8 Apply multi lingual hazard labels supplied with kit to control basket as required 9 Reinstall options module if previously present See User s Manual VDOC06T306_ for removal installation instructions 1996 Square D All Rights Reserved 115 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D16N4 and ATV66D23N4 December 1996 10 Install the keypad display as described in the procedure on page 112 11 Reprogram the user settings as previously noted during the control basket removal Replacing Control Terminal This procedure explains how to replace the control terminal blocks for the Blocks following drive controllers Drive Controller No Control Terminal Block Kit No ATV66D16N4 ATV66D23N4 MTS A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER
17. Bulletin NO VDUCUOS U1 December 1996 ATV66D54N4 to D79N4 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 This section contains spare parts information and change out procedures for drive controllers e ATV66D54N4 e ATV66D64N4 e ATV66D79N4 Table 13 Spare Parts for Drive Controllers ATV66D54N4 to D79N4 Description For Drive Catalog Number For Change Out Controllers Procedure See Control Kit ATV66D54N4 to D79N4 VX4 A66CK1 Pages 191 194 Control Terminal Block Kit ATV66D54N4 to D79N4 VZ3 NO06 Pages 194 195 Board Fan ATV66D54N4 to D79N4 VZ3 V6654 Pages 196 197 Gate Driver Board ATV66D54N4 VX5 A66107 Pages 198 201 ATV66D64N4 VX5 A66108 ATV66D79N4 VX5 A66109 Power Board ATV66D54N4 VX5 A66D54N4 Pages 201 204 ATV66D64N4 VX5 A66D64N4 ATV66D79N4 VX5 A66D79N4 IGBT Module ATV66D54N4 VZ3 IM2150M1201 Pages 205 208 ATV66D64N4 VZ3 IM2200M1201 ATV66D79N4 VZ3 IM2300M1201 Braking IGBT Module ATV66D54N4 VZ3 IM2100M1201 Pages 208 211 ATV66D64N4 and D79N4 VZ3 IM2150M1201 Bus Capacitor Assembly ATV66D54N4 VY1 ADC605 Pages 211 214 ATV66D64N4 and D79N4 VY1 ADC606 Filter Board ATV66D54N4 to D79N4 VX4 A66105 Pages 215 218 Diode Block ATV66D54N4 to D79N4 VZ3 DM2160M1606 Pages 219 221 Current Sensors 2 in kit ATV66D54N4 to D79N4 VY1 A66105 Pages 221 223 Main Fan ATV66D54N4 to D79N4 VZ3 V665 Pages 223 225 Precharge Resistor ATV66D54N4 to D79N4 VZ3 R010WA81 Pages 226 22
18. DC BUS UE 1996 Square D All Rights Reserved 47 Cnapter 3 Correcting tne Problem DC Bus Overvoltage 48 Bulletin NO VDUCUOS U1 December 1996 Figure 19 illustrates the troubleshooting procedure when the DC bus overvoltage fault is present DC BUS Fault Displayed OVERVOLTAGE No DB Resistor menu 7 4 DB Resistor menu 7 4 Braking too hard Line borne overvoltage Incorrect operation transient of DB Resistor Possible Braking too hard cause Overhauling load Deceleration time Check Resistance value to be Wiring performed Result Increase deceleration Install line reactors Increase the ramp upstream of controller deceleration ramp T Use a DB Resistor Change or decrease Solution the ohmic value of the resistor if it is not at its minimum Figure 19 DC Bus Overvoltage O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 DC Bus Overvoltage continued 2 of 3 Possible cause Check to be performed Result Solution Use a DB resistor with a higher rating O 1996 Square D All Rights Reserved Cnapter 3 Correcting the Problem DC Bus Overvoltage Instability on high inertia Internal drive controller fault Check the drive controller output current Current surging during
19. Drive System Energized Unapter 2 Investigating tne Problem Drive System Energized first noted What is the description of the problem Where was the problem noted Direct observation of the drive system and process is also extremely important when troubleshooting performance related problems such as a controller not performing as expected or tripping The troubleshooting instructions contained in this chapter are divided into two sections Drive System Energized and Drive System De Energized Power Removed Refer to the appropriate section depending upon the present state of the drive system In many instances the drive system may be energized and operating when troubleshooting assistance is requested Exercise extreme care if power is present refer to the Work Practice Precautions in chapter 1 of this manual If the drive system is operating additional hazards resulting from the driven machinery and process may be present Always consult with the operating personnel responsible for the machinery and process before changing the operating state or removing or applying power to any equipment Use and obey all applicable lock out tag out procedures in force at the specific location Inspect the drive controller and other major components of the system such as motor and auxiliaries for external signs of physical damage Look for e Cracked charred or damaged covers or enclosure parts e Excessiv
20. During transient operation check that the yellow indicator lamp on the controller is lit 2 Check that the dynamic brake IGBT is operating correctly either by noting that the current to the dynamic braking resistor is present or by connecting the series combination of a LED and a 66 kQ resistor in parallel with the dynamic brake resistor 3 Check whether the motor current displayed on the keypad display is consistent with the nominal motor current Measure the motor current at 5 Hz 20 Hz and 60 Hz 4 Conductan endurance test using the Process Cycle function available with the additional I O card option if installed See User s Manual VD0C06T306 for more information Test the drive controller for about an hour 5 Return to the total factory settings configuration All controllers are equipped with fans for cooling Refer to VDOCO065S304 for air intake and exhaust locations on the controller In addition certain controllers are equipped with air stirring fans to maintain air flow over internal components To check the controller main heat sink fans check the air flow from the controller exhaust louvers free fan air flow values are found in VDOC06S304_ for each controller under the section entitled Ventilation Absolute air velocity measurements are difficult and instrument dependent However a comparison of flow velocity between the controller under test and a properly operating controller can be done using hand held anemom
21. drive metric socket set 5 5 to 14 mm Gate driver board procedure tool list page 198 e Control basket procedure tool list page 192 With the drive controller door removed 1 Remove the gate driver board as described in the procedure on page 198 NOTE Older model ATV66D54N4 to D79N4 controllers do not contain a board fan Therefore it is not necessary to remove the J69 connector as described in step 2 2 Using needle nose pliers carefully disconnect J7 J8 J16 J17 1 black J17_2 black J33 J38 blue J39 white J40 red J53 1 blue J53 2 white J68 and J69 at the termination points located on the power board see Figure 107 on page 202 3 Using a flat blade screw driver carefully disconnect J42A J42B J43 at the termination points located on the power board see Figure 107 on page 202 J7 J8 J16 Mounting screw Mounting screws LA i ME KEY yas Figure 107 Power Board Connections NOTE On older model ATV66D54N4 to ATV66D79N4 controllers J69 is not present Furthermore the J69 shown in this figure is labeled J68 on the older models 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D54N4 to D79N4 4 Disconnect the J1 connector see
22. electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 4 Needle nose pliers e Control basket procedure tool list page 115 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D16N4 and ATV66D23N4 For the gate driver board to be installed 1 Loosen the J3 cable connector on the gate driver card see Figure 62 on page 114 Insert the J3 cable with the silver leads facing towards the top of the gate driver board Push the connector to the secure position 2 Using needle nose pliers carefully connect J20 3 J22 3 and J24 3 on the power board see Figure 65 on page 119 3 Position the gate driver board over the fixing pins on the power board Make sure the ribbon cable from J3 is routed under the gate driver board towards the top of the drive controller Make sure other cables are pointed out away from the board 4 Snap the gate driver board onto the fixing pins 5 Ifrequired re braid the twisted pair wires before connecting them to the IGBT modules 6 Using needle nose plier
23. 131 on page 262 10 Install the dynamic braking snubber board as described in the procedure page 267 270 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Dynamic Braking DB IGBT Module Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 The dynamic braking module kit contains one IGBT module This procedure explains how to remove the dynamic braking IGBT module from the following drive controllers Drive Controller No DB Module Kit No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 VZ3 IM1300M1207 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter set to 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STA
24. 3 If the resistance is greater than shown in Figures 39 and 40 there may be an open balancing or discharge resistor a loose bus connection or an open DC bus fuse ATV66C10N4 through ATV66C19N4 only If the resistance is greater than shown in Figure 39 and the resistance is within the range shown in Figure 40 the precharge resistor or precharge protective switch if used may be open If the resistance is less than that shown in Figures 39 and 40 there may bea short circuit on the DC bus of the controller If external wiring is present on the or PA terminals disconnect the wiring and repeat the test to determine whether the cause of the lower resistance readings is internal or external to the controller If the cause of the lower resistance readings is external to the controller repeat the resistance measurement to determine the actual state of the drive controller If the resistance measurements remain low after disconnecting the external wiring then there may be damage to the rectifier bridge multiple IGBTs and associated snubber boards if used DC bus insulation or DC bus capacitors If the resistance is within the range shown in Figure 39 and the resistance is less than shown in Figure 40 the precharge resistor or precharge protective switch if used may be open If external wiring is present on the PA and terminals disconnect the wiring and repeat the test to determine whether the cause of the lower resistance
25. Bulletin No VD0C06S701 December 1996 Chapter 1 Introduction Chapter 2 Investigating the Problem Chapter 3 Correcting the Problem ALTIVAR 66 Service and Troubleshooting Manual Table of Contents ALTIVAR 66 FAMILY cem Rr Es acne MEE Ed REA 2 SCOPE OF MANUAL wus ia dus RE i etes oe od ug 2 HOW TO USE THIS MANUAL o cccccccoccc mes 2 WORK PRACTICE PRECAUTIONS ssssseeeee m 3 Personnel Protection Precautions ooococcooccoorn tenes 3 Equipment Protection Precautions oooocccooccocco eee 4 Static Sensitive Components oooococccco ees 4 LIST OF TOOLS AND INSTRUMENTS sss ns 5 DOCUMENTATION LIST i iiie lee Aes peas koa arin ane eu 5 STANDARDS 9 eR eR A ee de Lio eee et 6 BEVISION EEVEL 001600 pur hu td o dao 6 INTRODUCTION 0 ti is 8 RECOMMENDED TROUBLESHOOTING INSTRUCTIONS 0000 0 e eee 8 Drive System Energized 00 ccc ete 9 Drive System De energized Power Removed o oocooccccccoc 11 LED INDICATIONS AND KEYPAD DISPLAY 00 00 eee eee eee 12 LEEDS Oe iste Loses A bey 12 KeypadiDisplay mis di a e mE CE a upon gU REIR CR Se es 13 Status Codes s ocupa A ue td e sitse drea des 14 Measurements sre a a eA Paes 14 VO MAD es a cet uins iae ha Ah PM os td ie de 15 Fault HISO 4s este thee br od er ben Dev ade graba fpes Vater SS 16 Parameter SettingS 00 cece es 16 FAULT CATEGORIES rep Uer ee ee ee eed ee RED 16 RUNS DOES NOT PERF
26. Bulletin No VD0C06S701 December 1996 Figure 101 Figure 102 Figure 103 Figure 104 Figure 105 Figure 106 Figure 107 Figure 108 Figure 109 Figure 110 Figure 111 Figure 112 Figure 113 Figure 114 Figure 115 Figure 116 Figure 117 Figure 118 Figure 119 Figure 120 Figure 121 Figure 122 Figure 123 Figure 124 Figure 125 Figure 126 Figure 127 Figure 128 Figure 129 Figure 130 Figure 131 Figure 132 Figure 133 Figure 134 Figure 135 Figure 136 Figure 137 Figure 138 Figure 139 Figure 140 Figure 141 Figure 142 Figure 143 Figure 144 Figure 145 Figure 146 Figure 147 ALTIVAR 66 Service and Troubleshooting Manual List of Figures amp Tables Control Basket Connector Locations rss 192 Cable Connector Secure and Release Positions 193 Location of J1 J2 J12 and J13 ConnectorS o ocoocoooooo 195 Location of IP20 Protection Covers and Panels 197 Gate Driver Board Connection and Board Fan Locations 199 Gate Driver Board Connections on IGBT Modules 199 Power Board Connections 2000 eee e cece eens 202 Bus Bar Screws oo es eee oa eae o RR EY EY 206 Drive Controller with Bus Bar Removed 20 000 206 Bus Capacitor sci Ree wed ea ei eae us 213 J2 Terminal BIOCK oer Aem te eee Red ed met re 216 J2 Terminal Block Torque Specs iles esee 218 Diode Bridge Mounting
27. Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 216 Bulletin NO VDUCUOS U1 December 1996 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm e 1 4 drive metric socket set 5 5 to 14 mm Gate driver board procedure tool list page 198 e Control basket procedure tool list page 192 With the drive controller door removed 1 Remove the gate driver board as described in the procedure on page 198 Using a phillips or Torx screw driver loosen and remove the four screws which hold the right side panel Remove the right side panel see Figure 104 on page 197 3 Remove the J1 terminal block see Figure 104 on page 197 4 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place see Figure 104 on page 197 Remove the bottom IP20 protection cover 5 Using a hex key wrench loosen the terminal screws for L1 L2 L3 PA PB U T1 V T2 W T3 and ground connection at both the field side and drive controller side of the J2 terminal block see Figure 111 on page 216 Pull the cables and wires out of the way Identify all field wiring for future re assembly 6 Using a flat blade screw driver loosen the J2 terminal block screws for CL1 CL2 L21 and L22 at
28. December 1996 ATV66D16N4 and ATV66D23N4 j Mounting pin Mounting pins Bus bar screws Bus bar screws Bus bar IGBT modules Bus bar screws Figure 69 Bus Bar Screw and Mounting Pin Locations With the drive controller door removed 1 Remove the power board as described in the procedure on page 121 2 Remove the bus bar isolating screen See Figure 68 on page 124 NOTE In order to keep the proper spacing for the components keep all washers with their respective mounting pins or screws Washers are used to level the power board 3 Usingan open end wrench loosen and remove the four mounting pins on the bus bar see Figure 69 on page 127 Keep the washers with each pin 4 Using a hex key wrench loosen and remove the 11 screws which hold the bus bar to the drive controller Note the location of all cables connected to the bus bar to assist during the re installation of the bus bar see Figure 69 on page 127 Mounting screws Mounting pins at C2E1 IGBT modules on IGBT modules Mounting screws Figure 70 IGBT Modules Bus Bar Removed 5 Remove the bus bar 6 For the IGBT module to be removed use an open end wrench to loosen and remove the mounting pin located at the C2E1 terminal point see Figure 70 on page 127 Keep the washers with the pin 7 Using a hex key wrench loosen and remove the two screws holding the inoperative IGBT module in place see Figure 70 on page 127 8 Remove the IGBT module
29. Display Mode Status Codes 2 20000 cece llle 14 Runs Does Not Perform as Expected llle sees 16 Trips Resettable by Keypad Ll Automatic Power Cycle 17 Trips Requires Power to Be Recycled ooooocoooocooo 17 Equipment Damage 0 cee eee eh 17 Checking the Precharge Resistor 000ee cece eeeee 75 Spare Parts for Drive Controllers ATV66U41N4 to 72N4 86 Spare Parts for Drive Controllers ATV66U90N4 and D12N4 99 Spare Parts for Drive Controllers ATV66D16N4 and D23N4 111 Spare Parts for Drive Controllers ATV66D33N4 and D46N4 145 Auto Transformer Connections 00 cece eee ences 187 Spare Parts for Drive Controllers ATV66D54N4 to D79N4 189 Auto Transformer Connections 020 cece eee eens 231 Spare Parts for Drive Controllers ATV66C10N4 to C19N4 233 Transformer Connections ATV66C10N4 to C19N4 290 1996 Square D All Rights Reserved Xi ALTIVAR 66 Service and Troubleshooting Manual Bulletin No VD0C06S701 List of Figures amp Tables December 1996 xii 1996 Square D All Rights Reserved Bulletin NO VDUCUOS UT Cnapter 1 Introauction December 1996 Contents CHAPTER 1 ALTIVAR 66 FAMILY inc is OY A eg ea ete wa 2 INTRODUCTION
30. Is function programmed as described in VDOC06S305_ For factory supplied functions on Class 8839 controllers is function programmed per applicable user documents and manuals Refer to VD0C06S305 to choose correct settings Check availability and interchangeability function with configuration selected See VD0C06S304_ VD0CO06S305 and VD0CO6T306 O 1996 Square D All Rights Reserved Program lost due to use of partial total factory settings function Reprogram settings as desired Bulletin NO VDUCUOS U1 December 1996 TRIPS RESETTABLE BY KEYPAD LI AUTOMATIC POWER CYCLE Undervoltage Cnapter 3 uorrecting tne Problem Undervoltage Figure 14 illustrates the measurement principle used for the undervoltage fault Power board L Figure 14 Undervoltage Measurement The presence of the line supply is recognized from the measurement of frequency when the control part is powered up and line voltage L1 L2 L3 The line und ervoltage fault is detected from the measurement of the DC bus voltage The line undervoltage fault appears when one of the following occurs e With the line supply voltage present the DC bus voltage is less than 450 VDC for a 380 VAC line supply or less than 575 VDC with a 460 VAC line supply During operation if the DC bus voltage is less than 400 VDC for a 380 VAC line supply or less than 525 VDC with a 460 VAC line supply The follo
31. J12 J13 and J32 into place see Figure 80 on page 148 NOTE The yellow keys in both the plugs and sockets are designed to prevent incorrect insertion of both J12 and J13 4 Make sure all three cable connectors are pulled out on connectors J3 J4 and J5 see Figure 81 on page 149 5 Carefully insert the three ribbon cables into the cable clasp at the J3 seven connector cable J4 six connector cable and J5 18 connector cable connectors Ensure the silver leads of the cables are facing outwards from the controller 6 Push the three ribbon cable connectors to their secure position 7 Apply multi lingual hazard labels supplied with kit to control basket as required 8 Reinstall the options module if previously present See User s Manual VDOCO06T1306 for removal installation instructions 9 Install the keypad display as described in the procedure on page 146 10 Reprogram the user settings as previously noted during the control basket removal Replacing Control Terminal This procedure explains how to replace the control terminal blocks for the Blocks following drive controllers Drive Controller No Control Terminal Block Kit No ATV66D33N4 ATV66D46N4 reese A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DA
32. Position the power board over the mounting holes in the controller 3 Using a phillips screw driver and hex key wrench install the three power card mounting screws see Figure 107 on page 202 Do not tighten until all of the screws and nuts are installed 4 Using a drive socket install the nine nuts which attach the power board to the three IGBT modules see Figure 107 on page 202 5 Using a torque wrench with a drive socket tighten the nine nuts installed above to 17 7 lb in 2 0 Nem 6 Using a phillips screw driver and hex key wrench tighten the three power board mounting screws 7 Thread the two main fan leads from the power board under the power terminal block assembly Connect the two fan lead connectors to the fan see Figure 114 on page 224 This is an AC fan The two fan leads can be connected to either terminal 8 Connect J42A J42B J43 at the termination points located on the power board see Figure 107 on page 202 NOTE If the controller does not contain a board fan see Figure 105 on page 199 plug the J68 connector into the J69 jack on the power board The J68 jack will be left empty 9 Using needle nose pliers carefully connect J7 J8 J16 J17 1 black J17_2 black J33 J38 blue J39 white J40 red J53_1 blue J53 2 white J68 and J69 at the termination points located on the power board see Figure 107 on page 202 10 Install the bottom IP20 protection cover Using a phillips scr
33. Set of magnetized flat blade screw drivers Metric drive sockets for torque wrench Torque wrench set to 164 lb in 4 6 Nem 1 4 drive metric socket set 5 5 to 14 mm 12 1 4 drive socket extension Metric hex key sockets for torque wrench 2 to 14mm Flat blade screw driver sockets for torque wrench Electrical tape Set of open box end wrenches 5 5 to 19 mm To install the precharge contactor 1 Slide the saved auxiliary contact block LAIDN04 into place on the new precharge contactor Make sure that the locking lever for the contact block locks into place see Figure 146 on page 300 For ATV66C15N4 and C19N4 drive controllers Slide the new contactor coil module into place on the side of the new precharge contactor assembly Make sure that the lock lever for the coil module locks into place see Figure 146 on page 300 For ATV66C10N4 and C13N4 drive controllers Insert the three prongs from one of the saved terminal links into the top three terminals of the new precharge contactor see Figure 146 on page 300 Using a torque wrench with flat blade screw driver socket tighten the terminal screws to 74 3 lb in 8 4 Nem Repeat for the bottom terminal link For ATV66C15N4 and C19N4 drive controllers While holding one of the new terminal links in place over the terminal link mounting holes on the top of the new precharge contactor assembly use a torque wrench with hex key socket to install and tighten the three termin
34. Using a phillips screw driver loosen and remove the remaining two screws which hold the bottom cover in place Remove the bottom cover 5 Remove the bus bar isolating screen see Figure 68 on page 124 6 Usinga phillips screw driver loosen the four corner screws which hold the back cover to the drive controller Remove the back cover from the drive controller This allows access to the bus capacitors 7 Turn the drive controller chassis over to gain access to the bus capacitors Using a phillips screw driver loosen and remove the four mounting screws for the brackets which hold the bus capacitors in place 8 Remove the bus capacitor brackets 9 Onthe bus bar use a hex key wrench to loosen and remove the eight screws which hold the capacitors to the bus bar 10 Remove all four capacitors O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D16N4 and ATV66D23N4 Figure 77 Bus Capacitors Installing the Bus In the event that one capacitor goes bad at least two other capacitors will be Capacitors damaged Therefore all four capacitors should be replaced This procedure explains how to install the bus capacitors in the following drive controllers Drive Controller No Bus Capacitor No ATV66D16N4 VY1 ADC152V450 ATV66D23N4 NOTE Kit VY1 ADC152V450 contains one capacitor A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be d
35. Using a phillips screw driver loosen and remove the three screws which hold the left side panel in place Remove the left side panel 1996 Square D All Rights Reserved _ Bulletin NO VDUCUOS U1 December 1996 7 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 Using needle nose pliers carefully disconnect J26 J27 J28 J29 J30 J31 and J34 at the termination points located on the power board see Figure 65 on page 119 Power board J31 J34 J26 gt J27 Figure 65 Gate Driver Board Connections on Power Board 8 10 Using needle nose pliers carefully disconnect J20_1 J20_2 J21_1 J21_2 J22_1 J22_2 J23_1 J23_2 J24_1 J24_2 J25 1 and J25_2 at the termination points located on the IGBT modules See Figure 66 on page 119 Using needle nose pliers depress the tabs on the five plastic fixing pins and unsnap the gate driver board from the fixing pins Do not attempt to remove the gate driver board until all the connectors have been disconnected Lift the board and using the needle nose pliers carefully disconnect J20_3 grey J22_3 brown and J24_3 orange at the termination points located on the power board underneath the gate driver board Left Side of Drive Controller
36. Using needle nose pliers carefully remove the connector at the bottom of the current sensor to be replaced Using a flat blade screw driver or hex key wrench loosen and remove the two mounting screws for the current sensor to be replaced Remove the old current sensor Install the new current sensor with the orientation arrow pointing towards the J2 terminal block Do not disturb the settings of the potentiometers on the current sensor Using a flat blade screw driver or hex key wrench install and tighten the two mounting screws O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D54N4 to D79N4 13 Using needle nose pliers carefully reattach the connector at the bottom of the sensor 14 Pull the U T1 or W T3 cable back through the current sensor 15 Insert the V T2 cable and the cable from the previous step into the J2 terminal block and tighten the terminal screws using a torque wrench and hex key attachment Tighten to 170 Ib in 19 Nem 16 Insert the ground wires in the J2 terminal block and tighten the terminal screw using a torque wrench and a hex key attachment to 26 5 Ib in 3 Nem 17 Install the right side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the right side panel in place see Figure 104 on page 197 18 Install the top IP20 protection cover Route the five control basket cables through the hol
37. coating gaps gt 1 8 round discard the Thermstrate foil Obtain new foil 2 Place the new dynamic braking IGBT module on the heat sink and align the mounting holes O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66C10N4 to C19N4 3 Using the torque wrench with a hex key socket initially tighten the four mounting screws in the sequence shown to 6 0 9 0 Ib in 0 7 1 0 Nem The final torque is 26 5 Ib in 3 Nem OG MO Oe oQ 4 Install the Q7 E terminal screw with the Q7 E power and control cables landed underneath Using a torque wrench and hex key socket tighten the screw to 26 5 Ib in 3 Nem see Figure 134 on page 275 5 Install the dynamic braking gate driver board as described in the procedure on page 269 Removing the Dynamic This procedure explains how to remove the dynamic braking diode block from the Braking DB Diode Block following drive controllers Drive Controller No DB Block Kit No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 VZ3 IM1300M1207 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controlle
38. grae ge pm Replacing the DC Bus Fuse This procedure explains how to replace the DC bus fuse for the following drive controllers Drive Controller No DC Bus Fuse No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 VY1 ADF400V700 VY1 ADF450V700 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury 306 c 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Torque wrench set to 323 Ib in 36 5 Nem e Metric hex key sockets for torque wrench 2 to 14 mm e Metric hex key set 2 to 14 mm With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Using a hex key wrench loosen and remove the two DC bus fuse mounting screws see Figure 118 on page 234 Remove the DC bus fuse 3 Position the new DC bus fuse over the mounting holes in the drive controller see Figure 118 on page 234 4 Usingatorque wrench and hex key socket install and tighten th
39. precharge resistor assembly If the paper is torn or scratched do not operate drive controller Replace the insulating paper 6 Using torque wrench and a hex key socket tighten the two discharge resistor mounting screws to 35 4 lb in 4 0 Nem 7 Install jumper between wire connection tabs R10 A bottom resistor and R11 B top resistor see Figure 144 on page 296 Using a torque wrench and flat blade screw driver socket tighten the wire connection screws to 8 9 Ib in 1 0 Nem 8 Install R10 B and R11 A wires see Figure 144 on page 296 Using a torque wrench with flat blade screw driver socket tighten the wire connection screws to 8 9 Ib in 1 0 Nem This procedure explains how to replace the auxiliary contact block for the following drive controllers Drive Controller No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Auxiliary Contact Block No LA1DN04 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 1 4 drive metric socket set 5 5 to 14 mm e Aset of magnetized flat blade screw drivers Torq
40. resistance of DB option Refer to SC100 R5 95 for more information 29 Cnapter 3 uorrecting tne Problem Bulletin NO VDUCU6GS U1 Motor Decelerates Too Slowly Overspeeds Overspeed Trip December 1996 Motor Decelerates Too Slowly Overspeeds Overspeed Trip continued 3 of 4 Too high load inertia for Motor currents voltages desired deceleration rate are unbalanced or Feedback not used Possible Overhauling load unstable Controller parameters cause condition are incorrectly set Overspeed Trip Velocity Motor Check settings for Check Controller damping and bandwidth to be Load side conductors performed overloads switchgear contactors etc Motor controller or other equipment damage Result Controller may require Refer to Checking Refer to VD0C06S305 Dynamic Braking Option Peripheral Equipment to choose correct settings Solution Refer to SC100 R5 95 for in chapter 5 more information 30 s 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Motor DeceleratesToo Slowly Overspeeds Overspeed Trip continued 4 of 4 Possible cause Check to be performed Result Solution Overspeed Trip Velocity Feedback used Tachometer encoder velocity feedback incorrectly set on speed regulated drive system Tachometer with unidirectional output used on speed regulated drive System P
41. statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 4 Needle nose pliers e Aset of Torx screw drivers e Control basket procedure tool list page 192 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 191 Using a phillips or Torx screw driver loosen and remove the four screws which hold the left side panel Remove the left side panel see Figure 104 on page 197 3 Remove the J1 terminal block see Figure 104 on page 197 4 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place see Figure 104 on page 197 Remove the bottom IP20 protection cover NOTE If repairing the controller with field wiring in place the wiring knockout panel can be detached from the bottom panel in the next step 5 Using a phillips or TorxG screw driver loosen and remove the remaining four screws which hold the bottom panel in place see Figure 104 on page 197 6 Remove the bottom panel Fan mounting screws Figure 114 Fan Mounting 7 Using needle nose pliers carefully disconnect the two connectors for the fan 8 Using a Torx screw driver loosen and remove the two screws holding the fan to the fan shroud see Figure 114 on page 224 9 Remove the fan O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS
42. 10 Using a torque wrench and the appropriate socket tighten the mounting pins and screws to 17 7 Ib in 2 Nem 11 Replace the bus bar isolating screen see Figure 89 on page 162 12 Remove static protective foam from Braking IGBT module control terminals 13 Install the power board as described in the procedure on page 159 In the event that one capacitor goes bad at least two other capacitors will be damaged Therefore all four capacitors should be replaced This procedure explains how to remove the bus capacitors from the following drive controllers Drive Controller No ATV66D33N4 ATV66D46N4 Bus Capacitor No VY1 ADC472V450 NOTE Kit VY1 ADC472V450 contains one capacitor A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved L 167 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D33N4 and ATV66D46N4 December 1996 A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be
43. 123 Note which nuts have cables landed under them to assist in the re installation of the power board 6 Using a drive socket loosen and remove the four nuts on the power board for the braking IGBT module see Figure 67 on page 123 Note which nuts have cables landed under them to assist in the re installation of the power board 7 Using a drive socket loosen and remove the one nut on the power board for the capacitor bank see Figure 67 on page 123 8 Using the clip pliers remove the six clips holding the voltage regulators to the heat sink 9 Using a phillips screw driver loosen and remove the three power card mounting screws 10 Pull the U and W power cables through the Hall effect sensors on the power board Note the exact orientation of the U and W power wires through the Hall effect sensors to ensure proper re installation Refer to Detail A Figure 67 on page 123 11 Remove the power board If the power board is being replaced remove the five gate driver board standoffs for use during installation of the new board 1996 Square D All Rights Reserved 123 Cnapter 4 Equipment Cnange vut ATV66D16N4 and ATV66D23N4 Installing the Power Board 124 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to install the power board in the following drive controllers Power Board No
44. 14mm e 12 1 4 drive socket extension With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Usinga drive socket loosen and remove the two plexiglass shield screws see Figure 139 on page 283 Remove the plexiglass shield 3 Using a flat blade screw driver loosen the right side terminal screws on TB3 see Figure 142 on page 288 Remove the right side control wires from the terminal block assembly 4 Usingahex key wrench loosen and remove the DCB and DCB control wire connection screws Figure 139 on page 283 Pull the wires back out of the way 1996 Square D All Rights Reserved c 287 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 5 Using a hex key wrench loosen and remove the DCB DCB RB and RB power wire connection screws see Figure 139 on page 283 TB3 terminal block Rio ug Transformer Contactor assembly mounting Screws Transformer Contactor assembly mounting Screws Figure 142 Transformer Contactor Assembly Front View 6 While supporting the transformer contactor assembly use a drive socket with a 12 extension to loosen and remove the four transformer contactor assembly mounting screws see Figure 142 on page 288 Remove the assembly 7 Using a flat blade screw driver loosen and remove the screws for the T1 X1 T1 X2 T1 X3 T1
45. 4 Equipment Cnange vut ATV66D16N4 and ATV66D23N4 Route the U and W power cables through the Hall Effect sensors on the power board see Detail A in Figure 67 on page 123 NOTE Routing of the power cables through the sensors must be correct for the sensors to function properly Run the U and W power cables through the Hall effect sensors in the opposite direction of the direction in which the arrows point on the sensors Using a phillips screw driver install the three power card mounting screws Do not tighten until all of the nuts are installed Using a drive socket install the five nuts for the IGBT modules see Figure 67 on page 123 Ensure the U V and W cables that were disconnected in the power board removal procedure are landed on the power board at their respective marked locations Figure 67 on page 123 detail A Do not tighten until all of the nuts are installed Using a drive socket install the four nuts for the braking IGBT module see Figure 67 on page 123 Ensure the cable that was disconnected in the power board removal procedure is properly connected under the nut on the bottom left mounting hole Do not tighten until all of the nuts are installed Using a drive socket install the one nut for the capacitor bank Using a torque wrench with a drive socket tighten the ten nuts installed above to 17 7 Ib in 2 Nem Using a phillips screw driver tighten the three power board mounting screws Place the insulating li
46. 5 to 19 mm e Thermal grease Thermalloy Thermalcote II Part No 349 or equivalent e Power board procedure tool list page 124 Gate driver board procedure tool list page 120 e Control basket procedure tool list page 115 For the braking IGBT module to be installed 1 Cleanthe portion of the mounting pedestal which will make contact with the new braking IGBT module 2 Evenly coat the bottom of the new braking IGBT module with a thin coat of thermal grease 3 Install the new braking IGBT module with the slotted hole toward the left side of the drive controller away from the bus capacitors Using a torque wrench with a flat blade socket install and tighten the two mounting screws to 13 3 Ib in 1 5 Nem a a O ege Slotted end of Braking IGBT Module pointed towards the left side of the drive controller Slotted End Figure 73 Braking IGBT Module Installation Orientation NOTE Mounting pins and screws are marked with red paint Always mount pins and screws with the red painted side facing upwards 1996 Square D All Rights Reserved 131 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 Removing the Filter Board 132 Bulletin NO VDUCUOS U1 December 1996 4 Install the four mounting pins on the braking IGBT module There should be two washers on the bus bar post and three washer
47. 64 and the cool down period has not yet expired Consult the fault display on the keypad or the fault history in Menu 3 to determine the most recent fault Illuminated Fault exists L ooooooooo ooooooooo CAUTION Yellow See table POWER Green Illuminated Drive controller is powered DC bus 2 50 V or voltage is present at CL1 CL2 Figure 2 LED Indications Keypad Display The keypad display can be used to determine Drive controller status Display screen Drive controller measurements Display screen Logic input states 2 1 gt Logic Input Map Logic output states 2 3 gt Logic Output Map Analog input levels 2 2 Analog Input Map Analog output levels 2 4 gt Analog Output Map Fault history 3 Fault History Map Parameter settings 7 General Configuration menu If the keypad display is operational this is the best source of troubleshooting information The following information may be viewed on the keypad display to assist in troubleshooting O 1996 Square D All Rights Reserve J _ KK 13 Cnapter 2 Investigating tne Problem measurements speed reference Status Codes Measurements 14 Bulletin NO VDUCUOS U1 October 1997 The following status codes may be displayed on the Display screen Table 2 Display Mode Status Codes Definition Code Definition No Line Power control power supplied Current Limit separately Drive Controller Ready DC Injection Bra
48. ATV66D16N4 VZ3 IM2050M1201 Pages 126 129 ATV66D23N4 VZ3 IM2075M1201 Braking IGBT Module Filter Board ATV66D16N4 D23N4 ATV66D16N4 D23N4 VZ3 IM1025M1001 VX4 A66103 Pages 129 131 Pages 132 134 Diode Bridge ATV66D16N4 D23N4 VZ3 DM6075M1601 Pages 135 136 Precharge Resistor Fan Assembly 2 fans ATV66D16N4 D23N4 ATV66D16N4 D23N4 VZ3 R033W009 VZ3 V664 Pages 137 138 Pages 138 141 Bus Capacitor ATV66D16N4 D23N4 VY1 ADC152V450 Pages 141 144 O 1996 Square D All Rights Reserved 111 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 Replacing the Keypad Display 112 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to replace the keypad display for the following drive controllers Drive Controller No Control Kit No ATV66D16N4 ATV66D23N4 VX4 A66CK1 NOTE All ALTIVAR 66 drive controllers use the same model keypad display However the version of software present within the keypad display may be specific to the version of software present in the control basket Mixing incompatible versions of keypad display and control basket software can result in non recognition of the keypad display by the drive controller or garbled message displays Therefore keypad displays are not supplied as separate kitted items Keypad displays are supplied with control kits Keep keypads with their associated control basket Do not mix keypads and control b
49. All Rights Reserved 129 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 130 Bulletin NO VDUCUOS U1 December 1996 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Set of open end wrenches 5 5 to 19 mm e Power board procedure tool list page 122 Gate driver procedure tool list page 118 e Control basket procedure tool list page 113 With the drive controller door removed 1 Remove the power board as described in the procedure on page 121 2 Remove the bus bar isolating screen See Figure 68 on page 124 r A Braking IGBT module with four mounting pins and 2 mounting screws Figure 72 Braking IGBT Module Location NOTE Keep washers with respective mounting pins and screws for aiding in proper reinstallation 3 Using an open end wrench loosen and remove the four mounting pins
50. C19N4 December 1996 Capacitor bus bar Laminated insulating Capacitor bus bar sheet Mounting lt tabs Mounting Figure 141 Orientation of Capacitor Bus Bars and Laminated Insulating Sheet 17 Install the laminated insulation sheet that electrically isolates the and capacitor bus bars See Figure 141 on page 286 for correct orientation and where to insert tabs into buswork Do not scratch or damage laminated insulating sheet If sheet has been damaged replace A DANGER EXPLOSION EXPULSION HAZARD Inspect existing insulator for damage DO NOT use damaged insulator Install insulator per Figure 141 on page 286 Failure to follow these instructions will cause shock or burn resulting in death or serious injury 18 Install the capacitor bus bar See Figure 141 on page 286 for correct orientation The side with the danger label should be facing out Install the four or six capacitor bus bar screws in the and capacitor bus bars The two DCB cables should be mounted under the bottom left screw and the DCB cable should be mounted under the bottom right screw Using a torque wrench and hex key socket tighten the screws to 40 7 Ib in 4 6 Nem 286 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Control Power Transformer Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 19 Install the DCB and DC
51. CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Power board procedure tool list page 124 Gate driver procedure tool list page 120 e Control basket procedure tool list page 115 With the drive controller door removed 1 Remove the power board as described in the procedure on page 121 2 Remove the bus bar isolating screen see Figure 68 on page 124 3 Using a phillips screw driver loosen and remove the two screws holding the precharge resistor and end clamps in place see Figure 75 on page 138 The terminals for the precharge resistor also have cables connected to them Note the installation of the cables for future reference 1996 Square D All Rights Reserved L 137 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D16N4 and ATV66D23N4 December 1996 KCB2 Cable KCB1 Cable Precharge resistor mounting screws ra Precharge resistor Figure 75 Precharge Resistor 4 Remove the old prec
52. Cccc DB Gate ower Boat Braking IGBT Module Figure 106 Gate Driver Board Connections on IGBT Modules 1996 Square D All Rights Reserved c 199 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 Installing the Gate Driver Board 200 Bulletin NO VDUCUOS U1 December 1996 7 Using needle nose pliers carefully disconnect J26 1 J26 2 and J34 at the termination points located on the braking IGBT module see Figure 106 on page 199 8 Using needle nose pliers depress the tabs on the six plastic fixing pins and unsnap the gate driver board from the fixing pins Do not attempt to remove the gate driver board until all the connectors have been disconnected 9 Lift the board and using the needle nose pliers carefully disconnect J21 3 black J23 3 yellow J25_3 green J35 blue J36 white and J37 red at the termination points located on the power board underneath the gate driver board 10 Remove the gate driver board 11 If the gate driver board is to be replaced loosen the J3 and J4 cable connectors and remove the J3 and J4 cables see Figure 102 on page 193 and Figure 105 on page 199 These cables will be needed during the installation of the new gate driver board Remove and save the ferrite cores from cables J28 J29 and J30 for use on the new board NOTE Be sure the ribbon cables have been released before pulling to avoid damage to the cables This procedure explains how to install the gate driver boa
53. Checking Fuses in ATV66C10N4 to C19N4 controllers on page 72 If a blown DC bus fuse is found the inverter bridge is probably damaged The blown fuse must be replaced before checking for DC bus short circuits To check for DC bus short circuits 1 Connect the ohmmeter s volts ohm lead to the controller s terminal and the ohmmeter s com lead to the controller s terminal and measure resistance readings 2 Connect the ohmmeter s volts ohm lead to the controller s PA terminal LP and the ohmmeter s com lead to the controller s terminal and measure resistance readings The readings shown in Figures 39 and 40 on page 74 should result NOTE Capacitance charging will be observed during these tests The resistances listed are the steady state values 1996 Square D All Rights Reserved 73 Cnapter 3 Correcting tne Problem Checking the Power Part of the Controller 74 Bulletin NO VDUCUOS U1 December 1996 Controller Resistance ATV66U41N4 D12N4 80 110 ka ATV66D16N4 D23N4 17 0 25 0 KQ ATV66D33N4 D46N4 4 0 5 0 KQ ATV66D54N4 D79N4 2 0 2 6 KQ ATV66C10N4 C19N4 900 1500 Q Controller Resistance ATV66U41N4 D12N4 80 110 KQ ATV66D16N4 D23N4 17 0 25 0 kQ ATV66D33N4 D46N4 4 0 5 0 KQ ATV66D54N4 D79N4 2 0 2 6 KQ ATV66C10N4 C19N4 900 1500 Q Figure 40 Checking the Capacitor and Inverter Bus
54. DB diode block Q7 C DB bus jumper bar bracket DB IGBT le mone DB gate driver board Q7 C power cable i Q7 E Q7 E Q7 C power cable control cable control cable Figure 133 Dynamic Braking Snubber Board Gate Driver Board IGBT Diode 266 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Dynamic Braking DB Snubber Board Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 The dynamic braking module kit contains one snubber board This procedure explains how to install the dynamic braking snubber board in the following drive controllers Drive Controller No DB Module Kit No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the VZ3 IM1300M1207 electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Torque wr
55. Failure to follow these instructions will cause shock or burn resulting in death or serious injury REMOVE ALL POWER FROM CONTROLLER BEFORE PROCEEDING Read and follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 When power is removed from an undamaged controller the stored energy in the bus and snubber capacitors is automatically discharged to nonhazardous levels However the discharge mechanisms in a damaged controller may not be operating properly and stored energy may be present Before touching any capacitor termi nals always check for the presence of voltage across the capacitor terminals The presence of voltage can affect resistance readings and may signal the presence of hazardous stored energy If capacitive voltages are present refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 Diode Bridge Freewheel Inverter Bridge diode and IGBT Modules O 1 Precharge Resistor 1 Filter Capacitors 7 Balancing Discharge Braking Freewheel Resistors Resistor 2 GBT Diode 2 Module U V Ww 1 ATV66C10N4 through ATV66C19N4 2 ATV66D16N4 through ATV66C19N4 controllers equipped with a series thermal cut off switch GV2 Figure 36 Power Part Electrical Schematic 1996 Square D All Rights Reserved 71 Cnapter 3 Correcting the Pr
56. Module o o Circuit Protector gt 4 eb del Leib o S ERIT L m x E Ex Diode Bridge 9 53 E 9 Ke ll o o Control Power o o Transformer 6 Momo AS Contactor Aux Contact ee Terminal Block Precharge Resistor e A 2 9 el TB1 Discharge Resistor L o S oF He Precharge Contactor 5 d o 6 ata 9 o o o CH e io P e off o o Control Fuses CER e Main Wiring 2 i Access Hole Drive Controller Bottom Plate Mounting Screws Typical of 10 Filter Board Main Fan Main Fan Capacitor Assembly Figure 118 Spare Parts Location Diagram Front View 234 1996 Square D All Rights Reserved lL Bulletin NO VDUCUOS
57. O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 TRIPS REQUIRES POWER TO BE CYCLED Short Circuit Cnapter 3 Correcting tne Problem Short Circuit Figure 28 illustrates the measurement principle used for the short circuit fault S i C U V W I I I Power board I ATV66U41N4 E a aL ATV66U54N4 i ATV66U72N4 ATV66U90N4 I 0 OQ ATV66D12N4 I i I Gate driver board ATV66D16N4 ATV66D64N4 ATV66C19N4 ATV66D23N4 ATV66D79N4 ATV66D33N4 ATV66C10N4 ATV66D46N4 ATV66C13N4 ATV66D54N4 ATV66C15N4 Figure 28 Short Circuit Measurement Protection for drive controllers ATV66U41N4 through ATV66D12N4 is provided by Intelligent Power Module IPM Protection for drive controllers ATV66D16N4 through ATV66C19N4 is provided by the T1 and T3 current sensors as well as desaturation detectors in the gate driving circuitry When desaturation is detected it indicates an IGBT power block is not properly conducting current when it is gated on A display of SHORT CIRCUIT is generated in drive controllers ATV66U41N4 through ATV66D12N4 by the IPM when there is a short circuit in the power section of the drive controller or a short circuit between output phases A display of SHORT CIRCUIT is generated in drive controllers ATV66D16N4 through ATV66C19N4 by the gate driver desaturation detection circuitry when there is a short circuit between output phases a short circuit in the po
58. O A A A e et aur 2 HOW TO USE THIS MANUAL eee RR eee ee 44 nn 2 WORK PRACTICE PRECAUTIONS eeee re 3 Personnel Protection Precautions llle 3 Equipment Protection Precautions liiis 4 Static Sensitive Components eee 4 LIST OF TOOLS AND INSTRUMENTS o occccccoccc eee 5 DOCUMENTATION LIST 00 000 s nn 5 STANDARDS A 6 REVISION EEVEL 45st Rio E ep to ela ee 6 O 1996 Square D All Rights Reserve gt _ _ 1 Cnapter 1 Introauction ALTIVAR 66 Family ALTIVAR 66 FAMILY SCOPE OF MANUAL HOW TO USE THIS MANUAL Bulletin NO VDUCUOS U1 December 1996 ALTIVAR 66 is a family of 3 to 350 hp CT or 400 hp VT 2 2 to 300 kW adjustable speed AC drive controllers Capable of controlling either constant or variable torque loads and designed to handle simple or complex applications ALTIVAR 66 drive controllers can function as stand alone drive controllers or as part of complex drive systems This manual covers the ALTIVAR 66 drive controllers listed in Table 1 Table 1 ALTIVAR 66 Drive Controllers Model Number Outline ATV66U41N4 ATV66U54N4 1 ATV66U72N4 ATV66U90N4 ATV66D12N4 ATV66D16N4 ATV66D23N4 ATV66D33N4 ATV66D46N4 ATV66D54N4 ATV66D64N4 5 ATV66D79N4 ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 This manual consists of five chapters Chapter 1 Introduction expl
59. RUNNING STATE 2 4 ANALOG OUT MAP OUT ASSIGNMENT VAL RO1 MOTOR SPEED R 2 MOT CURRENT The I O Map is a series of display only screens that show the analog and logic input output terminal assignments The I O Map is useful for determining whether the drive controller is receiving the proper terminal commands and reference levels I O map Cnapter 2 Investigating tne Problem faults categories Fault History Parameter Settings FAULT CATEGORIES 16 The last eight faults of the controller can be viewed in the 3 Fault History screen along with the run status at the time of the fault The most recent fault is displayed first on the list The arrow under the M column is used to mark a fault so that it can be followed for future observation S3FBULT HISTORY AULT MAME STA H IN PHASE LOSS RIY AC LIA OVERUOL RUN MOT OVERLOAD ACC ENT to set marker Figure 5 Fault History It is often useful and necessary to determine the parameter settings when troubleshooting a drive controller All parameter settings are viewable from the keypad display See the Level 1 amp 2 Configuration manual VD0C065305 for Bulletin NO VDUCUOS U1 more information on viewing parameter settings Tables 3 through 6 list the faulty operating conditions and faults for the drive controllers For applicable troubleshooting procedure see the sections in chapter 3 referenced in the tables Table 3 Runs
60. Service and Troubleshooting Manual Bulletin No VD0C06S701 Table of Contents Chapter 4 Equipment Change Out Procedures December 1996 TRIPS REQUIRES POWER TO BE CYCLED sssssssee eee 61 Short Circuit sians ake ied a ae BA ae Si cee 61 Ground Faults es hosed At Race CR ae week atonal ate at ax esee ear 63 Internal Fault iia pinks Sb bdd eh edad hee bate RS 65 Internal Fault continued 2012 ooooocoocoocornr tee ee 66 Dynamic Brake Fault 0 a a tte 67 Dynamic Brake Resistor Overtemperature llle 68 Memory Fallure ec RRERAD ED PE VL me RR YAT oe A 69 Precharge Failte ios RR ER Ere a t AER 69 Link FAUNA PESE ET 69 Control Supply Fault 11 eser hme RU wea e ia be dy e DERE 69 EQUIPMENT DAMAGE ssssssesee ee mmn 70 KEYPAD DISPLAY IS OFF gt cipuri a sanae ia mmn 70 External Signs of Equipment Damage 0 0 cece ee 70 No External Signs of Equipment Damage 0 0 cee eee 70 Checking the Power Part of the Drive Controller oo oooooooooo 71 Checking Fuses in ATV66C10N4 to C19N4 controllers 72 Checking the Diode Bridge oooococccccccccocna eee 73 Checking the DG B s cuc gpEDtrie4EEIA GE Gh AE C MEA IRN DI 73 Checking the Precharge Resistor 00 0 0 cece eee eee eee 75 Checking the Inverter Bridge liliis 75 Checking the IGBT Modules in ATV66D16N4 to C19N4 Drive Controllers 75 Checking the Brakin
61. The tools needed for this procedure are A set of magnetized flat blade screw drivers A set of magnetized phillips screw drivers Torque wrench set to 8 9 Ib in 1 0 Nem Metric hex key sockets for torque wrench 5 5 to 14 mm A set of phillips screw driver sockets for torque wrench Plastic tie wraps Wire cutters For the control basket to be installed 1 Thread the three ribbon cables through the cable guides on the back of the control basket Place the control basket in the drive controller Using a torque wrench and either phillips screw driver socket or a hex key attachment tighten the one captive screw and install and tighten the three other corner screws see Figure 121 on page 239 Tighten the four corner screws to a torque of 8 9 Ib in 1 0 Nem NOTE The captive mounting screw provides the grounding connection for the control basket and shield connection on J13 Ensure that this screw is properly threaded and torqued to 8 9 Ib in 1 0 Nem NOTE On the power board the jacks are designated with a J whereas the corresponding connector plugs are designated with a P For example the P9 connector plug connects to the J9 jack on the power board and the J9 jack on the control basket Snap the two connector plugs P9 and P18 connected at J32 into place Snap the two connectors J12 and J13 into place see Figure 121 on page 239 NOTE The yellow keys in both plugs and sockets are designed to prevent incorrect in
62. Torx screw driver loosen and remove the four screws located along the left edge of the controller top and bottom panels in order to remove the left side panel O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Unapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 3 Remove the left side panel see Figure 104 on page 197 4 Using a phillips screw driver loosen and remove the four screws which hold the top IP20 protection cover in place see Figure 104 on page 197 Remove the top IP20 protection cover This allows access to the gate driver board see Figure 105 on page 199 5 Using needle nose pliers carefully disconnect the J68 board fan leads on the power board see Figure 107 on page 202 6 Carefully pull the board fan leads out from underneath the gate driver board see Figure 105 on page 199 7 Using the phillips screw driver loosen and remove the screw holding the board fan in place 8 Slide the old board fan down and remove it from the drive controller Top panel Top IP20 protection cover Right side panel Bottom IP20 protection cover J1 terminal block Bottom panel Figure 104 Location of IP20 Protection Covers and Panels 9 Install the new board fan on the drive controller by sliding it up until the mounting hole is aligned see Figure 105 on page 199 10 Using a phillips screw driver install and tighten the screw for the board fan 11 Using needle nose plier
63. U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Power Board Control Basket gt Control Terminal Blocks Om Stirring Fan ll Current Sensor Figure 119 Spare Parts Location Diagram Side View O 1996 Square D All Rights Reserved 235 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Replacing the Keypad Display 236 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to replace the keypad display for the following drive controllers Drive Controller No Control Kit No ATV66C10N4 ATV66C13N4 VX4 A66CK2 ATV66C15N4 ATV66C19N4 NOTE All ALTIVAR 66 drive controllers use the same model keypad display However the version of software present within the keypad display may be specific to the version of software present in the control basket Mixing incompatible versions of keypad display and control basket software can result in non recognition of the keypad display by the drive controller or garbled message displays Therefore keypad displays are not supplied as separate kitted items Keypad displays are supplied with control kits Keep keypads with their associated control basket Do not mix keypads and control baskets The keypad display is normally mounted on the control basket of ATV66U41N4 through ATV66D79N4 controllers For ATV66C10N4 through ATV66C19N4 controllers and Class 8839 Enclosed
64. VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66U41N4 to ATV66U72N4 To install the fan a With the drive controller inverted thread the J6 connector from the new fan through the fan lead hole in the back of the controller see Figure 52 on page 97 Install the new fan Ensure the label side of the fan is facing towards the heat sink Install the fan mounting bracket Install and tighten the two mounting screws With the drive controller returned to its upright position route the J6 connector and wire lead diagonally over to the right side of the controller see Figure 52 on page 97 Fan lead routing Figure 52 Fan Lead Routing 10 11 12 13 NOTE When routing the wire in the above step the J6 connector and attached fan leads are routed between the back of the heat sink and the underside of the printed circuit board Continue to route the J6 connector and wire leads along the right side of the controller around the outside of the top right corner and under the voltage regulator heat sink bar Attach the J6 connector at the top of the power board See Figure 52 on page 97 Fit the drive controller chassis to the controller back cover Using a drive socket or a phillips screw driver as necessary tighten the four screws holding the drive controller chassis to the back cover Install the two side panels by sliding them towards the bottom of the controller until the mounting tabs lock in
65. VX5 A66D16N4 VX5 A66D23N4 Drive Controller No ATV66D16N4 ATV66D23N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Clip pliers Catalog No VY1 ADV608 e 1 4 drive metric socket set 5 5 to 14 mm e Torque wrench set to 17 7 lb in 2 Nem Gate driver board procedure tool list page 120 e Control basket procedure tool list page 115 For the power board to be installed NOTE Make sure the bus bar isolating screen is in place between the bus bar and the power board see Figure 68 on page 124 Bus bar isolating screen Figure 68 Bus Bar Isolating Screen 1 For a new power board install the five gate driver board standoffs that were removed from the old power board 2 Align the mounting holes on the power board to the studs and mounting posts on the drive controller 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 10 11 12 13 14 15 Cnapter
66. aS 96 Fan Lead Routing icc ex RR RR UE Lp RERO 97 ATV66U90N4 and D12N4 Front View ooocooocoocoo oo 100 Control Basket Connector Locations ooooooooooo 102 Cable Connector Secure and Release Positions 102 Location of J1 J2 J12 and J13 Connectors 105 Power Board Connector Locati0NS oo o oooooooooo 107 Fan Removal se bnsa csi al ew elite ded due EUER 109 Fan Lead Routing 110 ATV66D16N4 to D23N4 Front VieW ooocooocoooco oo 112 Control Basket Connector Locations ooooooooooo 114 Cable Connector Secure and Release Positions 114 Location of J1 J2 J12 and J13 Connectors 117 Location of Various Covers s sassarese aranaren 118 Gate Driver Board Connections on Power Board 119 Gate Driver Board Connections on IGBT Modules 119 Connector Wire and Nut Locations on Power Board 123 Bus Bar Isolating Screen oooococcccococo ee 124 Bus Bar Screw and Mounting Pin Locati0nS 127 IGBT Modules Bus Bar Removed issues sees 127 Bus Bar Cable Locations oooooocooococococn eee 129 Braking IGBT Module Location lille eee eee eee 130 Braking IGBT Module Installation Orientati0n 131 Filter Board Connections 0 000 cono 133 Precharge Resistor oooooooocoreroanr eee 138 F n Mountings
67. acceleration Increase the Refer to chapter 4 to acceleration time change the Review bandwidth and Power board damping parameters Control basket Refer to VD0C06S305 Gate driver board Connections 49 Cnapter 3 Uorrecting tne Problem Bulletin NO VDUCUOS UT DC Bus Overvoltage December 1996 DC Bus Overvoltage con tinued 3 of 3 DB Resistor present and correctly Possible sized cause Test the brake module DB Resistor Assembly Check thermal switch to be performed Problem Switch tripped Result Refer to chapter 4 to Refer to chapter 4 to Reset switch Check change the power board change the for proper application of Solution Braking IGBT module Dynamic Braking and gate drive board 1 Power board 2 Test brake module 1 2 ATV66D16N4 ATV66D64N4 ATV66C19N4 ATV66U41N4 ATV66D23N4 ATV66D79N4 ATV66U54N4 ATV66D33N4 ATV66C10N4 ATV66U72N4 ATV66D46N4 ATV66C13N4 ATV66U90N4 ATV66D54N4 ATV66C15N4 ATV66D12N4 50 5 _ _ ___ 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 3 Correcting tne Problem December 1996 Input Phase Loss Input Phase Loss Figure 20 illustrates the measurement principle used for the input phase loss fault Connection is made through the filter board 9 on the following models ATV66D16N4 ATV66D23N4 ATV66D33N4 ATV66D46N4 La ee N I ATV66D54N4 Power board ATV66D
68. and drive controller side of the terminal block The CL1 CI2 jumper if present may be left in place Pull the cables and wires out of the way Identify and tag all field wiring for future re assembly see Figure 82 on page 151 Using a hex key wrench loosen and remove the two screws holding the J2 terminal block assembly in place Remove the terminal block assembly see Figure 82 on page 151 On the gate driver board use needle nose pliers to depress the tabs on the six plastic fixing pins and unsnap the gate driver board from the fixing pins This allows access to the bottom of the power board to disconnect the J42A and J42B connector which are soldered to the filter board No other wires need to be disconnected to do this Using a flat blade screw driver carefully disconnect the J42A and J42B connector on the power board see Figure 87 on page 158 Using needle nose pliers carefully disconnect J38 blue J39 white J40 red J53_1 blue and J53 2 white on the power board which are soldered on the filter board see Figure 87 on page 158 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Filter Board Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 Current Sensors Filter board mounting Screws Filter board Figure 92 Filter Board shown with Terminal Block Removed 13 Using a phillips screw driver loosen and remove the five screws holding the filter boa
69. braking GBT module to the bus bar see Figure 89 on page 162 9 Usingadrive socket or open end wrench install the three mounting pins with ne washer which connect the U V and W cables to the IGBT modules sing a torque wrench and the appropriate socket tighten the mounting pins and screws to 17 7 Ib in 2 Nem 11 Replace the bus bar isolating screen see Figure 89 on page 162 12 Install the power board as described in the procedure on page 159 ge ocac 10 a 170 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Filter Board Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 This procedure explains how to remove the filter board from the following drive controllers Drive Controller No Filter Board No ATV66D33N4 ATV66D46N4 VX4 A66104 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on large tubular capacitors on filter board assembly see Figure 94 on page 176 Always check for presence of voltage between terminals L1 L2 and L3 on J2 connector see Figure 82 on page 151 using voltmeter set to1000 VDC scale If voltage is present allow
70. connectors for the fan 6 Using a Torx screw driver loosen and remove the two screws holding the fan to the fan shroud If the Torx screw driver will not fit through the fan housing holes try using a hex key wrench If using a hex key wrench is successful replace the Torx screws with hex head screws see Figure 97 on page 182 7 Remove the fan Fan mounting screw 9 Fan mounting screw Figure 97 Fan Location and Mounting Bottom View of Controller This procedure explains how to install the fan in the following drive controllers Drive Controller No Fan No ATV66D33N4 VZ3 V665 ATV66D46N4 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized phillips screw drivers e Aset of thin shaft Torx screw drivers e Metric hex key set 2 to 14 mm e 4 Needle nose pliers For the fan to be installed 1 Fit up the new fan and align the mounting holes with the holes on the fan shroud Ensure the airflow arrow on the fan is facing towards the drive controller see Figure 97 on page 182 2 Using a Torx screw driver or hex key wrench install and tighten the two mounting screws 3 Using needle nose pliers carefully connect the two fan leads This is an AC fan The two fan leads can be connected to either terminal 4 Install
71. controllers the keypad display is located in a door mounted holder If the door mounted holder requires replacement or repair refer to document VDOC06N904_ for the VW3A66100 and VW3A66101 Keypad Door Mounting Kits Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers At the outside of the drive controller door 1 Usingthe flat blade screw driver push in on the top of the keypad display tab and remove the keypad display 2 Insert the new keypad Ensure that the lip on the bottom of the keypad display is behind the tab on the keypad display holder 3 Remove the RUN STOP cover if desired see Figure 120 on page 236 ALIAR 66 Keypad display tab Location of RUN STOP cover Figure 120 ATV66C10N4 to C19N4 Front View O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66C10N4 to C19N4 Removing the Control This procedure describes how to remove the control basket from the following Basket drive controllers Drive Controller No Control Kit No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 VX4 A66CK2 Before removing power note and record all the drive controller settings using the keypad display A DANGER HAZARDOUS VOLTAGE Remove all p
72. cover in place 7 Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the two screws which hold the bottom IP20 protection cover in place 8 Install the top IP20 protection cover Using a phillips screw driver install and tighten the two screws which hold the top IP20 protection cover in place 9 Install the J1 connector at the bottom of the power board 10 Using torque wrench and a flat blade screw driver socket install and tighten the field wiring on the termination points on connector J2 See Receiving and Installation Manual VDOC06S304_ for torque specifications 11 Install the control basket as described in the procedure on page 115 Removing the Bus In the event that one capacitor goes bad at least two other capacitors will be Capacitors damaged Therefore all four capacitors should be replaced This procedure explains how to remove the bus capacitors from the following drive controllers Drive Controller No Bus Capacitor No ATV66D16N4 VY1 ADC152V450 ATV66D23N4 NOTE Kit VY1 ADC152V450 contains one capacitor A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verif
73. damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm e Set of open end wrenches 5 5 to 19 mm e Power board procedure tool list page 158 Gate driver board procedure tool list page 154 e Control basket procedure tool list page 147 With the drive controller door removed 1 Remove the power board as described in the procedure on page 157 Remove the bus bar isolating screen see Figure 89 on page 162 3 Using an open end wrench loosen and remove the nine mounting pins and washers on the bus bar Pull the U V and W cables back out of the way see Figure 89 on page 162 4 Using a phillips screw driver loosen and remove the two screws which attach the bus bar to the braking IGBT module The BR3 cable is connected to the C1 terminal of the braking IGBT module Pull the BR3 cable back out of the way 5 Using a hex key wrench loosen and remove the eight screws which hold the bus bar to the bus capacitors The balancing resistors are mounted under these screws Note the lo
74. dei picar e rl dia 140 Bus Capacitar 143 Bus Capacitor PA and TerminalS o ooocoocoooooo 144 ATV66D33N4 to D46N4 Front VieW oooooooooco oo 146 Control Basket Connector Locations ooooooooooo 148 Cable Connector Secure and Release Positions 149 Location of J1 J2 J12 and J13 Connectors 151 Location of Various Covers 0 ccc eee eee eens 153 Board Fan Top Left Side of Drive Controller 153 Gate Driver Board Connection Locations oo o o o 155 Gate Driver Board Connections on IGBT Modules 155 Power Board Connections 000 cece eee eee 158 Bus Bar Isolating Screen 00 0 tees 160 Bus Bar Screws 0 ce eee tenes 162 Drive Controller with Bus Bar Removed 0000005 163 Bus Capacitar ia 169 Filter Board shown with Terminal Block Removed 173 J2 Terminal Block Torque Specs 0 00 eee eee eee 174 Diode Block Bottom left side view of controller 176 Diode Block Wiring Terminations 002 cee eee eee 178 Current SensOF 22x wu Pee ee a eee oa Pe ER 180 Fan Location and Mounting Bottom View of Controller 182 Discharge Resistor 0 00 eee cette 184 Auto Traristormer merenah aici hon Shien See wes ER eI 186 ATV66D54N4 to D79N4 Front View 20000 eee eee 190 1996 Square D All Rights Reserved
75. drivers e 4 Needle nose pliers e Control basket procedure tool list page 149 For the gate driver board to be installed 1 Ifthe gate driver board is being replaced perform the following steps Loosen the J3 and J4 cable connectors see Figure 81 on page 149 Insert the J3 and J4 cables saved earlier with the silver leads facing towards the top of the gate driver board Push the connectors to the secure position Install the ferrite cores saved earlier onto cables J28 J29 and J30 2 Using needle nose pliers carefully connect J35 blue J36 white and J37 red on the power board see Figure 86 on page 155 3 Position the gate driver board over the fixing pins on the power board and snap the gate driver board onto the fixing pins 4 Ifrequired re braid the twisted pair wires before connecting them to the IGBT modules O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D33N4 and ATV66D46N4 5 Using needle nose pliers carefully connect J20_1 J20_2 J21_1 J21_2 J22_1 J22 2 J23 1 J23_2 J24 1 J24 2 25 1 and J25_2 at the termination points located on the IGBT modules see Figure 86 on page 155 6 Using needle nose pliers carefully connect J26_1 J26_2 and J34 at the termination points located on the braking IGBT module see Figure 86 on page 155 7 Using needle nose pliers carefully connect J27 J28 J29 J30 J57 J58 J59 J60 and J61 at th
76. electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm e Metric hex key sockets for torque wrench 2 to 14 mm e Power board procedure tool list page 124 Gate driver board procedure tool list page 120 e Control basket procedure tool list page 115 For the filter board to be installed 1 Using needle nose pliers carefully connect the small red connector at the top of the filter board see Figure 74 on page 133 2 Install the filter board Using a torque wrench and hex key socket install and tighten the five screws to 17 7 lb in 2 Nem Ensure the cables to the card are connected as follows see Figure 74 on page 133 Two black LP wires on the negative Two red LP wires on the positive One blue wire per phase L1P L2P L3P 3 Install the power board as described in the procedure on page 124 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Diode Bridge Cnapter 4 Equipment Cnange vut ATV66D16N4 and ATV66D23N4 This procedure explains how to remo
77. electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of Torx screw drivers e Torque wrench set to 17 7 lb in 2 Nem e 4 Needle nose pliers e Control basket procedure tool list page 193 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 191 2 Using a phillips or Torx screw driver loosen and remove the four screws which hold the left side panel Remove the left side panel see Figure 104 on page 197 3 Using a phillips or Torx screw driver loosen and remove the four screws which hold the right side panel Remove the right side panel see Figure 104 on page 197 4 Remove the J1 terminal block see Figure 104 on page 197 228 z _ _ _ _ _ 0 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 10 11 12 13 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place Remove the bottom IP20 protection cover
78. for the cable to the remote LED status indicators see Figure 123 on page 242 As needed use wire cutters to remove any tie wraps 7 Using two flat blade screw drivers carefully pull out on each side of the cable clasp of J3 J4 and J5 to the release position see Figure 122 on page 239 Pull the ribbon cables from the sockets O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66C10N4 to C19N4 J9 J32 J4 J3 J5 Mountingscrew Mounting screw r Cable guides located vf on back of control basket The connector plug labeled P18 is landed at the J32 jack The location on the power board where the other end of the the P18 connector plug is landed is designated J18 Location of I O Extension Module if installed Captive mounting Ye screw J13 J12 Mounting screw Figure 121 Control Basket Connector Locations NOTE Ensure that the ribbon cables have been released before pulling to avoid damage to the cables There are two versions of the cable clasps blue and white White Cable Clasp Ribbon Cable a aan Cable Circuit Board D Circuit Board gt Blue Cable Clasp i Secure Position Secure Position White Cable Clasp Pull Out Pull Out m Ribbon Cable Ribbon Cable Circuit Board al Circuit Board N gt _ Blue Cable Clasp Release Position Release Posit
79. illuminate and a fault message appears on the keypad display If this occurs make note of the fault displayed and proceed to Tables 3 and 4 on page 16 If the controller has not faulted but does not perform as expected proceed to Table 2 on page 14 LEDs Figure 2 illustrates the LED indications available on the drive controller If the drive controller is powered up and the keypad display is OFF proceed to Table 6 on page 17 for Equipment Damage 12 _ S 8 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 October 1997 DC BUS Red Illuminated DC bus gt 50 V Cnapter 2 Investigating tne Problem keypad display CAUTION FAULT FAULT Red Yellow Red DRIVE CONTROLLER STATE e e Caution LED Illuminated w Fault LED OFF Drive controller D A a is running and in current limit NOTE LED may appear to flash rapidly as drive controller regulates at current limit Caution LED Slow Flashing w Fault LED OFF Pre Alarm indication of a Drive Overtemperature Fault ATV66D16N4 C19N4 only or a Motor Overload Fault Consult Keypad 69 Display for Motor Thermal State or Drive Thermal State ATV66D16N4 C19N4 only to determine which condition is causing the Pre Alarm If either of these thermal states exceeds 100 the Caution LED will flash slowly Caution LED Illuminated w Fault LED ON Drive controller V lt 4 fault exists on Motor Overload or Drive Overtemperature
80. in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Aset of magnetized phillips screw drivers e Torque wrench set to 8 9 Ib in 1 0 Nem e Aset of phillips screw driver sockets for torque wrench For the control basket to be installed 1 Place the control basket in the controller and ensure the mounting holes are aligned with the holes in the controller see Figure 80 on page 148 2 Insert the three screws that are not captive Using a torque wrench and phillips screw drive socket tighten the three screws and the one captive screw to 8 9 Ib in 1 0 Nem see Figure 80 on page 148 1996 Square D All Rights Reserved 149 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D33N4 and ATV66D46N4 December 1996 NOTE The captive mounting screw provides the grounding connection for the control basket and shield connection on J13 Ensure this screw is properly threaded and torqued 3 Snap the four connectors J9
81. key wrench loosen and remove the two mounting screws 5 Remove the snubber board 243 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Snubber Board Cnapter 4 rquipment Change vut J1 J4 J3 J2 J2 a J3 J4 x J1 SB1 Snubber Capacitors SB4 P N 52012 630 50 P N 52012 630 51 Snubber Capacitors 2 HY us J Slat Metal Can rx Capacitors J1 J4 J3 J2 SB6 SB3 P N 52012 630 54 P N 52012 630 53 Snubber Capacitors n s nal S vat E J2 J3 J4 Ji SB5 SB2 P N 52012 630 50 P N 52012 630 51 ATV66C10N4 to C19N4 Metal Can Capacitors Figure 127 Snubber Board Connector and Capacitor Locations There are six snubber boards in the ATV66C10N4 to C19N4 drive controllers The power pole kit contains snubber boards with four different part numbers When replacing a snubber board match the part number of the replacement board with the part number of the board to be replaced NOTE Replace the snubber boards in horizontal pairs SB1 and SB4 SB6 and SB3 SB5 and SB
82. line voltage INPUT LINE 1 Perform Bus Voltage Measurement procedure see page 310 VOLTAGE r As MEASUREMENT 2 Attach meter leads to L1 and L2 Set voltmeter to the PUNASE scale 3 Reapply power and check for correct line voltage per drive controller nameplate rating 4 Remove power and repeat procedure for L2 and L3 and L1 and L3 5 When all phases have been measured remove power Remove meter leads and reinstall covers PROCEDURE 4 The following equipment may need to be checked Follow the manufacturer s CHECKING procedures when checking this equipment PERIPHERAL 1 A protective device such as fuse or circuit breaker may have tripped EQUIPMENT 2 A switching device such as a contactor may not be closing at the correct time 3 Conductors may require repair or replacement 4 Connection of cables to the motor DB resistor or connections to ground may need to be checked Follow NEMA standard procedure WC 53 5 Motor insulation may need to be checked Follow NEMA standard procedure MG 1 Do not apply high voltage to drive controller output terminals U T1 V T2 or W T3 Do not connect high potential dielectric test equipment or insulation resistance tester to the drive controller since the test voltages utilized may damage the drive controller Always disconnect the drive controller from the conductors or motor while performing such tests O 1996 Square D All Rights Reserved A 313 Cnapter 5 Bbasic Procedures Checking Pe
83. list page 202 Gate driver procedure tool list page 198 e Control basket procedure tool list page 192 With the drive controller door removed 1 Remove the power board as described in the procedure on page 201 Remove the bus bar isolating screen NOTE In order to keep the proper spacing for the components keep all washers with their respective mounting pins or screws Washers are used to level the power board 3 Using a metric socket loosen and remove the nine mounting pins on the bus bar see Figure 108 on page 206 Pull the U V and W cables back out of the way Cc 4 Usinga phillips screw driver loosen and remove the three screws which ttach the bus bar and two cables to the braking IGBT module see Figure 109 n page 206 Pull the two cables marked BR1 and BR3 back out of the way om e E sing a hex key wrench loosen and remove the 12 screws which hold the bus ar to the bus capacitors see Figure 108 on page 206 The balancing resistors re mounted under these screws 9o 6 Using a hex key wrench loosen and remove the two screws which hold the C and C cables to the bus bar see Figure 108 on page 206 Pull the cables back out of the way 7 Remove the bus bar 8 Usinga hex key wrench loosen and remove the four mounting screws for the braking IGBT module see Figure 109 on page 206 9 Using a flat blade screw driver gently pry loose and remove the braking IGBT module 1996 Square D Al
84. needle nose pliers carefully disconnect the connector plugs P2 and P10 at the top of the power board see Figure 125 on page 245 Using needle nose pliers carefully disconnect the connector plugs P11 P12 and P13 at the right side of the power board see Figure 125 on page 245 Using a hex key wrench loosen and remove the ground screw at the top right corner of the power board see Figure 125 on page 245 If the power board is to be replaced remove the cables attached at J3 J4 J5 J9 and J18 see Figure 125 on page 245 Refer to Figure 122 on page 239 for removal of cable These will be reused when the new power board is installed O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66C10N4 to C19N4 11 Unsnap the seven fixing pins and lift the power board out of the hinged assembly Ground Screw xa Coa COI J4 J3 J5 Figure 125 Power Board Connections 1996 Square D All Rights Reserved 245 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 Installing the Power Board This procedure explains how to install the power board in the following drive controllers Drive Controller No Power Board No ATV66C10N4 VX5 A66C10N4 ATV66C13N4 VX5 A66C13N4 ATV66C15N4 VX5 A66C15N4 ATV66C19N4 VX5 A66
85. new document A wv 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 October 1997 CHAPTER 2 INVESTIGATING THE PROBLEM Cnapter 2 1nvestgating the Problem Contents INTRODUCTION eM A A Reni 8 RECOMMENDED TROUBLESHOOTING INSTRUCTIONS 200000 000 8 Drive System Energized oococococcococ res 9 Drive System De energized Power Removed liiis eee eee eee aes 11 LED INDICATIONS AND KEYPAD DISPLAY sssssseee eee 12 LEDS UIS E IRR ERR ERR EE E ANS 12 Keypad Display uiae iD OPE M ere eg 13 Status Codes x xc sz urn hack RE EN pO A 14 Measurements i c rp eed erp equ e eee ee 14 l O Map a A SERA ARR RE REIR RR RR ERO ROG 15 Fault HIStory ic A AA Re Vb pe m ues ds 16 Parameter Settings sis pea sci c ri ene Rel RUE pedes eR te 16 FAULT CATEGORIES ao ERR REPRE REFER RE PIX EX E dx 16 M 1996 Square D All Rights Reserve 7 Cnapter 2 Investigating tne Problem Bulletin NO VDUCU6S UT Recommended Troubleshooting Instructions October 1997 INTRODUCTION The ALTIVAR 66 drive controller is part of an overall electrical distribution and control system While a specific fault may occur with the drive controller there are times when the fault may be caused by external factors Figure 1 provides a general overview of the typical causes and severity of faults Equipment Damage S Trips Not Resettable by Keypad Ll Automatic Trips Resettable by Key
86. on the braking IGBT module see Figure 72 on page 130 4 Using a flat blade screw driver loosen and remove the two mounting screws for the braking IGBT module see Figure 72 on page 130 5 Carefully remove the braking IGBT module by pulling it out from under the bus bar Leave the mounting pedestal with the drive controller for installation of the new braking IGBT module AAA 1996 Square D All Rights Reserved _ Bulletin NO VDUCUOS U1 December 1996 Installing the Braking IGBT Module Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 This procedure explains how to install the braking IGBT module in the following drive controllers Drive Controller No IGBT Module No ATV66D16N4 ATV66D23N4 VZ3 IM1025M1001 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Torque wrench set to 13 3 Ib in 1 5 Nem Flat blade screw driver sockets for torque wrench e Set of open end wrenches 5
87. or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized phillips screw drivers e Aset of Torx screw drivers e 4 Needle nose pliers With the drive controller door removed 1 Using a phillips screw or Torx driver loosen and remove the four screws which hold the left side panel see Figure 83 on page 153 Two screws are located at the top and two screws are located at the bottom Remove the left side panel 2 Using a phillips or Torx screw driver loosen and remove the four screws which hold the right side panel see Figure 83 on page 153 Two screws are located at the top and two screws are located at the bottom Remove the right side panel 3 Disconnect the J1 connector This will allow the bottom IP20 protection cover to be removed see Figure 82 on page 151 1996 Square D All Rights Reserved 183 Cnapter 4 rquipment Cnange Out ATV66D33N4 and ATV66D46N4 184 4 Bulletin NO VDUCUOS U1 December 1996 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place see Figure 83 on page 153 Remove the bottom IP
88. over their mounting hole on the capacitor bus bar plate Using a torque wrench and hex key socket install and tighten the mounting screw to 40 7 lb in 4 6 Nem see Figure 139 on page 283 Position the one DCB control wire over its mounting hole on the capacitor bus bar plate Using a torque wrench and hex key socket install and tighten the mounting screw to 40 7 Ib in 4 6 Nem see Figure 139 on page 283 Install the TB3 control wires into their respective locations on the TB3 terminal block assembly see Figure 142 on page 288 Using a flat blade screw driver tighten the TB3 terminal screws O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Replacing the Circuit Protector Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 21 Using a drive socket install and tighten the two plexiglass shield screws while holding the plexiglass shield in place see Figure 139 on page 283 This procedure explains how to replace the circuit protector for the following drive controllers Drive Controller No Circuit Protector No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 GV2M10 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precau
89. page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Power board procedure tool list page 202 Gate driver procedure tool list page 198 e Control basket procedure tool list page 192 With the drive controller door removed 1 Remove the power board as described in the procedure on page 201 2 Remove the bus bar isolating screen NOTE In order to keep the proper spacing for the components keep all washers with their respective mounting pins or screws Washers are used to level the power board 1996 Square D All Rights Reserved 205 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 206 Bulletin NO VDUCUOS U1 December 1996 3 Usinga drive socket loosen and remove the nine mounting pins and washers on the bus bar see Figure 108 on page 206 Pull the U V and W cables back out of the way A A us bar screws E Nine mounting pins Figure 108 Bus Bar Screws 4 Using a phillips screw driver loosen and remove the two screws which attach the bus bar to the braking IGBT module Pull th
90. readings is internal or external to the controller If the cause of the lower resistance readings is external to the controller repeat the resistance measurements to determine the actual state of the drive controller If the resistance measurements remain low after disconnecting the external wiring additional damage may be present to multiple IGBTs and associated snubber boards if used DC bus insulation or DC bus capacitors If the resistance is less than shown in Figure 39 and the resistance is within the range shown in Figure 40 the precharge resistor or precharge protective switch if used may be open If external wiring is present on the and terminals disconnect the wiring and repeat the test to determine whether the cause of the lower resistance readings is internal or external to the controller If the cause of the lower resistance readings is external to the controller repeat the resistance measurements to determine the actual state of the drive controller If the resistance measurements remain low after disconnecting the external wiring additional damage may be present in the rectifier bridge 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Checking the Precharge Resistor Checking the Inverter Bridge Checking the IGBT Modules in ATV66D16N4 to C19N4 Drive Controllers NOTE If one filter capacitor is damaged all the filter capacitors should be changed Cnapter 3 Correcting tne Prob
91. replaced see Figure 96 on page 180 10 Remove the old current sensor 1996 Square D All Rights Reserved 179 Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 Bulletin NO VDUCUOS U1 December 1996 Current sensors Figure 96 Current Sensor 11 12 13 14 15 16 17 18 19 180 Install the new current sensor Do not disturb the settings of the potentiometers on the current sensor The current sensor must be oriented with the arrow pointing towards the bottom of the controller Using a hex key wrench install and tighten the two mounting screws Using needle nose pliers carefully connect the wire at the bottom of the sensor Pull the U T1 or W T3 cable back through the current sensor Insert the cable in its terminal on the J2 terminal block assembly and tighten the terminal screw using a torque wrench and hex key attachment Tighten to 26 5 Ib in 3 Nem Insert the V T2 cable in its terminal on the J2 terminal block assembly and tighten the terminal screw using a torque wrench and hex key socket to 26 5 Ib in 3 Nem Insert the ground wires in the J2 terminal block assembly and tighten the terminal screw using a torque wrench and flat blade attachment to 26 5 Ib in 8 Nem Install the top IP20 protection cover Route the five control basket cables through the hole i
92. result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 4 Needle nose pliers e Metric hex key set 2 to 14 mm e Aset of Torx screw drivers Flat blade screw driver sockets for torque wrench e Torque wrench set to 26 5 lb in 3 Nem e Control basket procedure tool list page 149 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 147 2 Using a phillips or Torx screw driver loosen and remove the four screws which hold the left side panel see Figure 83 on page 153 Two screws are located at the top and two screws are located at the bottom Remove the left side panel 1996 Square D All Rights Reserved 185 Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 186 10 Bulletin NO VDUCUOS U1 December 1996 Using a phillips or Torx screw driver loosen and remove the four screws which hold the right side panel Two screws are located at the top and two screws are located at the bottom Remove the right side panel see Figure 83 on page 153 Using a phillips screw driver loosen and remove the four screws which hold the top IP20 protection cover in pl
93. screw driver install and tighten the four screws which hold the left side panel in place see Figure 104 on page 197 8 Install the control basket as described in the procedure on page 193 1996 Square D All Rights Reserved 225 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66D54N4 to D79N4 December 1996 Replacing the Precharge This procedure explains how to replace the precharge resistor for the following Resistor drive controllers Drive Controller No ATV66D54N4 ATV66D64N4 VZ3 R010W481 ATV66D79N4 A DANGER Precharge Resistor No HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing c
94. screws which hold the right side panel in place see Figure 104 on page 197 18 Install the left side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the left side panel in place see Figure 104 on page 197 19 Install the control basket as described in the procedure on page 193 Replacing the Discharge There are two discharge resistors in this size of drive controller This procedure Resistor explains how to replace the discharge resistor for the following drive controllers 1996 Square D All Rights Reserved CL 227 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66D54N4 to D79N4 December 1996 Drive Controller No Main Fan No ATV66D54N4 ATV66D64N4 VZ3 R5KOW040 ATV66D79N4 NOTE Kit V23 R5KOW040 contains one resistor A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the
95. see Figure 104 on page 197 NOTE If repairing the controller with field wiring in place the wiring knockout panel can be detached from the bottom panel in the next step Remove the bottom panel screws and remove the bottom panel see Figure 104 on page 197 Using needle nose pliers carefully disconnect the wires to the discharge resistor to be replaced see Figure 116 on page 229 Using a phillips screw driver loosen and remove the mounting screw for the discharge resistor see Figure 116 on page 229 Remove the old discharge resistor Install the new discharge resistor Using a torque wrench and phillips screw driver socket install and tighten the mounting screw to 17 7 lb in 2 Nem Using needle nose pliers carefully connect the wires to the discharge resistor Install the bottom panel see Figure 104 on page 197 Mounting screws Discharge resistors Figure 116 Discharge Resistor 14 15 16 17 18 Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the three screws for the bottom IP20 protection cover see Figure 104 on page 197 Install the J1 terminal block see Figure 104 on page 197 Install the right side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the right side panel in place see Figure 104 on page 197 Install the left side panel Using a phillips or Torx screw driver install and tight
96. sensor As the sensor comes up out of the drive remove the copper center cylinder from the center of the sensor When the sensor is removed sufficiently to reach the signal cable unplug it from the sensor using needle nose pliers pull on the connector not the wires Remove the sensor completely from the drive T2 power cable T3 power cable T1 power cable Current sensor connector Current sensor connector Center cylinder screw Center cylinder Right current sensor Screw T3 sensor wire Pm T2 sensor wire i i L LEER sensor wire Figure 131 Current Sensor Assembly Left current sensor To remove the right current sensor 1 Remove the left current sensor by following the above procedure 2 Using needle nose pliers carefully disconnect and pull back out of the way the T3 sensor wire see Figure 131 on page 262 3 Using a hex key wrench loosen and remove the screw at the back of the T1 terminal block Remove the L bar that goes from the T1 terminal block to the center cylinder on the left current sensor 4 Using a hex key wrench loosen and remove the center cylinder screw on the left side of the right current sensor see Figure 131 on page 262 Pull the T3 power cable and current sensor connector back out of the way and remove the center cylinder 5 Using a phillips screw driver loosen and remove the top screw holding the current sensor to the mounting bracket O 1996 Square D All Rights Reserv
97. system or process systems experiencing trips Internal or external damage to some component of the drive system or process The maintenance person should be alert to the possibility that portions of the equipment may still be energized Always confirm that all power has been removed using a properly rated voltage sensing device before working inside any equipment For the drive controller use PROCEDURE 1 BUS VOLTAGE MEASUREMENT on page 310 of chapter 5 Always consult with the operating personnel responsible for the machinery and process before changing the operating state or removing or applying power to any equipment Use and obey all applicable lock out tag out procedures in force at the specific location Before energizing the system inspect the drive controller and other major components of the system such as motor and auxiliaries for external damage see Drive System Energized on page 9 Visible signs of damage warrant a thorough internal examination and subsequent corrective action Table 4 on page 17 contains specific information for troubleshooting damaged equipment The repair process should also include inspection of the drive controller and other system components for internal damage Such an inspection should include e Perform PROCEDURE 4 CHECKING PERIPHERAL EQUIPMENT on page 313 of chapter 5 Repair or replace any damaged protective equipment per the manufacturer s instruction e Check the integrity of the cont
98. the components keep all washers with their respective mounting pins or screws Washers are used to level the power board 4 Usinga drive socket loosen and remove the nine mounting pins and washers on the bus bar see Figure 108 on page 206 Pull the U V and W cables back out of the way 5 Using a phillips screw driver loosen and remove the two screws which attach the bus bar to the braking IGBT module Pull the cable marked BR3 back out of the way see Figure 109 on page 206 6 Usingahex key wrench loosen and remove the 12 screws which hold the bus bar to the bus capacitors see Figure 108 on page 206 The balancing resistors are mounted under these screws M c sing a hex key wrench loosen and remove the two screws which hold the C and C cables to the bus bar see Figure 108 on page 206 Pull the cables back out of the way 8 Remove the bus bar O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Bus Capacitor Assembly Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 Bus Capacitor Assembly M le Is sms mms Me y Figure 110 Bus Capacitor 9 Using a phillips screw driver loosen and remove the two mounting screws on the left hand corners of the bus capacitor assembly see Figure 110 on page 213 10 Using a drive socket loosen and remove the two mounting nuts on the right hand corners of the bus capacitor assembly see Figure 110 on pag
99. the control basket Mixing incompatible versions of keypad display and control basket software can result in non recognition of the keypad display by the drive controller or garbled message displays Therefore keypad displays are not supplied as separate kitted items Keypad displays are supplied with control kits Keep keypads with their associated control basket Do not mix keypads and control baskets The keypad display is mounted on the control basket for drive controllers ATV66D33N4 and ATV66D46N4 see Figure 79 on page 146 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers With the drive controller door open 1 Using a flat blade screw driver push in on the keypad display tab and remove the keypad display see Figure 79 on page 146 2 Insert the new keypad display into the front of the control board Ensure the lip on the bottom of the keypad display is behind the tab on the control basket i Fal a El w 0 display tab Location of RUN STOP cover Figure 79 ATV66D33NA to D46N4 Front View O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Control Basket Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 This procedure explai
100. the drive controller and align the five mounting holes see Figure 92 on page 173 Using a torque wrench and phillips screw driver socket install and tighten the five screws to 17 7 Ib in 2 Nem Using needle nose pliers carefully connect J38 blue J39 white and J40 red on the power board see Figure 87 on page 158 Route the wires underneath the sensor assembly bracket to the power board Using needle nose pliers carefully connect J53 1 blue and J53 2 white on the power board see Figure 87 on page 158 NOTE Ensure 53 1 and J53_2 are routed away from the power resistors located next to the J53 connection on the power board Connect the J42A and J42B connector on the power board see Figure 87 on page 158 Align the gate driver board over the fixing pins on the power board and snap the gate driver board into place Install the J2 terminal block assembly Using a hex key wrench install and tighten the two screws holding the J2 terminal block assembly in place see Figure 82 on page 151 Install the cables and wires for L1 L2 L3 U T1 V T2 W T3 CL1 CL2 L21 L22 PA PB and ground at both the field side and drive controller side of the J2 terminal block Using a torque wrench and appropriate attachment tighten the terminal screws as shown in Figure 93 on page 174 Ensure that the U T1 cable passes through the left current sensor and that the W T3 cable passes through the right current sensor 6 73 Ib
101. the drive controller door open or removed 1 Remove the dynamic braking snubber board as described in the procedure on page 264 2 Using needle nose pliers carefully disconnect and pull back out of the way the T2 sensor wire see Figure 131 on page 262 3 Using a hex key wrench loosen and remove the screw at the back of the T2 terminal block Pull the T2 power cable back out of the way sing a hex key wrench loosen and remove the current sensor mounting racket screw e zc e Cc sing a hex key wrench remove the remaining dynamic braking bus bar racket screw see Figure 134 on page 275 Remove the bus bar bracket Jsing a drive socket remove the two standoffs Pull the Q7 C jumper back ut of the way see Figure 135 on page 275 ion on od N c sing a hex key wrench remove the screw from the DM4 2 terminal of the dynamic braking diode block see Figure 135 on page 275 Pull the DM4 2 cable back out of the way and remove the dynamic braking diode block connector see Figure 135 on page 275 8 Using a hex key wrench remove the two dynamic braking diode block screws Using a flat blade screw driver gently pry loose the diode block see Figure 135 on page 275 9 Remove the dynamic braking diode block Remove all of the old Thermstrate foil from the heatsink 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 DM4 2 cable DB diode block Cnapter 4 Equipment Cnange Out
102. the filter board as described in the procedure on page 132 2 Using a hex key wrench loosen and remove the two screws on the diode bridge The diode bridge is located directly under the filter board mounting location 3 Remove the diode bridge 1996 Square D All Rights Reserved 135 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 Installing the Diode Bridge 136 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to install the diode bridge in drive controllers Drive Controller No ATV66D16N4 ATV66D23N4 Diode Bridge No VZ3 DM6075M1601 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Thermal grease Thermalloy Thermalcote II Part No 349 or equivalent Filter board procedure tool list page 134 e Power board procedure tool list page 124 Gate dri
103. to Be Recycled Fault Designation on Keypad Display SHORT CIRCUIT Troubleshooting Procedure Chapter 3 page 61 GROUND FAULT Chapter 3 page 63 INTERNAL FAULT Chapter 3 page 65 DYNAMIC BRAKE Chapter 3 page 67 DB RESISTOR Chapter 3 page 68 MEMORY FAILURE Chapter 3 page 69 PRECHARGE FAIL Chapter 3 page 69 LINK FAULT Chapter 3 page 69 CONTROL SUPPLY FAULT Table 6 Equipment Damage Keypad display is OFF Chapter 3 page 69 Chapter 3 page 70 External signs of equipment damage No external signs of equipment damage Chapter 3 page 70 Chapter 3 page 70 Checkout of the power part of the drive controller Chapter 3 page 71 Checkout of the control part of the drive controller O 1996 Square D All Rights Reserved Chapter 3 page 77 17 Cnapter 2 Investigating tne Problem Bulletin NO VDUCU6S U1 fault analysis categories October 1997 8 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 CHAPTER 3 CORRECTING THE PROBLEM Cnapter 3 Correcting the Probiem Contents RUNS DOES NOT PERFORM AS EXPECTED sssssee esee 20 Poor Speed Stability vp A As 20 Excessive Motor Temperature o ooooocococoorrr eee 22 Motor Accelerates Too Slowly 25 Motor Decelerates Too Slowly Overspeeds Overspe
104. to ground The ground fault is used to pro tect the drive controller only The and terminals on the DC bus pass via the current transformer During nor mal operation the difference in the current is close to 0 The ground fault is trig gered upon the following deviation e ATV66D16N4 ATV66D23N4 current transformer with a turns ratio of 550 The fault is triggered if the deviation is gt 15 A rms e ATV66D33N4 ATV66D46N4 current transformer with a turns ratio of 500 The fault is triggered if the deviation is gt 6 5 A rms e ATV66D54N4 ATV66D64N4 ATV66D79N4 current transformer with a turns ratio of 1800 The fault is triggered if the deviation is gt 16 A rms e ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 current transformer with a turns ratio of 120 The fault is triggered if the deviation is gt 21 A rms The measurement is taken every millisecond In the event of a ground fault the transistors are locked directly by the control card at the channel controls O 1996 Square D All Rights Reserve 63 Cnapter 3 Correcting tne Problem Ground Fault 64 Bulletin NO VDUCUO6S U1 December 1996 Figure 31 illustrates the troubleshooting procedure when a ground fault is present Fault Displayed Grounding of the motor motor cable or DB Possible Resistor cause Check to b
105. voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage 1996 Square D All Rights Reserved L 171 Cnapter 4 rquipment Cnange Out ATV66D33N4 and ATV66D46N4 172 Bulletin NO VDUCUOS U1 December 1996 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are A set of Torx screw drivers Metric hex key set 2 to 14 mm 4 Needle nose pliers Control basket procedure tool list page 147 With the drive controller door removed 1 10 11 12 Remove the co
106. will exit this test and the keypad will display this message MINI CONSOLE TEST TEST DISPLAY TEST MICRO amp RAM TEST KEYPAD TEST SWITCH TEST SERIAL LINK The Test Switch will indicate 0 if the lock switch on the back of the keypad is in the unlocked position If the lock switch is in the Test Switch display will indicate Mh 1 n O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Diagnostic Mode Autodiagnostics Logic and Analog Input Output Tests Cnapter 3 Correcting tne Problem Checking the Power Part of the Controller Press ENT to enter the Serial Link Test Currently all of these tests fail with an ER ROR message Press ENT again to exit the Keypad diagnostics Removing and reinstalling the keypad from the drive while the test is in progress will cause the test to abort Menu 8 allows access to various tests for locating failed components in case of an internal drive controller fault This menu is accessible only when The drive controller is stopped Supply line power L1 L2 and L3 is disconnected e Control power supply CL1 CL2 is connected If any of these conditions are not met an error message appears and access to the Diagnostic Mode is denied Exit the error message screen and return to the Main menu by pressing ESC The motor should be connected when performing these tests The following sec tions cover the functions available from the Diagnostic Mod
107. 03 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 304 10 11 12 13 14 15 16 17 18 19 20 Bulletin NO VDUCUOS U1 December 1996 install and tighten the large mounting screw to 164 Ib in 18 5 Nem Install and tighten the small screw to 40 7 Ib in 4 6 Nem Replace the resistor plate assembly into its mounting location on the front of the transformer contactor assembly Using a torque wrench with a drive socket install and tighten the five mounting screws to 35 4 Ib in 4 0 Nem see Figure 145 on page 297 Put the large PCC 1 cable through the wire tie in the back of the transformer contactor assembly Position the large PCC 1 cable over the mounting hole at the bottom of the contactor Using a torque wrench and hex key socket install and tighten the mounting bolt to 164 Ib in 18 5 Nem see Figure 144 on page 296 and Figure 145 on page 297 Align the R11 A and R8 A wire connectors over their mounting locations on the two resistors Using a torque wrench and flat blade screw driver socket install and tighten the two mounting screws to 8 9 Ib in 1 0 Nem see Figure 144 on page 296 and Figure 145 on page 297 NOTE Before performing step 12 make the following preparations Cut off two 3 4 inch pieces of electrical tape Place these pieces of tape where they will be easily accessible when installing the transformer contactor assembly Position the transformer contactor assembly
108. 05 O 1996 Square D All Rights Reserved Set auto manual to correct setting for Check external wiring and circuitry for damage Provide speed reference command for controller Check that Controlled Stop or Sequence Input in Bypass mode have been properly applied per Cnapter 3 Correcting tne Problem Cannot Start Motor Motor load preventing motor from spinning Wrong torque type or control setting is selected for application Check for Material jam Driven load damaged Check settings under menus 6 and 7 13 Material or load is preventing motor shaft from turning e Refer to VD0C06S305 to choose correct setting Refer to SC100 R5 95 for more information Clear jam Repair motor load 33 Cnapter 3 Correcting the Probiem Cannot Start Motor Cannot Start Motor continued 3 of 5 34 Possible cause Check to be performed Result Solution Control parameters incorrectly set Check settings for IR Compensation and Voltage Boost menu 1 Refer to VD0CO6S305 to choose correct settings Controller motor are incorrectly sized for expected load Peak current Peak torque Peak current required exceeds drive capability Peak torque required exceeds motor capability Apply controller and or motor which is correctly sized See SC100 R5 95 for more information O 1996 Square D All Rights Reserved Bulletin NO VDUCUO6S U
109. 1 December 1996 Damaged controller or motor Perform equipment damage check procedure in Controller Not Powered Up section in chapter 2 Motor controller or other equipment damage Perform equipment damage check procedures under Controller Not Powered Up section in chapter 2 Bulletin NO VDUCUOS UT Cnapter 3 Correcting tne Probiem December 1996 Cannot Start Motor continued 4 of 5 Controller current limit or motoring torque limit Possible settoo low cause Current limit setting Check menu 7 11 to be Motoring torque limit performed setting menu 7 11 Current limit set too low Current limit already set Motoring torque limit to maximum value Result set too low Motoring torque limit already set to maximum limit Increase current limit Load cannot be setting accelerated Solution Increase motoring torque See SC100 R5 95 for limit setting more information O 1996 Square D All Rights Reserved Cannot Start Motor Motor currents voltages are unbalanced Motor Controller Load side conductors overloads switchgear contactors etc Motor controller or other equipment damage Replace damaged components or equipment 35 Cnapter 3 Correcting tne Problem Cannot Start Motor Cannot Start Motor continued 5 of 5 36 Motor currents voltages Mechanical brake not are unstable released
110. 10N4 and C13N4 drive controllers Using a flat blade screw driver loosen the three top precharge contactor terminal screws Remove the terminal link and save for use on new precharge contactor Repeat this step for the removal of the bottom terminal link For ATV66C15N4 and C19N4 drive controllers Using a hex key wrench loosen and remove the three screws for the top terminal link Save the screws and terminal link for later use Repeat this step for the removal of the bottom terminal link 17 Using a flat blade screw driver lift and hold the auxiliary contact block release lever at the top of the auxiliary contact block While holding the release lever up slide the auxiliary contact block upwards and remove from the precharge contactor assembly Save contact block for use on new precharge contactor 18 Discard the old precharge contactor assembly This procedure explains how to install the precharge contactor in the following drive controllers Drive Controller No Precharge Contactor No ATV66C10N4 VY1 A661C1010 ATV66C13N4 ATV66C15N4 VY1 A661C1510 ATV66C19N4 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 The tools needed for this procedure are
111. 10N4 to C19N4 The tools needed for this procedure are 1 4 drive metric socket set 5 5 to 14 mm 4 Needle nose pliers With the drive controller door open or removed 1 Filter board assembly Measure the bus voltage if not already performed as described in chapter 5 of this manual Using a drive socket loosen and remove the two mounting nuts and lock washers located at the bottom of the filter board assembly see Figure 137 on page 281 The fan capacitor assembly is also secured with the same mounting nuts Using needle nose pliers carefully disconnect the nine connectors located at the top of the filter board assembly Pull the fan capacitor assembly out and then remove the old filter board assembly Install the filter board assembly and fan capacitor assembly on the two mounting posts see Figure 137 on page 281 Using needle nose pliers carefully connect the nine connectors located at the top to the new filter board assembly see Figure 138 on page 282 NOTE Once the wiring has been connected to the filter board an ohmmeter check should be made from points A to B B to C and C to A of Figure 138 on page 282 The ohmmeter should initially indicate a low resistance The resistance should gradually increase over a period of 5 10 seconds as the filter and bus capacitors within the controller charge Continuous low resistance is an indication of a mis wiring of the filter board and possible phase to phase short circu
112. 11 12 13 transformer in place see Figure 117 on page 231 Remove the old auto transformer Install the new auto transformer Using a phillips screw driver install and tighten the two screws Using needle nose pliers carefully connect the four wires to the auto transformer see Table 14 on page 231 Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the three screws for the bottom IP20 protection cover see Figure 104 on page 197 Install the J1 terminal block see Figure 104 on page 197 Install the right side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the right side panel in place see Figure 104 on page 197 Install the control basket as described in the procedure on page 193 1996 Square D All Rights Reserved 231 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66D54N4 to D79N4 December 1996 232 _ _ _ _ _ _ _ 1996 Square D All Rights Reserved Bulletin NO VDUCUOS UT December 1996 ATV66C 10N4 to C19N4 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 This section contains spare part information and change out procedures for the following drive controllers e ATV66C10N4 e ATV66C13N4 e ATV66C15N4 e ATV66C19N4 Table 15 lists the spare parts Refer to th
113. 2 see Figure 127 on page 249 This procedure explains how to install an individual snubber board in the following drive controllers Drive Controller No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Power Pole Kit No VZ3 IM1300M1206 VZ3 IM1400M1206 VZ3 IM1400M1206 VZ3 IM1500M1206 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage O 1996 Square D All Rights Reserved 249 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Torque wrench set to 17 7 Ib in 2 Nem e Metric hex key sockets for torque wrench 2 to 14 mm e 4 Needle nose pliers To install a snubber board 1 Align the mounting holes on the snubber board with the mounting posts in the drive controller 2 Install the two mounting screws Using the torque wrench with a hex key socket tighten the two mounting screws to 17 7 Ib in 2 Nem 3 Using needle nose
114. 20 protection cover NOTE If repairing the controller with field wiring in place the wiring knockout panel can be detached from the bottom panel in the next step Discharge resistor Discharge resistor mounting screw Figure 98 Discharge Resistor 5 10 11 12 13 14 15 16 Using a phillips or Torx screw driver loosen and remove the three screws which hold the bottom panel in place see Figure 83 on page 153 Remove the bottom panel Using a phillips screw driver loosen the one screw holding the discharge resistor in place see Figure 98 on page 184 Using needle nose pliers carefully disconnect the wires connected to the terminals of the discharge resistor Remove the old discharge resistor Install the new discharge resistor Using needle nose pliers carefully connect the wires to the discharge resistor Install the discharge resistor Using a phillips screw driver install and tighten the screw Install the bottom panel Using a phillips or Torx screw driver install and tighten the three screws for the bottom panel Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the three screws for the bottom IP20 protection cover Reconnect the J1 connector see Figure 82 on page 151 Install the right side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the right side panel in place Two screws are located at
115. 33N4 and ATV66D46N4 December 1996 Bus bar isolating screen terminal Figure 88 Bus Bar Isolating Screen 1 For a new power board loosen the J5 cable connector see Figure 81 on page 149 Insert the J5 cable with the silver leads facing towards the center of the drive controller Push the connector to the secure position 2 For a new power board install the six gate driver board standoffs that were removed from the old power board 3 Align the mounting holes on the power board to the studs and mounting posts on the drive controller 4 Usinga phillips screw driver install the four power board mounting screws Do not tighten until all of the screws are installed see Figure 87 on page 158 5 Usinga phillips screw driver install the nine screws which attach the power board to the three IGBT modules see Figure 87 on page 158 6 Usinga torque wrench with a phillips screw driver socket tighten the nine screws installed above to 17 7 Ib in 2 Nem 7 Usinga phillips screw driver tighten the four power board mounting screws 8 Route the two red fan leads soldered at J6 1 and J6 2 on the power board under the terminal block to the fan Using needle nose pliers carefully connect the two fan leads This is an AC fan The two red leads can be connected to either terminal 9 Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the three screws which hold the bottom IP20 protectio
116. 4 Installing the Precharge Contactor 302 Bulletin NO VDUCUOS U1 December 1996 9 Using a drive socket loosen and remove the five resistor mounting plate screws Lift the resistor plate assembly out and swing over to the left to expose the precharge contactor see Figure 145 on page 297 10 Using a hex key wrench loosen and remove the three screws holding the PCC 2 cables at the top of the precharge contactor Pull the PCC 2 cables back out of the way see Figure 146 on page 300 11 Using a flat blade screw driver loosen the A1 and A2 coil module terminal screws Pull the two PCC A1 cables and one PCC A2 cable out of the terminals see Figure 144 on page 296 12 For ATV66C10N4 and C13N4 drive controllers Pull on locking pull tab at bottom of precharge contactor and lift contactor away from the mounting rail For ATV66C15N4 and C19N4 drive controllers Using an open ended metric wrench loosen and remove the four contactor mounting nuts Slide the contactor assembly forward off of the mounting screws 13 Remove the precharge contactor assembly through the bottom of the transformer contactor mounting plate 14 Using a hex key wrench loosen and remove the screw holding the small PCC cable at the bottom of the precharge contactor see Figure 146 on page 300 Save the cable for later use 15 Using a flat blade screw driver remove AUX 52 and AUX 82 control wires from the auxiliary contact block 16 For ATV66C
117. 4 ATV66C19N4 VX5 A66C19N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 4 Needle nose pliers e Control basket procedure tool list page 238 With the drive controller door open or removed 1 Remove the control basket as described in the procedure on page 237 However do not remove the keypad 2 Using a flat blade screw driver loosen the two screws holding the hinged assembly in place Swing the hinged assem
118. 4 Install the BR1 cable and the screw at the C2E1 terminal on the braking IGBT module Using a torque wrench and phillips screw driver socket tighten the screw to 17 7 lb in 2 Nem 5 Position the bus bar and align the mounting holes NOTE When executing steps 6 through 9 perform the following checks Ensure the red C cable from the contactor is connected to the terminal of the top capacitor Ensure the black C cable is connected to the terminal of the third capacitor down from the top Ensure the BR3 cable is connected to the C1 terminal of the braking IGBT module Ensure the U V and W cables are connected to the C2E1 terminals of their respective IGBT modules as labeled on the bus Do not tighten any one screw or mounting pin until all of the hex head screws phillips head screws and mounting pins are started with all required cables connected 6 Using a hex key wrench install the eight bus capacitor hex head screws with the balancing resistors see Figure 89 on page 162 7 Using a drive socket or open end wrench install the six mounting pins with two washers which connect the bus bar to the IGBT modules see Figure 89 on page 162 8 Usinga phillips screw driver install the two screws which attach the braking IGBT module to the bus bar see Figure 89 on page 162 9 Using a drive socket or open end wrench install the three mounting pins with one washer which connect the U V and W cables to the IGBT modules
119. 4 ATV66D64N4 ATV66C19N4 ATV66D23N4 ATV66D79N4 ATV66D33N4 ATV66C10N4 ATV66D46N4 ATV66C13N4 ATV66D54N4 ATV66C15N4 Figure 27 Output Phase Loss O 1996 Square D All Rights Reserve 59 Cnapter 3 Correcting tne Problem Sequence Time Out Sequence Time Out Process Time Out Serial Link Fault 60 Bulletin NO VDUCUOS U1 December 1996 The sequence time out fault is only available if the bypass application function is configured It is triggered e If the auxiliary contact on the drive controller output contactor is closed before a run command is issued or is not closed before the end of the time delay This also prevents the drive controller from applying power to the motor e If the contactor opens while the motor is operating In the event of a fault check the sequencing circuitry and operation of the output contactor The process time out fault is associated with the bypass application function and is only available if the process function is configured The fault is triggered if after the process time out the assigned LI has not changed to 1 Serial link faults occur with the serial communication card option when information exchange is not occurring at periodic intervals between the drive controller and the master device i e PLC Serial link faults can occur due to damaged communication cable improperly configured communication options incorrect control programs in the PLC or excessive electrical noise
120. 4 and ATV66D12N4 December 1996 Removing the Fan This procedure explains how to remove the fan from the following drive controllers Drive Controller No Fan No ATV66U90N4 VZ3 V663 ATV66D12N4 VZ3 V663 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 1 4 drive metric socket set 5 5 to 14 mm e 4 Needle nose pliers e Wire cutters e Control basket procedure tool list page 101 With the drive controller do
121. 4 drive controllers The power pole kit contains two IGBT modules NOTE Replace the IGBT modules in horizontal pairs see Figure 129 on page 255 IGBT 1and IGBT 4 IGBT 6 and IGBT 3 IGBT 5 and IGBT 2 This procedure explains how to remove an individual IGBT module from the following drive controllers Drive Controller No Power Pole Kit No ATV66C10N4 VZ3 IM1300M1206 ATV66C13N4 VZ3 IM1400M1206 ATV66C15N4 VZ3 IM1400M1206 ATV66C19N4 VZ3 IM1500M1206 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved c 253 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter setto 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller compon
122. 45 on page 297 Circuit Protector TB3 terminal block Resistor Mounting Plate Screw Resistor Mounting Plate Screw Transformer Contactor assembly mounting Screws Transformer Contactor assembly mounting Screws R11 TOP R10 BOT Resistor Mounting Plate Screws R11 A Wire Resistor Mounting Plate Screw Transformer Contactor assembly mounting Screws Transformer Contactor assembly mounting screws R8 AW BA Wire Large PCC 1 Cable Figure 145 Transformer Contactor Assembly Front View 3 Using a hex key wrench loosen the two precharge resistor mounting screws see Figure 145 on page 297 Remove the two precharge resistors still stacked together Record the arrangement of washers and use this as a guide when assembling the new precharge resistor assembly 4 Stackthe two new precharge resistors in the arrangement noted from step 2 5 Place the new precharge resistor assembly in the drive controller with the white laminated insulating paper behind the assembly Orient assembly with wire connection screws on right 1996 Square D All Rights Reserved 297 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Replacing the Contactor Auxiliary Contact Block 298 Bulletin NO VDUCUOS U1 December 1996 NOTE Be careful not to scratch white laminated insulating paper when installing
123. 6 Square D All Rights Reserve 53 Cnapter 3 Correcting tne Problem Motor Overload 54 Bulletin NO VDUCUO6S U1 December 1996 Figure 22 illustrates the troubleshooting procedure when the motor overload fault is present Fault Displayed Possible cause Check to be performed Result Solution Figure 22 Motor Overload MOTOR OVERLOAD Motor thermal state gt 118 Motor current Motor load status Operating cycle Thermal state while tripped Motor RMS current during operating cycle exceeds motor FLC Motor thermal capability envelope not coordinated with overload function Motor is overloaded for application Reduce motor load or use larger drive Refer to SC100 R5 95 for application considerations Adjust motor overload thermal envelope to coordinate with motor capability O 1996 Square D All Rights Reserved Motor RMS current does not exceed motor FLC Motor thermal capability envelope correctly coordinated with overload function Motor thermal state does not gradually decay with controller in standby tripped mode Refer to chapter 4 to change Power board T1 T3 current sensor Control basket Connections Bulletin NO VDUCUOS UT Cnapter 3 Correcting the Probiem December 1996 Drive Overtemperature Drive Overtemperature
124. 64N4 ATV66D79N4 ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Figure 20 Input Phase Loss Measurement The measurement diagram is the same as that for detection of line overvoltage After rectifying the 3 phases the mean value is used for detection If all 3 phases are missing a fault is triggered if the line voltage is less than 50 V peak If 1 phase is missing the value of the ripple rate is measured In all cases the presence of the fault is checked for 1 second before the input phase loss fault is triggered This circuit will also respond to input line voltage unbalance Voltage unbalance greater than 18 20 will trigger an input phase loss Voltage unbalance is defined in NEMA ICS 7 Input Phase Loss is a self clearing fault If the cause of the fault is corrected i e the missing phase is restored to an acceptable level internal logic will clear the fault and unlatch the drive controller The drive controller will then be ready to start 1996 Square D All Rights Reserved 51 Cnapter 3 Correcting tne Probiem Bulletin NO VDUCU6S UT Input Phase Loss December 1996 Figure 21 illustrates the troubleshooting procedure when the input phase loss fault is present INPUT PHASE LOSS Fault Displayed Internal drive controller fault Loss of input line phase Transient fault on 1
125. 68 connector are not present Mounting screw Mounting screw IGBT module mounting Screw locations Figure 87 Power Board Connections 4 Using a flat blade screw driver carefully disconnect J42A J42B J43 at the termination points located on the power board see Figure 87 on page 158 5 Disconnect the J1 connector This will allow the bottom IP20 protection cover to be removed see Figure 82 on page 151 6 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place see Figure 83 on page 153 Remove the bottom IP20 protection cover This allows access to the fan leads 7 Using needle nose pliers carefully disconnect the two fan leads located at the terminals on the fan These two wires are soldered at J6 1 and J6_2 on the power board Pull the fan leads out from under the terminal block 8 Using a phillips screw driver loosen and remove the nine screws which attach the power board to the three IGBT modules see Figure 87 on page 158 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Power Board Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 9 Usinga phillips screw driver loosen and remove the four mounting screws for the power board see Figure 87 on page 158 10 If the power board is to be replaced loosen the J5 cable connector and remove the J5 cable see Figure 81 on page 149 This cabl
126. 7 Discharge Resistor 2 required ATV66D54N4 to D79N4 VZ3 R5KOW040 Pages 227 229 Auto Transformer ATV66D54N4 to D79N4 1996 Square D All Rights Reserved VY1 ADA604 Pages 230 231 189 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 Replacing the Keypad Display 190 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to replace the keypad display for the following drive controllers Drive Controller No Control Kit No ATV66D54N4 ATV66D64N4 VX4 A66CK1 ATV66D79N4 NOTE All ALTIVAR 66 drive controllers use the same model keypad display However the version of software present within the keypad display may be specific to the version of software present in the control basket Mixing incompatible versions of keypad display and control basket software can result in non recognition of the keypad display by the drive controller or garbled message displays Therefore keypad displays are not supplied as separate kitted items Keypad displays are supplied with control kits Keep keypads with their associated control basket Do not mix keypads and control baskets The keypad display is mounted on the control basket for drive controllers ATV66D54N4 through ATV66D79N4 see Figure 103 on page 195 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure T
127. 9 removing 247 software revision level checking 317 spare parts list 86 99 145 189 233 111 speed drive not following speed command 41 standards 6 314 static sensitive components 4 status codes 14 stirring fan inspection 315 replacing 291 stored energy 71 311 supply input line 313 T terminals CL1 CL2 78 PA 311 thermal switch replacing 277 tool list Removing the Bus Capacitors 168 Replacing the Thermal Switches 278 tools and instruments 5 86 troubleshooting instructions 8 V validation 10 12 after repair 314 voltage bus capacitor 310 Numerics 10 VDC power supply 79 24 VDC power supply 79 O 1995 Square D All Rights Reserved GROUPE SCHNEIDER M Merlin Gerin MW SquareD BM Telemecanique VD0CO06S701 December 1996 Printed in USA 10M FP 10 96 O 1996 SquareD All Rights Rese rved
128. ATV66C10N4 to C19N4 DB snubber board gt DB bus bar bracket B t Figure 134 Top View of Dynamic Braking Module NOTE Maintain a 3 8 9 5 mm space between non insulated connectors on terminals Q7 C Q7 E DM4 1 and DM4 2 a M ES Hp DB bus bar oo NE pa bracket Standoffs ae CU EL in TER DB snubber board DB diode block DB diode block PEE ii Ed connector Figure 135 Side View of Dynamic Braking Module O 1996 Square D All Rights Reserved 275 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Installing the Dynamic Braking DB Diode Block 276 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to install the dynamic braking diode block in the following drive controllers Drive Controller No DB Block Kit No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the VZ3 IM1300M1207 electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equ
129. AUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Torque wrench set to 17 7 Ib in 2 0 Nem e Metric drive sockets for torque wrench e Metric hex key set 2 to 14 mm e Metric hex key sockets for torque wrench 2 to 14 mm e Gate driver board procedure tool list page 200 e Control basket procedure tool list page 193 1996 Square D All Rights Reserved 203 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66D54N4 to D79N4 December 1996 For the power board to be installed NOTE Make sure the bus bar isolating screen is in place between the bus bar and the power board 1 Ifa new power board is to be installed loosen the J5 cable connector see Figure 102 on page 193 Insert the J5 cable with the silver leads facing towards the center of the drive controller Push the connector to the secure position 2
130. B power cables and connection bolts on the capacitor bus bars see Figure 139 on page 283 Using a torque wrench and a hex key socket tighten the bolts to 164 Ib in 18 5 Nem 20 Install the bus connector bolt see Figure 139 on page 283 Using a torque wrench and hex key socket tighten the bolt to 164 Ib in 18 5 Nem 21 Install the bus capacitor fuse and two screws see Figure 139 on page 283 Using a torque wrench and a hex key socket tighten the two screws to 323 lb in 36 5 Nem 22 Install the plexiglass shield Using a drive socket install and tighten the two screws which hold it in place see Figure 139 on page 283 This procedure explains how to remove the control power transformer from the following drive controllers Drive Controller No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Transformer Assembly No VY1 ADA606 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 1 4 drive metric socket set 5 5 to 14 mm e Set of magnetized flat blade screw drivers e Metric hex key set 2 to
131. C 2 Cables N o B O dice dc O Precharge Contactor PCC 2 o PCC 7 Aux Contact Block Small PCC 1 Cable ee 9 O O o O Drive Controllers ATV66C15N4 and C19N4 Figure 146 Transformer Contactor Assembly Inside View 30 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Precharge Contactor Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 This procedure explains how to replace the precharge contactor for the following drive controllers Drive Controller No Precharge Contactor No ATV66C10N4 VY1 A661C1010 ATV66C13N4 ATV66C15N4 VY1 A661C1510 ATV66C19N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Set of magnetized flat blade screw drivers e Metric hex key set 2 to 14mm e Set of open box end wrenches 5 5 to 19 mm e 1 4 drive metric socket set 5 5 to 14 mm e 12 1 4 drive socket extension With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of thi
132. C19N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Torque wrench set to 17 7 Ib in 2 0 Nem e Metric hex key set 2 to 14 mm e 4 Needle nose pliers e Plastic tie wraps 8 length e Control basket procedure tool list page 240 To install the power board 1 Ifanew power board is being installed install the cables removed from the old power board at the J3 J4 J5 J9 and J18 jacks on the new power board see Figure 125 on page 245 Ensure that the silver leads of the cables are facing outwards from the controller and are seated firmly against the bottom of the cable jacks Refer to Figure 122 on page 239 for cable installation NOTE J3 is a seven wire cable J4 is a six wire cable and J5 is an 18 wire cable 2 Place the power board down into the hinged assembly and align the mounting holes with the seven fixing pins Snap the board onto the fixing pins 3 Usinga torque wrench and a hex key attachment tighten th
133. Configuration VDOCO6T306 latest revision e ALTIVAR 66 AC Drives Catalog VD0C065201_ latest revision Dynamic Braking Resistor Kit VDOCO6N908_ latest revision e Application Guide SC100 R5 95 e Communication Carrier Module VDOCO6N915_ latest revision e PCMCIA Memory Card VD0CO6T919 latest revision e Gasket Kit for Recess Mounting VDOCO6T918 latest revision e Mounting Adapter Plate Kit VDOCO6N922_ latest revision 1996 Square D All Rights Reserve MMMM 5 Cnapter 1 1ntroduction Documentation List Bulletin NO VDUCUOS U1 December 1996 Keypad Door Mounting Kit VDOCO6N904_ latest revision Additional documentation is provided with the optional peripherals STANDARDS The following standards are referenced NFPA 70B Electrical Equipment Maintenance 1990 Edition NFPA 70E Electrical Safety Requirements for Employee Workplaces 1988 Edition NEMA ICS 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control 1990 Edition NEMA ICS 1 3 Preventive Maintenance of Industrial Control and Systems Equipment 1992 Edition NEMA ICS 2 1993 Annex A Maintenance of Motor Controllers After a Fault Condition NEMA ICS 7 Adjustable Speed Drives NEMA ICS 7 1 Safety Standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems OSHA 29 CFR Part 1910 Electrical Safety Related Work Practices REVISION LEVEL This is a
134. D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Loss of Follower Cnapter 3 Uorrecting tne Problem Loss of Follower The loss of follower fault is triggered if the reference current to Al2 is less than 2 8 mA There is an automatic reset if the current increases to 3 2 mA This is valid if Al2 is configured as 4 20 mA or 20 4 mA Figure 25 details the troubleshooting procedure when the loss of follower fault is present Fault Displayed Possible cause Check to be performed Result Solution Figure 25 Loss Follower O 1996 Square D All Rights Reserved LOSS OF FOLLOWER Faulty 4 20 mA signal at Al2 Check value of Al2 signal present in l O Map menu 2 Value below trip level Value above trip level Refer to chapter 4 to Check the wiring and g change the control basket sequence 57 Cnapter 3 uorrecting tne Problem Bulletin NO VDUCU6GS U1 Output Phase Loss December 1996 Output Phase Loss Figure 26 shows the measurement principle used for the output phase loss fault I i C U V W Power board l ATV66U41N4 ATV66U54N4 l ATV66U72N4 i ATV66U90N4 I I ATV66D12N4 Gate driver board ATV66D16N4 ATV66D64N4 ATV66C19N4 ATV66D23N4 ATV66D79N4 ATV66D33N4 ATV66C10N4 ATV66D46N4 ATV66C13N4 ATV66D54N4 ATV66C15N4 Figure 26 Output Phase Loss Measurement The motor phase current is measured by the T1 T3 sensors The curren
135. D64N4 VZ3 V6654 ATV66D79N4 NOTE Older versions of the ATV66D54N4 to D79N4 drive controllers do not contain a board fan A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of Torx screw drivers e 4 Needle nose pliers e Control basket procedure tool list page 193 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 191 2 Using a phillips or
136. DOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm e Set of open end wrenches 5 5 to 19 mm e Power board procedure tool list page 158 Gate driver procedure tool list page 154 e Control basket procedure tool list page 147 1996 Square D All Rights Reserved c 1611 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D33N4 and ATV66D46N4 December 1996 With the drive controller door remove
137. DUCUOS UT ATV66U90N4 and ATV66D12N4 December 1996 connectors Ensure the silver leads of the cables are facing outwards from the controller 7 Push the three ribbon cable connectors to their secure position 8 Apply multi lingual hazard labels supplied with kit to control basket as required 9 Reinstall option module if previously present See User s Manual VDOCO061306 for removal installation instructions 10 Install the controller top cover Tighten the two screws using a phillips screw driver 11 Install the keypad display as described in the procedure on page 100 12 Reprogram the user settings as previously noted during the control basket removal Replacing Control Terminal This procedure explains how to replace the control terminal blocks for the Blocks following drive controllers Drive Controller No Control Terminal Block Kit No ATV66U90N4 VZ3 N006 ATV66D12N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if installed connectors Verify that all power has been removed from J1 J12 and J13 connectors If I O Extension Module is installed verify that all power is r
138. December 1996 ALTIVAR 66 Service and Troubleshooting Manual List of Figures amp Tables LIST OF FIGURES Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 Typical Causes and Severity of Faults o oooooooooooo 8 LED Indications 5 2 ee pate ARIA ERR M RE 13 Display Screen Status Code Location liliis isle 14 l O Map i ore See ev ime ein ipa v VIR erus 15 Faults ISO Y anios ei oce quio c E ed 16 Poor Speed Stability lille 20 Excessive Motor Temperature esee 22 Motor Accelerates Too Slowly 0 000 eese 25 Motor Decelerates Slowly Not at All Overspeeds Overspeed Trip 28 Cannot Start Motor ococcccccococ eee 32 Cannot Stop Motor 0 0 eh 37 Motor Turns in Wrong Direction 0 0 0 0 eee eee 40 Specific Drive Function Does Not Work as Expected Not at All 41 Undervoltage Measurement lslllls elles elles 43 Undervoltage elec em RR RR REPE 44 Lin
139. December 1996 PRECAUTIONS This chapter contains basic procedures that are referenced throughout this manual Read the safety statement below before proceeding with any maintenance or troubleshooting procedures A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury PROCEDURE 1 BUS VOLTAGE A DANGER MEASUREMENT HAZARDOUS VOLTAGE This product contains energy storage devices Read and understand this procedure before continuing Measurement of DC bus capacitor voltage must be performed by qualified personnel DC bus LED is not an accurate indication of absence of DC bus voltage DO NOT short across capacitors or touch unshielded components or terminal strip screw connections with voltage present Many parts in this drive controller including printed wiring boards operate at line voltage DO NOT TOUCH Use only electrically insulated tools Failure to follow these instructions will cause shock or burn resulting in death or serious injury The PA and terminals are located inside the drive controller see Figure 147 on page 311 To measure the bus capacitor voltage 1 Disconnect and verify all power is removed from drive controller 2 Wait one minute to allow the DC bus to discharge 3 Open the front cover of the drive controller 4 S
140. Does Not Perform as Expected Operating Condition Poor speed stability Troubleshooting Procedure Chapter 3 page 20 Excessive motor temperature Chapter 3 page 22 Motor accelerates too slowly Chapter 3 page 25 Motor decelerates too slowly Motor does not decelerate Motor overspeeds overspeed trip Chapter 3 page 28 Motor will not start Chapter 3 page 32 Motor will not stop Chapter 3 page 37 Motor turning turns in wrong direction Chapter 3 page 40 The drive controller does not follow the speed command Chapter 3 page 41 A specific drive function does not work as expected or at all O 1996 Square D All Rights Reserved Chapter 3 page 41 Bulletin NO VDUCUOS U1 October 1997 Cnapter 2 1nvestigating the Problem fault analysis categories Table 4 Trips Resettable by Keypad Ll Automatic Power Cycle Fault Designation on Keypad Display UNDERVOLTAGE Troubleshooting Procedure Chapter 3 page 43 AC LIN OVERVOL Chapter 3 page 45 DC BUS OVERVOL Chapter 3 page 47 IN PHASE LOSS Chapter 3 page 51 MOT OVERLOAD Chapter 3 page 53 DRIVE OVERTEMP Chapter 3 page 55 LOSS FOLLOWER Chapter 3 page 57 OUT PHASE LOSS Chapter 3 page 58 SEQUENCE T OUT Chapter 3 page 58 PROCESS T OUT Chapter 3 page 58 SERIAL LINK FAULT Chapter 3 page 60 Table 5 Trips Requires Power
141. E Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury QQ M 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66U41N4 to ATV66U72N4 A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 1 4 drive metric socket set 5 5 to 14 mm e 4 Needle nose pliers Wire cutters e Control Basket procedure tool list page 88 With the drive controller door open or removed 1 Remove the control basket as described
142. Figure 104 on page 197 This will allow the bottom IP20 protection cover to be removed 5 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place see Figure 104 on page 197 Remove the bottom IP20 protection cover This allows access to the main fan leads 6 Using needle nose pliers carefully disconnect the two main fan leads at the fan see Figure 114 on page 224 7 Using a drive socket loosen and remove the nine nuts which attach the power board to the three IGBT modules see Figure 107 on page 202 8 Using a phillips screw driver and a hex key wrench loosen and remove the three mounting screws for the power board see Figure 107 on page 202 9 Remove the power board Slide the main fan leads out as the power board is being removed 10 Ifthe power board is to be replaced loosen the J5 cable connector and remove the J5 cable see Figure 102 on page 193 This cable will be needed during the installation of the new power board Additionally remove the gate driver board standoffs for use during installation of the new power board NOTE Be sure the J5 ribbon cable has been released before pulling to avoid damage to the cable Installing the Power Board This procedure explains how to install the power board in the following drive controllers Drive Controller No Power Board No ATV66D54N4 VX5 A66D54N4 ATV66D64N4 VX5 A66D64N4 ATV66D79N4 VX5 A66D79N4 A C
143. Figure 23 illustrates the measurement principle used for the drive overtempera ture fault po PA a a I I I I Probe J16 TE Js I I I I l I I i Power board Control basket l For drive controllers ATV66D16N4 ATV66D64N4 ATV66C19N4 ATV66D23N4 ATV66D79N4 ATV66D33N4 ATV66C10N4 ATV66D46N4 ATV66C13N4 ATV66D54N4 ATV66C15N4 Figure 23 Drive Overtemperature Measurement There is no temperature probe on the ATV66U41N4 through ATV66D12N4 drive controllers For these sizes overtemperature information is provided by the Intel ligent Power Module IPM If the temperature of the module is greater than 111 C the drive overtemperature fault is triggered For drive controllers ATV66D16N4 through ATV66C19N4 a probe is fixed to the heatsink If the drive thermal state reaches 100 there is a thermal early warning and the yellow LED blinks If after 1 minute the drive thermal state has not dropped to 89 the drive overtemperature fault is triggered The drive thermal state can be displayed on the keypad display at the DRIVE THERMAL STATE line The following are the triggering thresholds for the ATV66D16N4 through ATV66C19N4 drive controllers e ATV66D16N4 ATV66D23N4 heatsink temperature is greater than 100 C e ATV66D33N4 ATV66D46N4 heatsink temperature is greater than 90 C e ATV66D54N4 ATV66D64N4 ATV66D79N4 heatsink temperature is greater than 110 C e ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 heatsink te
144. Figure 44 for the Module Freewheel Diode resistance values shown Use a multimeter as recommended in LIST OF TOOLS AND INSTRUMENTS on page 5 Set the meter on the diode scale Refer to Figure 36 on page 71 for the relationship between the PA and PB terminals NOTE It is necessary to disconnect the dynamic brake resistor to perform this check Figure 44 Checking the Braking IGBT Module Freewheel Diode 75 1996 Square D All Rights Reserved Bulletin NO VDUCU6S UT Cnapter 3 Correcting tne Propiem December 1996 Checking the Power Part of the Controller Checkout of the Control Part of the Drive Controller A DANGER HAZARDOUS VOLTAGE The remaining tests in this section are performed with power present in controller Read and understand these procedures before servicing ALTIVAR 66 drive controllers Installation adjustment repair and maintenance of these drive controllers must be performed by qualified personnel Review WORK PRACTICE PRECAUTIONS on page 3 of this manual before proceeding Before proceeding any devices components or wiring removed or disconnected must be reassembled per the procedures found in chapter 4 Before restoring power all shields and covers must be in place Always attach test equipment to circuits prior to applying power to controller Remove test equipment from circuits only after removing power from controller and following PROCEDURE 1 BUS V
145. Figure 90 Drive Controller with Bus Bar Removed Installing the IGBT Module There are three IGBT modules in this size of drive controller This procedure explains how to install the IGBT module in the following drive controllers Drive Controller No IGBT Module No ATV66D33N4 VZ3 IM2100M1201 ATV66D46N4 VZ3 IM2150M1201 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 1 4 drive metric socket set 5 5 to 14 mm e Metric hex key set 2 to 14 mm Torque wrench set to 26 5 lb in 3 Nem e Metric hex key sockets for torque wrench 2 to 14 mm e Set of open end wrenches 5 5 to 19 mm e Thermal grease Thermalloy Thermalcote II Part No 349 or equivalent e Power board procedure tool list page 159 Gate driver procedure tool list page 156 e Control basket procedure tool list page 149 1996 Square D All Rights Reserved c 163 Cnapter 4 rquipment Cnange Out ATV66D33N4 and ATV66D46N4 Bulletin NO VDUCU
146. H1 and T1 H2 connections on the control power transformer see Figure 143 on page 289 8 Using a drive socket loosen and remove the four transformer mounting nuts and washers Remove the transformer see Figure 143 on page 289 23 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Control Power Transformer Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Transformer mounting nuts and washers 2 Terminals X1 X2 X3 Transformer Terminals H1 H2 Transformer mounting nuts and washers 2 Figure 143 Transformer Contactor Assembly Side View This procedure explains how to install the control power transformer in the following drive controllers Drive Controller No Control Power Transformer No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 VY1 ADA606 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 1 4 drive metric socket set 5 5 to 14 mm e Aset of magnetized flat blade screw drivers Torque wrench set to164 Ib in 18 5 Nem Electrical tape e Metric hex key sockets for torque wrench 2 to 14 mm e 12 1 4 drive socket extension e Metric drive sockets for torque wrench To install the
147. IS RB cable p DCB power cable Precharge resistor lel 9 plate mounting lo screws lo Precharge assembly o gt le Precharge resistor plate mounting screws Figure 139 Capacitor Assembly Mounting Diagram Front View 1996 Square D All Rights Reserved 283 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 284 8 9 10 11 12 13 14 15 16 Bulletin NO VDUCUOS U1 December 1996 Remove the capacitor bus bar and laminated insulating sheet Using a hex key wrench loosen and remove the bus mounting bolt see Figure 139 on page 283 Remove the capacitor bus bar Using a hex key wrench loosen and remove the three screws holding the two capacitor jumpers which connect the center posts of the three capacitor assemblies Remove the two jumpers see Figure 139 on page 283 Using a drive socket loosen and remove the two capacitor assembly screws holding the carriage of the capacitor assembly see Figure 140 on page 285 Remove the capacitor assembly NOTE To remove the bottom capacitor assembly it is necessary to pull the circuit protector the precharge resistor plate and the RB and RB cables out of the way see Figure 139 on page 283 To loosen the circuit protector follow the procedure on page 305 but do not remo
148. ITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Control basket procedure tool list page 90 Torque wrench set to 17 4 Ib in 1 96 Nem Flat blade screw driver sockets for torque wrench With the drive controller door removed 1 Remove the control basket as described in the procedure on page 88 2 Remove the IP20 protective cover See Figure 49 on page 92 3 Using a phillips screw driver loosen and remove the two screws holding the controller top cover in place Remove the top cover 4 Usingaphillips screw driver loosen and remove the three screws holding the controller bottom cover in place Remove the bottom cover 5 Disconnect the J1 connector at the bottom of the power board See Figure 49 on page 92 6 Identify and tag all field wiring for future re assembly 7 Disconnect the field wiring on the J2 connector at the bottom of the power board See Figure 50 on page 94 1996 Square D All Rights Reserved
149. Ib in 2 Nem 4 Align the Q7 C jumper over the DM4 1 mounting hole of the diode block Using a torque wrench and a metric drive socket install and tighten the two standoffs in the DM4 1 and DM4 3 mounting holes of the diode module to 17 7 lb in 2 Nem 5 Align the dynamic braking bus bar bracket over the left standoff Using a torque wrench and a hex key socket install and tighten the bus bar bracket screw to 17 7 lb in 2 Nem O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66C10N4 to C19N4 6 Align the mounting hole for the current sensor mounting bracket with the mounting hole inside the controller Using a hex key wrench install and tighten the mounting screw 7 Install the T2 power cable at the back of the T2 terminal block and install the mounting screw Using the torque wrench and a hex key socket tighten the screw to 164 Ib in 18 5 Nem 8 Using needle nose pliers carefully reconnect the 12 sensing wire see Figure 131 on page 262 9 Install the dynamic braking snubber board as described in the procedure on page 267 Replacing the Thermal There are two thermal switches located on the heat sink see Figure 136 on page Switches 279 One is located behind the DB gate driver snubber board another behind the GD 4 gate driver board The thermal switch kit contains one switch This procedure explains how to replace the thermal switches for the following d
150. Install the L bar that goes from the back of the T1 terminal block to the left current sensor Using the torque wrench and a hex key socket tighten the screw at the back of the T1 terminal block to 164 Ib in 18 5 Nem 6 Using needle nose pliers carefully reconnect the 13 sensing wire see Figure 131 on page 262 7 Reinstall the left current sensor using the following procedure To install the left current sensor NOTE Do not alter the factory set current sensor adjustment settings 1 Ifalso installing the right current sensor install it first with the above procedure 2 Gently pull the left current sensor signal cable labeled CT1 out from the drive just enough to attach it to the socket on current sensor using a needle nose pliers pull on the wires not the connector 3 Install the current sensor into the drive positioning the bottom mounting hole of the sensor over the fixed screw in the mounting bracket and aligning the top mount hole of the sensor over the top screw hole in the mounting bracket With a phillips screw driver reinstall and tighten the mounting screw 4 Install the copper center cylinder into the center of the current sensor 5 While holding the T1 power cable and current sensor connector in place beside the left current sensor install the center cylinder screw see Figure 131 on page 262 Using the torque wrench and hex key socket tighten the center cylinder screw to 164 Ib in 18 5 Nem 6 Using need
151. Instruction Bulletin VDO0CO06S701 December 1996 Price 120 00 AIAR 66 Adjustable Frequency Drive Controllers for Asynchronous Motors Service and Troubleshooting Manual 1 to 200 hp 460 V Note This manual does not cover e 230V Drives 250 400 Hp Drives ATV56 Drives 8 telemecania ue D SQUARE D A DANGER HAZARDOUS VOLTAGE This product contains energy storage devices Read and understand this bulletin as well as bulletins supplied with your specific equipment before maintaining or servicing the ALTIVAR 66 Drive controller Installation adjustment service and maintenance of these drive controllers must be performed by qualified personnel Confirm that drive controller has been correctly selected installed and applied before performing any service or maintenance Verify that all drive controller overcurrent protective devices conductors enclosures and other circuit elements have been correctly selected for application and that drive controller is properly grounded in accordance with equipment instruction bulletin recommendations and applicable code requirements Some measurements must be done with power applied to equipment Many parts in this drive controller including printed circuit boards operate at line voltage DO NOT TOUCH Use personal protective equipment and follow precautions and measurement procedures referenced in this bulletin when making any measurements on energized equipment Use instr
152. K PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Torque wrench set to 17 7 Ib in 2 Nem e Flat blade screw driver sockets for torque wrench e 4 Needle nose pliers e Control basket procedure tool list page 115 For the fan to be installed 1 With the drive controller chassis inverted pass the J6 connector and leads on the new fan through the hole in the chassis of the drive controller Push the fan leads plug securely into the hole 2 Install the fan Using a torque wrench and a phillips screw driver socket tighten the two mounting screws to 6 2 lb in 0 7 Nem 3 Turn the drive controller over and route the fan leads to the power board Using needle nose pliers carefully connect the J6 connector on the power board 140 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D16N4 and ATV66D23N4 4 Fit up the drive controller chassis to the back cover Using a phillips screw driver install and tighten the four corner screws 5 Install the bottom cover Using a phillips screw driver install and tighten the four screws which hold the bottom cover in place 6 Install the top cover Using a phillips screw driver install and tighten the two screws which hold the top
153. Load side conductors overloads switchgear contactors etc Motor controller or other Controller improperly equipment damage tuned Refer to Checking Peripheral Equipment in chapter 5 Review VDOCO6S305 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Bulletin NO VDUCUOS U1 December 1996 Motor Accelerates Too Slowly Cnapter 3 Correcting tne Propiem Motor Accelerates Too Slowly Figure 8 illustrates the troubleshooting procedure if the motor is accelerating too slowly Operating Condition Possible cause Check to be performed Result Solution Figure 8 MOTOR ACCELERATES TOO SLOWLY Wrong torque type or control type is selected for the application Controller being commanded to accelerate as observed Speed reference command Ramp type selected menu 7 12 Ramp selected menu 7 12 Check settings under menu 6 and menu 7 13 Ramp rates of speed reference signal sent to controller incorrect Wrong ramp type selected Wrong ramp selected e Modify speed reference Refer to VD0C06S305 ramp to choose correct settings Change ramp type Refer to SC100 R5 95 menu 7 12 for more information Select correct ramp menu 7 12 Motor Accelerates Too Slowly O 1996 Square D All Rights Reserved Controller acceleration ramps incorrectly set Modify acceleration set
154. NGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if installed connectors Verify that all power has been removed from J1 J12 and J13 connectors If I O Extension Module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury 15 0 lt a AA 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are A set of magnetized flat blade screw drivers With the drive controller door removed 1 Measure the bus voltage if not already performed as described in Chapter 5 of this manual Remove options module if present See User s Manual VDOCO06T306 for removal installation instructions Identify all field wiring for future re assembly Using a flat blade screw driver loosen the terminal screws on the J1 J12 and J13 connectors see Figure 82 on page 151 Pull the field wiring back out of the way Using a flat blade screw driver gently pry the J1 J12 and J13 terminal blocks away from the board side connecto
155. NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66U90N4 and ATV66D12N4 Disconnect the field wiring on the J2 connector at the bottom of the power board See Figure 57 on page 107 Disconnect the J3 J4 and J5 cables at the connectors located on the power board see Figure 57 on page 107 See Figure 55 on page 102 for connector construction Figure 57 Power Board Connector Locations 9 10 11 12 13 14 15 16 Discard the old power board and chassis Install the controller bottom cover Using a phillips screw driver install and tighten the four screws holding the bottom cover in place Install the controller top cover Using a phillips screw driver install and tighten the two screws holding the top cover in place Install the IP20 protection cover saved from step 2 above On the new power board and chassis connect J1 at the bottom of the power board See Figure 56 on page 105 Using torque wrench and a flat blade screw driver socket install and tighten the field wiring at the termination points on connector J2 See Receiving and Installation Manual VDOCO065304 for torque specifications Install the J3 J4 and J5 cables at the connectors located on the power board see Figure 57 on page 107 Install the control basket as described in the procedure on page 103 1996 Square D All Rights Reserved L 107 Cnapter 4 Equipment Cnange Out Bulletin NO VUUCUOS UT ATV66U90N
156. OC06T306_ for removal installation instructions Identify and tag all field wiring for future re assembly Using a flat blade screw driver loosen the terminal screws on the J1 J12 and J13 connectors see Figure 123 on page 242 Pull the field wiring back out of the way Using a flat blade screw driver gently pry the J1 J12 and J13 connectors away from the board side jacks Discard the old connectors Insert the new connectors into their associated board side jacks NOTE The yellow keys in both plugs and sockets are designed to prevent incorrect insertion of J12 and J13 Install the field wiring on the new connectors for J1 J12 and J13 Using a flat blade screw driver tighten the terminal screws for the field wiring installed Reinstall options module if previously present See User s Manual VDOCO061306 for removal installation instructions Location of I O Extension Module if installed Connector for remote keypad display Connector for remote LED status indicators J12 Da Pa Figure 123 Location of J1 J12 and J13 Connectors 242 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66C10N4 to C19N4 Removing the Power Board This procedure explains how to remove the power board from the following drive controllers Drive Controller No Power Board No ATV66C10N4 VX5 A66C10N4 ATV66C13N4 VX5 A66C13N4 ATV66C15N4 VX5 A66C15N
157. OLTAGE MEASUREMENT on page 310 of this manual Always remove all power and follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT on page 310 of this manual before working on controller Failure to follow these instructions will cause shock or burn resulting in death or serious injury The following sections look at specific performance aspects of the control section of the controller All the tests are done with power applied to the controller Before restoring power all shields and covers must be in place Carefully review WORK PRACTICE PRECAUTIONS on page 3 of this manual The person performing the tests must consider the following points prior to performing any test 1 Do Ihave the appropriate skill set to understand the hazards involved and to safely implement the specific test in question 2 Havel reviewed and understood the requirements of each test prior to implementation 3 Havel the appropriate protective equipment and test apparatus to perform the test 4 Dolhave a thorough understanding of the safe operation and use of the protective equipment and test apparatus 5 Havel constructed a test plan that meets the test requirements and allows the test to be safely implemented considering the specific controller installation and application If the answer to any point is NO then STOP Do not proceed further until all the points can be answered in the affirmative Some of the voltages and currents being measured a
158. ORM AS EXPECTED 00 0c eee eee eee eee 20 Poor Speed Stability corn 2x e ER a RETO ERU rein 20 Excessive Motor Temperature 0 0 0 c cece eet 22 Motor Accelerates Too Slowly ococoocococcoro tte 25 Motor Decelerates Too Slowly Overspeeds Overspeed Trip o oo oo oooo o 28 Cannot Start Molor ado ER RR ERR ie HORE ie RUE AK RA RR 32 Cannot Stop Motor 1 ido Nep HEBR Ru bie PLE php pd 37 Motor Turns in Wrong Direction lllleeee I 40 Drive Will Not Follow Speed Command 0 0c cee eese 41 Specific Drive Function Does Not Work as Expected Not at All 41 TRIPS RESETTABLE BY KEYPAD LI AUTOMATIC POWER CYCLE 43 Undervoltage 4 2 ria ri is 43 Ovelvollage ia ss Ru eI ESER Ge ees ee alee gg eos QURE EORR RR 45 DC Bus Overvoltage ooococcoccco m e 47 Input Phase LOSS cssc a Rete RU RS Min Glog edd don ERE RE CRUS 51 Motor Overload sio REV ED ER re Re YA DDR DR ede 53 Drive Overtemperature o ooocoocococo ete tees 55 Loss of Follower oris ILL EE A RIP IS RAE E USE 57 Output Phase Oss cios ec A DERE E ERE NONE EN RU ee erie 58 Sequence Time Out uaua naunau eh 60 Process Time Out x tpe UE RR AA A AAA a wu D 60 S rialsMink Faulty ai erste Rn ERR Ee KDE IRR 29 a piel en ea 5 60 O 1996 Square D All Rights Reserve gt _ _ i ALTIVAR 66
159. OS U1 December 1996 For the IGBT module to be installed 1 Clean the portion of the heatsink which will make contact with the new IGBT module Evenly coat the bottom of the new IGBT module with a thin coating of thermal grease Install the new IGBT module with the push on connectors towards the outside of the drive controller Using a torque wrench and hex key socket install and tighten the four mounting screws to 26 5 lb in 3 Nem Torque screws in the sequence shown O 4 Position the bus bar and align the mounting holes NOTE When executing steps 5 through 8 perform the following checks Ensure the red C cable from the contactor is connected to the terminal of the top capacitor Ensure the black C cable is connected to the terminal of the third capacitor from the top of the controller Ensure the BR3 cable is connected to the C1 terminal of the braking IGBT module Ensure the U V and W cables are connected to the C2E1 terminals of their respective IGBT modules as labeled on the bus Do not tighten any one screw or mounting pin until all of the hex head screws phillips head screws and mounting pins are started with all required cables connected Using a hex key wrench install the eight bus capacitor hex head screws with the balancing resistors see Figure 89 on page 162 Using a drive socket or open end wrench install the six mounting pins with two washers which connect the
160. OUS VOLTAGE Read and understand these procedures before servicing ALTIVAR 66 drive controllers Installation adjustment repair and maintenance of these drive controllers must be performed by qualified personnel Failure to follow these instructions will cause shock or burn resulting in death or serious injury All procedures in this section must be performed with power removed from the controller A CAUTION EQUIPMENT DAMAGE The ALTIVAR 66 drive controllers use metric fasteners Do not substitute SAE or alternate fasteners Failure to observe this instruction can result in injury or equipment damage The ALTIVAR 66 controllers use metric fasteners and require the use of metric driver tools Do not substitute SAE or any alternate fastener Substitution may result in damage to threaded inserts breakage of components and subassemblies overheated electrical connections due to improper torque levels and general structural failure This section contains spare part information and change out procedures for drive controllers e ATV66U41N4 e ATV66U54N4 e ATV66U72N4 Table 8 lists the spare parts Refer to the pages indicated in the table for spare part change out procedures Table 8 Spare Parts for Drive Controllers ATV66U41N4 to 72N4 Description For Drive Catalog Number For Change Out Controllers Procedure See Control Kit ATV66U41N4 to U72N4 VX4 A66CK1 Pages 87 91 Control Terminal Block Ki
161. Overspeeds Over speed Trip page 28 Figure 13 illustrates the troubleshooting procedure when the specific drive func tion does not work as expected or not at all SPECIFIC DRIVE FUNCTION DOES NOT WORK AS EXPECTED NOT AT ALL Operating Condition Function requires Damaged controller Program lost due to connection of external I O replacement of main device for proper control board orientation position sensor condition sensor etc Possible cause I O devices are present Check I O devices are operating to be correctly performed I O devices are properly wired Result Add or repair I O devices Perform the equipment Reprogram settings as required check procedures in Solution Controller Not Powered Up section of chapter 2 Figure 13 Specific Drive Function Does Not Work as Expected Not at All 1996 Square D All Rights Reserved 4i Cnapter 3 Correcting tne Probiem Bulletin NO VDUCUOS U1 December 1996 Drive Function Does Not Work as Expected Not at All Specific Drive Function Does Not Work as Expected Not at All continued 2 of 2 42 Possible cause Check to be performed Result Solution Specific function is not available with controller configuration selected Controller incorrectly programmed
162. RED ENERGY IN HAZARDOUS VOLTAGE STORED ENERGY CAPACITORS Some capacitors used in drive controller store sufficient energy at voltage levels that can pose serious SHOCK BURN or EXPLOSION effects if their terminal connections are contacted or capacitors are improperly discharged Following procedure is for use only in event that normal capacitor discharge means are not operational Read and understand following procedure before attempting to discharge stored energy in capacitor or group of capacitors Wear protective equipment as recommended in WORK PRACTICE PRECAUTIONS on page 3 of this document Use only electrically insulated tools DO NOT short across capacitors or touch unshielded components or terminal strip screw connections with voltage present Failure to follow these instructions will result in death or serious injury 1996 Square D All Rights Reserved _ gt _ _ _ 311 Cnapter 5 basic Procedures Bus Voltage Measurement 312 Bulletin NO VDUCUOS U1 December 1996 Capacitors are used throughout the ATV66 drive controllers as energy storage devices Some of the capacitors can store potentially lethal amounts of energy at hazardous voltage levels during normal controller operation Such capacitors are associated with the power circuit and include but are not limited to the following categories e DC bus capacitors found in all controllers e Line filter capacitors found on ATV66D33N4 t
163. RK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Set of magnetized flat blade screw drivers e Set of magnetized phillips screw drivers e Metric hex key set 2 to 14 mm e 4 Needle nose pliers 1996 Square D All Rights Reserved L 261 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 262 Bulletin NO VDUCUOS U1 December 1996 With the drive controller door open or removed Measure the bus voltage if not already performed as described in chapter 5 of this manual To remove the left current sensor 1 Using a flat blade screw driver loosen the two screws holding the hinged assembly in place Swing the hinged assembly out to the right 2 Loosen the thumb screws and remove the plastic shield from in front of the line and motor terminals 3 Using needle nose pliers carefully disconnect and pull back out of the way the T1 sensor wire see Figure 131 on page 262 4 Using a hex key wrench loosen and remove the left sensor center cylinder screw see Figure 131 on page 262 5 Using a phillips screw driver loosen and remove the top screw holding the current sensor to the mounting bracket 6 While holding the T1 power cable out of the way gently pull the current sensor out and then up Be aware of the signal cable connected to the lower right hand corner of the
164. ROCEDURE 5 VALIDATION AFTER REPAIR on page 314 of chapter 5 e The controller may require reprogramming Refer to the Level 1 and 2 Configuration manual bulletin number VD0C065305 for controller configuration programming If the controller is a part of a larger system refer to the specific programming instructions provided by the system builder If the controller configuration program was saved in a PCMCIA Memory Card reload the program If the program was manually recorded reload the program through the keypad If problems persist and the controller can be energized follow the procedures as described in the section titled Drive System Energized on page 9 If problems persist after performing the recommended procedures then factory service may be required Have the following information available Controller part number Controller input voltage Controller power rating e Controller software version see PROCEDURE 9 CHECKING THE SOFTWARE REVISION LEVEL on page 317 of chapter 5 e Description of any physical damage or defect Operating environment e Application Any LED status light s illuminated e Any fault message display on the keyboard screen Contact your local Square D field office to arrange service LED INDICATIONS Check the LED indicators and keypad display for controller status information If AND KEYPAD the controller has faulted and control power is still present the red FAULT LED DISPLAY will
165. Remove the bottom cover Using needle nose pliers disconnect J6 from its termination point on the power board see Figure 65 on page 119 Using a phillips screw driver loosen the four corner screws which hold the back cover to the drive controller Remove the back cover from the drive controller This allows access to the fan assembly Turn the drive controller chassis over to gain access to the fan mounting screws Using a phillips screw driver loosen and remove the two mounting screws 1996 Square D All Rights Reserved 139 Cnapter 4 Equipment Cnange Out Bulletin NO VUUCUOS UT ATV66D16N4 and ATV66D23N4 December 1996 12 Remove the inoperative fan pulling the fan leads and J6 connector through the hole in the chassis of the drive controller Fan mounting screws Figure 76 Fan Mounting Installing the Fan This procedure explains how to install the fan in the following drive controllers Drive Controller No Fan No ATV66D16N4 ATV66D23N4 TENA A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WOR
166. Replacing the Circuit Protector lille 305 Replacing the Control Fuses ooccccccccccc ee 306 Replacing the DC Bus Fuse 0200s cece n 306 Chapter 5 PRECAUTIONS fe itr tre detras Ier MI EA deer Sea ee 310 Basic Procedures PROCEDURE 1 BUS VOLTAGE MEASUREMENT eee 810 PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS 311 PROCEDURE 3 INPUT LINE VOLTAGE MEASUREMENT sss eesee s 313 PROCEDURE 4 CHECKING PERIPHERAL EQUIPMENT 0 000 313 PROCEDURE 5 VALIDATION AFTER REPAIR 00000 esee 314 PROCEDURE 6 CHECKING FAN OPERATION 00000 e eee eee eee 315 PROCEDURE 7 CLEANING HEAT SINKSAND AIR PASSAGES 316 PROCEDURE 8 RUNNING DRIVE CONTROLLER FROM CONTROL POWER ONLY 316 PROCEDURE 9 CHECKING THE SOFTWARE REVISION LEVEL 317 Appendix TO ORDER REPLACEMENT PARTS 0000 cece eee e 319 LOCAL SUPPORT x iceberg 319 FACTORY TELEPHONE SUPPORT 00 0000 e eee teeta 319 FACTORY REPAIR vex x HR See ee eee Se Betas 319 ON SITE REPAIB 13i ore BERE PLU ePi eere M PS 319 O 1996 Square D All Rights Reserve v ALTIVAR 66 Service and Troubleshooting Manual Bulletin No VD0C06S701 Table of Contents December 1996 vi 0 1996 Square D All Rights Reserved Bulletin No VD0C06S701
167. Semiconductor devices can exhibit hazardous leakage currents in the off state and bus capacitors store energy which can be hazardous to personnel for some period after the controller is disconnected from line power All personnel who will perform troubleshooting or equipment change out procedures should be thoroughly familiar with ANSI NFPA 70E Read and understand the precautions and hazard statements found on the inside front cover of this manual A partial listing of safety measures which should be followed are listed below 1 Verify that the equipment has been installed and applied in a fashion that is consistent with the information in the equipment instruction manual applicable code requirements and regulations 2 Coordinate all troubleshooting equipment change out procedures with the operations manager of the facility 3 Ensure that the controlled equipment is disconnected from the drive controller or that access to it is prohibited 4 Read all precautions in this manual which relate to the procedure being followed 5 Make sure you are familiar with the tools and instruments required for the specific procedures described in this manual 6 Ensure that you have proper body protection including clothing eye protection helmet etc 7 Ensure that electrical equipment which surrounds the controller is either deenergized or isolated in such a way that maintenance personnel are not subject to electrical shock 8 Ensure tha
168. Separate power may be present on control basket power board and I O Extension Module if installed connectors Verify that all power has been removed from J1 J12 and J13 connectors If I O Extension Module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in Chapter 5 of this manual 2 Remove options module if present See User s Manual VDOC06T306_ for removal installation instructions 3 Identify and tag all field wiring for future re assembly 4 Using a flat blade screw driver loosen the terminal screws on the J1 J12 and J13 connectors see Figure 63 on page 117 Pull the field wiring back out of the way 5 Using a flat blade screw driver gently pry the J1 J12 and J13 field connectors away from the board side connectors Discard the old connectors 6 Insert the new field side connectors into their associated board side connectors 116 1996 Square D All Righ
169. T Modules 00 0c eee eee eee 76 Checking the Braking IGBT Module 002 0 eee eee 76 Checking the Braking IGBT Module Freewheel Diode 76 Drive Controller Power Part Measurements sees 78 ATV66U41N4 to U72N4 Front View 0 000 eee eee 87 Control Basket Connector Locations esee 89 Cable Connector Secure and Release Positions 89 Location of J1 J2 J12 and J13 Connectors 2 0005 92 1996 Square D All Rights Reserved vii ALTIVAR 66 Service and Troubleshooting Manual List of Figures amp Tables viii Figure 50 Figure 51 Figure 52 Figure 53 Figure 54 Figure 55 Figure 56 Figure 57 Figure 58 Figure 59 Figure 60 Figure 61 Figure 62 Figure 63 Figure 64 Figure 65 Figure 66 Figure 67 Figure 68 Figure 69 Figure 70 Figure 71 Figure 72 Figure 73 Figure 74 Figure 75 Figure 76 Figure 77 Figure 78 Figure 79 Figure 80 Figure 81 Figure 82 Figure 83 Figure 84 Figure 85 Figure 86 Figure 87 Figure 88 Figure 89 Figure 90 Figure 91 Figure 92 Figure 93 Figure 94 Figure 95 Figure 96 Figure 97 Figure 98 Figure 99 Figure 100 Bulletin No VD0C06S701 December 1996 Power Board Connector Locati0NS ooooooooocoooo 94 Fan Removal 2 eher here had Her eee uuu
170. T module to be installed 1 Clean the portion of the heatsink which will make contact with the new IGBT module 2 Evenly coat the bottom of the new IGBT module with a thin coating of thermal grease NOTE Mounting pins and screws are marked with red paint Always mount pins and screws with the red painted side facing upwards 3 Install the new IGBT module with the push on connectors toward the outside of the drive controller see Figure 70 on page 127 Using a torque wrench and hex key socket install and tighten the two mounting screws to 17 7 Ib in 2 Nem 4 Using a torque wrench and drive socket install and tighten the mounting pin at the C2E1 terminal point on the IGBT module to 17 7 Ib in 2 Nem see Figure 70 on page 127 5 Position the bus bar and align the mounting holes NOTE Ensure the red cable from the precharge resistor is connected to the right hand side of the top capacitor Ensure the two black cables are connected to the left hand side of the second cap down from the top Ensure the PA cable is connected to the screw on the left hand side of the top IGBT module see Figure 71 on page 129 6 Using a hex key wrench install the 11 hex head screws see Figure 69 on page 127 Using a drive socket or open end wrench install the four mounting pins O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D16N4 and ATV66D23N4 three on the bus bar on
171. TIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e DB Gate driver board procedure tool list page 268 DBSnubber board procedure tool list page 265 Current sensor assembly procedure tool list page 261 1996 Square D All Rights Reserved L 271 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Installing the Dynamic Braking DB IGBT Module 272 Bulletin NO VDUCUOS U1 December 1996 With the drive controller door open or removed 1 Remove the dynamic braking gate driver board as described in the procedure on page 268 2 Using a hex key wrench loosen and remove the Q7 E dynamic braking IGBT module screw see Figure 133 on page 266 Pull the Q7 E power cable and control cable back away from the dynamic braking IGBT module 3 Using a hex key wrench loosen and remove the four mounting screws on the dynamic braking IGBT module 4 Using a flat blade screw driver gently pry loose the dynamic braking IGBT module from the heat sin
172. U1 December 1996 Installing the Main Fan Unapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 This procedure explains how to install the main fan in the following drive controllers Drive Controller No Main Fan No ATV66D54N4 ATV66D64N4 VZ3 V665 ATV66D79N4 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of Torx screw drivers e 4 Needle nose pliers e Control basket procedure tool list page 193 For the main fan to be installed 1 Fit up the new fan and align the mounting holes with the holes on the fan shroud see Figure 114 on page 224 2 Using a Torx screw driver install and tighten the two mounting screws 3 Using needle nose pliers carefully connect the two fan leads This is an AC fan The two fan leads can be connected to either terminal 4 Install the bottom panel Using a phillips or Torx screw driver install and tighten the four screws which connect the right side panel to the bottom panel see Figure 104 on page 197 5 Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the three screws for the bottom IP20 protection cover see Figure 104 on page 197 6 Install the J1 terminal block see Figure 104 on page 197 7 Install the left side panel Using a phillips or Torx amp
173. UCUOS U1 December 1996 Checking the Diode Bridge Checking the DC Bus Cnapter 3 Correcting tne Problem Checking the Power Part of the Controller Check the diode bridge as shown in Figure 38 This should be done for each phase of the line supply with respect to the and terminals of the drive controller Use a 0 1000 V multimeter as recommended in the LIST OF TOOLS AND INSTRUMENTS on page 5 Set the meter on the diode scale In the event of any problem disconnect the diodes and test them directly on their terminals R 0 300 0 450 V Figure 38 Checking the Diode Bridge The DC Bus is composed of the bus capacitors bus capacitor balancing resistors means for discharging the bus capacitors upon removal of power low impedance buswork connecting the bus capacitors to the inverter bridge and on some controllers power semiconductor fuses to minimize damage in the event of a power diode or inverter switch failure For ATV66U41N4 to ATV66D12N4 controllers the switch mode power supplies connected to the DC bus are used as the main discharge means For the ATV66D16N4 to ATV66C19N4 controllers resistors are switched across this bus when power is removed from CL1 and CL2 Switching is done by a normally closed auxiliary contact on the precharge contactor The DC bus may be checked for short circuits after performing PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 On the ATV66C10N4 to ATV66C19N4 controllers also perform
174. UOS U1 December 1996 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 4 Needle nose pliers e Control basket procedure tool list page 113 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 113 Remove the J1 connector on the power board see Figure 64 on page 118 3 Using a phillips screw driver loosen and remove the two screws which hold the top IP20 protection cover in place Remove the top IP20 protection cover 4 Using a phillips screw driver loosen and remove the two screws which hold the bottom IP20 protection cover in place Remove the bottom IP20 protection cover 5 Using a phillips screw driver loosen and remove the two screws which hold the top cover in place Remove the top cover Top cover Top IP20 protection cover Bottom IP20 protection cover zu J1 connector s Bottom cover Figure 64 Location of Various Covers 6
175. VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury 178 _ _ _ _ _ 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm e Torque wrench set to 26 5 Ib in 3 Nem e Metric hex key sockets for torque wrench 2 to 14 mm e Aset of Torx screw drivers e Flat blade screw driver sockets for torque wrench e 4 Needle nose pliers e Control basket procedure tool list page 149 With the drive con
176. VX5 A66D54N4 ATV66D64N4 VX5 A66D64N4 ATV66D79N4 VX5 A66D79N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved 201 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 202 Bulletin NO VDUCUOS U1 December 1996 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm e 1 4
177. ables from the sockets 7 Using a phillips screw driver loosen the four corner screws on the control basket The bottom left screw is a captive screw see Figure 80 on page 148 8 Remove the control basket from the drive controller 143 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Control Basket Unapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 NOTE Be sure the ribbon cables have been released before pulling to avoid damage to the cables There are two versions of the cable clasps blue and white White Cable Clasp LL m Ribbon Cable Ribbon Cable m Circuit Board Ls Circuit Board N f ii Blue Cable Clasp Secure Position Secure Position White Cable Clasp Pull Out Pull Out Sa Ribbon Cable Ribbon Cable ee Circuit Board E Circuit Board i HE Ium i Blue Cable Clasp E l Release Position Release Position White Cable Clasps Blue Cable Clasps Figure 81 Cable Connector Secure and Release Positions This procedure explains how to install the control basket in the following drive controllers Drive Controller No Control Kit No ATV66D33N4 LIC NEN NN A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed
178. ace Remove the top IP20 protection cover Disconnect the J1 connector This will allow the bottom IP20 protection cover to be removed see Figure 82 on page 151 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place Remove the bottom IP20 protection cover see Figure 83 on page 153 Using a phillips or Torx screw driver loosen and remove the three screws which hold the bottom panel in place Remove the bottom panel see Figure 83 on page 153 Using a hex key wrench loosen the terminal screws for L1 L2 L3 4 U T1 V T2 and W T3 at both the field side and drive controller side of the J2 terminal block assembly Pull the cables and wires out of the way Identify and tag all field wiring for future re assembly see Figure 82 on page 151 Using a flat blade screw driver loosen the terminal screws for CL1 CL2 L21 L22 PA PB and the ground connections at both the field side and drive controller side of the terminal block The CL1 CL2 jumper if present may be left in place Pull the cables and wires out of the way Identify and tag all field wiring for future re assembly see Figure 82 on page 151 Using a hex key wrench loosen and remove the two screws holding the J2 terminal block assembly in place Remove the terminal block assembly see Figure 82 on page 151 Auto transformer Figure 99 Auto Transformer 11 12 13 14 15 Using a
179. age 313 Repair or replace any damaged protective equipment per the manufacturer s instruction e Check the integrity of the controller bonding and ground system and ensure that the controller is properly grounded per applicable codes and recommendations found in the Receiving Installation and Start Up VD0C06S304_ manual e Check the integrity of insulation and connections of all incoming and outgoing wiring both power and ground e Check the wiring method and routings Ensure that wiring is as recommended in the Receiving Installation and Start Up VD0C065304 manual e Check that the voltage present on the line side of the controller disconnect is within the controller specifications as listed on the controller nameplate Test with a properly rated voltage sensing device e Refer to Table 6 on page 17 when checking for controller damage Follow referenced troubleshooting procedures and repairs as required Upon completion of any recommended repairs the following should be performed Refer to the Receiving Installation and Start Up manual bulletin number VD0C06S304_ and follow all procedures for checking integrity of the controller and for re installing if necessary and starting up the controller e After the controller is re installed and powered up perform PROCEDURE 5 VALIDATION AFTER REPAIR on page 314 in chapter 5 e The controller may require reprogramming Refer to the Level 1 and 2 Configuration manual bu
180. ailure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed to replace the thermal switch behind the DB snubber board DB snubber board procedure tool list page 267 e Current sensor assembly procedure tool list page 263 The tools needed to replace the thermal switch behind the GD4 gate driver Gate driver procedure tool list page 253 e Snubber board procedure tool list page 250 With the drive controller door open or removed Measure the bus voltage if not already performed as described in chapter 5 of this manual To replace the thermal switch located on the heat sink behind the DB snubber board see Figure 136 on page 279 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Thermal Switch DB Snubber Board Thermal Switch gt Pas Figure 136 Thermal Switch Locations 1 Remove the dynamic braking snubber board as described in the procedure on page 264 Using needle nose pliers carefully disconnect the P2 connector from the GD2 gate driver board see Figure 136 on page 279 This allows access to the mounting screws on the thermal switch Using needle nose pliers carefully disconnect the two connectors to the thermal swi
181. ains how to use the troubleshooting manual and describes work practice precautions that should be read understood and observed before attempting any of the procedures in this manual It also lists the tools and instruments required for the procedures described in this manual related documentation and applicable standards Chapter 2 Investigating the Problem describes a general approach to identifying and correcting drive controller problems It describes how to use the controller s LED indications keypad display and various menus for identifying drive controller faults and faulty operating conditions Chapter 3 Correcting the Problem contains procedures for identifying and correcting the causes of the drive controller faults and faulty operating conditions described in chapter 2 Chapter 4 Equipment Change Out lists spare parts available for ALTIVAR 66 drive controllers and contains instructions for changing out faulty components and equipment Chapter 5 Basic Procedures contains procedures for measuring bus and input line voltage checking peripheral equipment removing mains power working on energized equipment testing the drive controller after corrective action has been taken checking fan operation cleaning heat sinks and air passages running the drive controller from control power only and checking the software revision level To effectively use the manual first review the work practice precautions in chapter 1 and t
182. aking IGBT module from the IGBT Module following drive controllers Drive Controller No Braking IGBT Module No ATV66D54N4 VZ3 IM2100M1201 ATV66D64N4 VZ3 IM2150M1201 ATV66D79N4 VZ3 IM2150M1201 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury 208 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Power board procedure tool
183. al link mounting screws to 74 3 Ib in 8 4 Nem see Figure 146 on page 300 Repeat for the bottom terminal link Install the AUX 52 and AUX 82 control wires into their marked locations on the auxiliary contact block see Figure 144 on page 296 and Figure 145 on page 297 Position the small PCC 1 cable over the bottom left mounting hole of the bottom precharge contactor terminal link Using a torque wrench and hex key socket install and tighten the mounting screw to 40 7 Ib in 4 6 Nem see Figure 146 on page 300 Slide the precharge contactor assembly through the bottom of the transformer contactor mounting plate For ATV66C10N4 and C13N4 drive controllers Position the precharge contactor over the mounting rail Pull on locking tab at bottom of contactor and snap contactor into place on the mounting rail Release tab For ATV66C15N4 and C19N4 drive controllers Slide the precharge contactor assembly mounting holes over the four mounting screws Using an open ended metric wrench install and tighten the four contactor mounting nuts Place the two PCC A1 cables and one PCC A2 cable into their respective terminals on the precharge contactor coil module Using a flat blade screw driver tighten the A1 and A2 terminal screws see Figure 144 on page 296 Position the three PCC 2 cables over the terminal link mounting holes at the top of the precharge contactor Using a torque wrench and hex key socket 1996 Square D All Rights Reserve C 3
184. amaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Flat blade screw driver sockets for torque wrench e Metric hex key set 2 to 14 mm e Metric hex key sockets for torque wrench 2 to 14 mm e Power board procedure tool list page 124 Gate drive procedure tool list page 120 e Control basket procedure tool list page 115 For the bus capacitors to be installed 1 Install the new capacitors Ensure that the polarity matches the polarity marking on the bus bar The PA terminal of a capacitor should be towards the outer right side of the drive controller see Figure 78 on page 144 1996 Square D All Rights Reserved 143 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 144 Bulletin NO VDUCUOS U1 December 1996 Using a torque wrench and hex key socket install and tighten the eight capacitor screws to 17 7 lb in 2 Nem Ensure the red C and black C cables are properly co
185. arred or damaged covers or enclosure parts e Excessive surface temperatures of enclosures and conduits Damage to power or control conductor conduit e Unusual noise or odors from any of the equipment e Abnormal environmental conditions i e temperature humidity vibration etc e Other conditions which may adversely affect the operation of the equipment e Check the integrity of the keypad display unit Note any scratches punctures burn marks chemical burns moisture in the screen or any other signs of damage e Check the vents for any blockage or obstructions e Check the bottom of the drive controller for any signs of oil or electrolyte which might have leaked from capacitors inside the controller No External Signs of If no external damage is noted thoroughly inspect the interior of the drive Equipment Damage controller A DANGER HAZARDOUS VOLTAGE Read and understand these procedures before servicing ALTIVAR 66 drive controllers Installation adjustment repair and maintenance of these drive controllers must be performed by qualified personnel Failure to follow these instructions will cause shock or burn resulting in death or serious injury REMOVE ALL POWER FROM CONTROLLER BEFORE PROCEEDING Read and follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in Chapter 5 Athorough visual and mechanical check of the controller should include but is not limited to the following points e General mechanical damage to components or
186. askets The keypad display is mounted on the control basket for drive controllers ATV66D16N4 and ATV66D23N4 see Figure 63 on page 117 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers With the drive controller door open 1 Using a flat blade screw driver push in on the keypad display tab and remove the keypad display see Figure 60 on page 112 2 Insert the new keypad display into the front of the control board Ensure the lip on the bottom of the keypad display is behind the tab on the control basket Keypad display tab Location of RUN STOP cover Figure 60 ATV66D16N4 to D23N4 Front View 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Control Basket Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 This procedure explains how to remove the control basket from the following drive controllers Drive Controller No Control Kit No ATV66D16N4 ATV66D23N4 VX4 A66CK1 Before removing power note and record all the drive controller settings using the keypad display A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructi
187. assemblies Loose or missing fasteners Unplugged loose or damaged connectors Damaged cables or cable assemblies e Cracked or damaged plastic castings e Leaking bulging or ruptured capacitors e Cracked or ruptured diode or IGBT power modules e Discolored cracked burnt or flashed insulation surfaces e Burnt or discolored precharge or bus discharge resistors 7 5 __ _ gt gt gt lt X 1996 Square D All Rights Reserved Bulletin NO VDUCU6S UT Cnapter 3 Correcting tne Probiem December 1996 Checking the Power Part of the Controller e Jammed or sticking fan impellers e Blocked or dirt laden air vents heatsink fins or fan impellers If damage is found refer to specific check out procedures on the following pages and the replacement procedures in chapter 4 Remember that non visible damage may be present even after visible damage is repaired If no external signs of equipment damage are observed check the power and con trol parts of the drive controller As defective parts or assemblies are found refer to chapter 4 for change out procedures Checking the Power Part of Figure 36 illustrates the relationship between the power parts of the controller the Drive Controller A DANGER HAZARDOUS VOLTAGE Read and understand these procedures before servicing ALTIVAR 66 drive controllers Installation adjustment repair and maintenance of these drive controllers must be performed by qualified personnel
188. ath or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Current sensor assembly procedure tool list page 261 With the drive controller door open or removed 1 Remove both current sensor assemblies as described in the procedure on page 261 2 Using needle nose pliers carefully disconnect the J2 connector on the dynamic braking snubber board see Figure 133 on page 266 3 Ifthe board is being replaced remove the jumper from J3 to JA 4 Using a hex key wrench loosen and remove the two mounting screws Remove the dynamic braking snubber board 1996 Square D All Rights Reserved 265 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUO6S U1 ATV66C10N4 to C19N4 December 1996 DB snubber board Current sensor assembly Figure 132 Dynamic Braking Snubber Board DB snubber board
189. atic electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are 4 needle nose pliers Control basket procedure tool list page 113 With the drive controller door removed P otn 10 11 Remove the control basket as described in the procedure on page 113 Disconnect the J1 connector at the bottom of the power board Identify and tag all field wiring for future re assembly Disconnect the field wiring on the J2 connector at the bottom of the controller Figure 63 on page 117 Using a phillips screw driver loosen and remove the two screws which hold the top IP20 protection cover in place see Figure 64 on page 118 Remove the top IP20 protection cover Using a phillips screw driver loosen and remove the two screws which hold the bottom IP20 protection cover in place Remove the bottom IP20 protection cover Using a phillips screw driver loosen and remove the two screws which hold the top cover in place Remove the top cover Using a phillips screw driver loosen and remove the four screws which hold the bottom cover in place
190. ault A EIER ieeERIA Sep hat E EU dg IS PR a Roses EE 69 GontroliSupply Fault EAD a ee UPS 69 EQUIPMENT DAMAGE er oid pede had Mea be ds RR 70 Keypad Display is Off a iriran a a a ea n a e a a a a eee 70 External Signs of Equipment Damage 0 0 0 cece eese 70 No External Signs of Equipment Damage lesse elles 70 Checking the Power Part of the Drive Controller 0 20000 e eee 71 Checkout of the Control Part of the Drive Controller o oooocco coooo 77 1996 Square D All Rights Reserve _ K 19 Cnapter 3 Correcting the Problem Poor Speed Stability RUNS DOES NOT PERFORM AS EXPECTED Poor Speed Stability 20 Bulletin NO VDUCUO6S U1 December 1996 Figure 6 illustrates the troubleshooting procedure when poor speed stability is ob served POOR SPEED Operating Condition STABILITY Speed reference signals Drive controller regulators Wrong torque setting or corrupted not properly tuned control type is selected Possible menu 7 11 for the application cause Check analog input map Check settings under Check menu 2 to be Ensure that wiring method menu 6 and menu 7 13 performed USed is correct per VD0C06S304_ e Check signal source output Incorrect speed reference level Result Incorrect wiring method used Bad signal source output Correct level of speed e Review VD0C06S305 reference Solution Correct
191. black and brown wires see Figure 118 on page 234 Using a drive socket loosen and remove the two mounting nuts and lock washers located at the top of the fan capacitor assembly see Figure 118 on page 234 The filter board assembly is also secured with the same mounting nuts Remove the fan capacitor assembly Using a drive socket loosen and remove the ten screws which hold the bottom drive controller cover in place Remove the bottom cover see Figure 118 on page 234 Loosen the black wire grommet if present Pull the main fan leads through the fan access hole see Figure 118 Using a drive socket loosen and remove the three screws which hold the fan assembly in place Lift up fan and pull off of mounting ledge Remove the old fan from the drive controller NOTE The fan capacitor assembly contains two capacitors The top capacitor is used in conjunction with the filter board assembly The bottom capacitor is the main fan capacitor Using a drive socket remove the main fan capacitor mounting nut and washers Remove the main fan capacitor from the fan capacitor assembly 1996 Square D All Rights Reserved 293 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUO6S U1 ATV66C10N4 to C19N4 December 1996 Installing the Main Fan This procedure explains how to install the main fan and fan capacitor in the follo
192. bly out to the right 3 Using a flat blade screw driver remove the plastic rivet which attaches the plastic shield over the power board see Figure 124 on page 244 1996 Square D All Rights Reserved 243 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 244 Bulletin NO VDUCUOS U1 December 1996 Using a hex key wrench remove the three plastic shield mounting screws and remove the plastic shield see Figure 124 on page 244 Using needle nose pliers carefully disconnect the connector plugs P1 P7 P8 and P15 at the bottom of the power board see Figure 125 on page 245 NOTE On the power board the jacks are designated with a J whereas the corresponding connector plugs are designated with a P For example the P9 connector plug connects to the J9 jack on the power board and the J9 jack on the control basket Plastic rivet Mounting screw Plastic shield y ll Mounting screw Mounting screw oj e el o LB 5 A DANGER Hinged Assembly 3 Holding Screws Figure 124 Front View of Hinged Assembly 6 10 Using needle nose pliers carefully disconnect the connector plug P6 at the left side of the power board see Figure 125 on page 245 Using
193. both the field side and drive controller side of the terminal block The CL1 CL2 jumpers if present may be left in place Pull the cables and wires out of the way Identify all field wiring for future re assembly 7 Using a hex key wrench loosen and remove the two screws holding the terminal block mounting channel Remove the terminal block assembly Current sensors rina i fe _ MX M J2 terminal block Filter board capacitors Figure 111 J2 Terminal Block 8 Using a flat blade screw driver carefully disconnect the J42A and J42B connector on the power board see Figure 107 on page 202 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Filter Board Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 9 Using needle nose pliers carefully disconnect J38 blue J39 white J40 red J53_1 blue and J53_2 white on the power board which are soldered on the filter board see Figure 107 on page 202 10 Using a drive socket loosen and remove the five nuts holding the filter board to the diode bridge bus work 11 Using a hex key wrench loosen and remove the two mounting screws on the filter board 12 Carefully remove the filter board 13 If the filter board is to be replaced remove the yellow green ground wire J41 connector and save the wire for installation on the new filter board This procedure explains how to install the filter board in the foll
194. bus bar to the IGBT modules see Figure 89 on age 162 sing a phillips screw driver install the two screws which attach the braking GBT module to the bus bar see Figure 89 on page 162 cac sing a drive socket or open end wrench install the three mounting pins with ne washer which connect the U V and W cables to the IGBT modules sing a torque wrench and the appropriate socket tighten the mounting pins and screws to 17 7 Ib in 2 Nem o a 10 Replace the bus bar isolating screen see Figure 89 on page 162 11 Remove the static protective foam from IGBT module control terminals 12 Install the power board as described in the procedure on page 159 164 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Braking IGBT Module Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 This procedure explains how to remove the braking IGBT module from the following drive controllers Drive Controller No IGBT Module No ATV66D33N4 ATV66D46N4 VZ3 IM2050M1201 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 conne
195. c hex key set 2 to 14 mm e Power board procedure tool list page 122 Gate driver procedure tool list page 118 e Control basket procedure tool list page 113 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D16N4 and ATV66D23N4 With the drive controller door removed 1 Remove the power board as described in the procedure on page 121 2 Remove the bus bar isolating screen see Figure 68 on page 124 Filter board Red connector location L1P cabl E LP Cables LP Cables L2P cable L3P cabl Figure 74 Filter Board Connections 3 Using needle nose pliers carefully disconnect the small red connector at the top of the filter board see Figure 74 on page 133 4 Using a hex key wrench loosen and remove the five screws holding the board to the diode bridge Note the location of the cables and wires landed under the five screws see Figure 74 on page 133 5 Remove the filter board 1996 Square D All Rights Reserved c 133 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 Installing the Filter Board 134 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to install the filter board in the following drive controllers Drive Controller No Filter Board No ATV66D16N4 ATV66D23N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the VX4 A66103
196. cation of all cables connected to the bus bar to assist during the re installation of the bus bar see Figure 89 on page 162 6 Remove the bus bar 7 Using a phillips screw driver loosen and remove the eight screws to the capacitor mounting brackets see Figure 91 on page 169 For access to the bottom capacitor loosen and remove the two current sensor mounting screws Carefully pull the current sensors out of the way to allow access to the bottom capacitor 8 Remove all four bus capacitors 9 Remove mounting bracket from each capacitor and save for installation on new capacitors 165 c 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D33N4 and ATV66D46N4 Bus capacitors Figure 91 Bus Capacitors Installing the Bus In the event that one capacitor goes bad at least two other capacitors will be Capacitors damaged Therefore all four capacitors should be replaced This procedure explains how to install the bus capacitors in the following drive controllers Drive Controller No Bus Capacitor No ATV66D33N4 VY1 ADC472V450 ATV66D46N4 NOTE Kit VY1 ADC472V450 contains one capacitor A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing compo
197. ce of voltage using voltmeter setto 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Metric hex key set 2 to 14 mm With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Using a flat blade screw driver loosen the two screws holding the hinged assembly in place Swing the hinged assembly out to the right see Figure 124 on page 244 3 Loosen the thumb screws and remove the plastic shield from in front of the line and motor terminals 1996 Square D All Rights Reserved 257 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 258 Bulletin NO VDUCUOS U1 December 1996 4 If present remove the plastic cap from the center diode block screw see Figure 130 on page 258 5 Using a hex key wrench loosen and remove the
198. cece tte 106 Removing the Fanti ee ig fe ee ee E ex 108 Installing the FaN cire ERR fale eek eara aR Adee Bact tee 109 1996 Square D All Rights Reserved Bulletin No VD0C06S701 December1996 ALTIVAR 66 Service and Troubleshooting Manual Table of Contents ATV66D16N4 AND D23N4 ooococcccc ehm 111 Replacing the Keypad Display ooooocoooccoccr IR 112 Removing the Control Basket eee 113 Installing the Control Basket o oocococcocccococo eae 115 Replacing Control Terminal Blocks 000 cece eet tees 116 Removing the Gate Driver Board 0 0 0 cece ects 117 Installing the Gate Driver Board 0 0 0 cece 120 Removing the Power Board ooooooccocoo tees 121 Installing the Power Board 0 cece tte 124 Removing the IGBT Module o ooooccocococccco eae 126 Installing the IGBT Module lsseseeree RII 128 Removing the Braking IGBT Module 000 c cece eee 129 Installing the Braking IGBT Module 0 000 eects 131 Removing the Filter Board 0 0 cece ees 132 Installing the Filter Board 0 eee tee 134 Removing the Diode Bridge 0 cece eee 135 Installing the Diode Bridge o oooooococorrorocr tees 136 Replacing the Precharge Resistor 0000 cee e eee eee eee 137 Removing the Fan sceler gu ee PR em ee RI Rn 138 Installingthe Fan s rnt eis eee ut whe Waa pte dee ee gan 140 Removing the Bus Capacitors
199. cr I 112 Removing the Control Basket eene 113 Installing the Control Basket 0 0 0 cece tenes 115 Replacing Control Terminal Blocks llle 116 Removing the Gate Driver Board 0 cece cette 117 Installing the Gate Driver Board 0 0 0 eee 120 Removing the Power Board ooocoocococoo ee 121 Installing the Power Board oooococococco I 124 Removing the IGBT Module o ococcooccccccoco e 126 Installing the IGBT Module ooooccccccccoc RII 128 Removing the Braking IGBT Module sseseeeeees essen 129 Installing the Braking IGBT Module 0 e eee BB 131 Removing the Filter Board 0 0 eects 132 Installing the Filter Board 0 eens 134 Removing the Diode Bridge 0 cece tees 135 Installing the Diode Bridge 00 eee eee eee 136 Replacing the Precharge Resistor 0 0 cece eee tees 137 Removing the F n ee n sce rra e AA Does 138 installing the Fan uum ekrL RR RARE A Se ee A ie ies 140 Removing the Bus Capacitors ococoococcccccocr tees 141 Installing the Bus CapacitorS oooooccoccocncr 143 ATV66D33N4 and D46N4 isusseleeeeeee 145 Replacing the Keypad Display ooooooooccoocn eee 146 Removing the Control Basket eere 147 Installing the Control Basket oooooccoccocccococo 149 Replacing Control Terminal Blocks 0 0 00 cece eect eese 150 Replacing the Board FaN oooooooooc
200. ctor Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm e Set of open end wrenches 5 5 to 19 mm e Power board procedure tool list page 158 Gate driver procedure tool list page 154 e Control basket procedure tool list page 147 With the drive controller door removed 1 Remove the power board as described in the procedure on page 157 2 Remove the bus bar isolating screen see Figure 89 on page 162 3 Using an open end wrench loosen and remove the nine mounting pins and washers on the bus bar see Figure 89 on page 162 Pull the U V and W cables back out of the way 1996 Square D All Rights Reserved 165 Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 Insta
201. d 1 Remove the power board as described in the procedure on page 157 2 Remove the bus bar isolating screen see Figure 89 on page 162 Bus bar Bus capacitor screws Bus bar isolating screen Bus capacitor screws IGBT module Figure 89 Bus Bar Screws 3 Using an open end wrench loosen and remove the nine mounting pins and washers on the bus bar Pull the U V and W cables back out of the way see Figure 89 on page 162 4 Using a phillips screw driver loosen and remove the two screws which attach the bus bar to the braking IGBT module see Figure 89 on page 162 The BR3 cable is connected to the C1 terminal of the braking IGBT module Pull the BR3 cable back out of the way 5 Using a hex key wrench loosen and remove the eight screws which hold the bus bar to the bus capacitors see Figure 89 on page 162 The balancing resistors are mounted under these screws Note the location of all cables connected to the bus bar to assist during the re installation of the bus bar 6 Remove the bus bar 7 Using a hex key wrench loosen and remove the four screws holding the IGBT module to be removed see Figure 90 on page 163 8 Using a flat blade screw driver gently pry loose and remove the IGBT module 162 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D33N4 and ATV66D46N4 IGBT modules Braking IGBT module
202. e capacitor bus bar plate Using a torque wrench and hex key socket install and tighten the mounting screw to 40 7 lb in 4 6 Nem see Figure 139 on page 283 12 Install the TB3 control wires into their respective locations on the TB3 terminal block assembly see Figure 142 on page 288 Using a flat blade screw driver tighten the TB3 terminal screws 13 Using a drive socket install and tighten the two plexiglass shield screws while holding the plexiglass shield in place see Figure 139 on page 283 290 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Replacing the Stirring Fan Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 This procedure explains how to replace the stirring fan for the following drive controllers Drive Controller No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Stirring Fan No VZ3 V667 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter set to 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor sto
203. e For Class 8839 controllers certain power circuit configurations those with input line contactors allow diagnostics to be run with the controller in the standby ready mode All other configurations require the disconnection of the power to the L1 L2 and L3 terminals of the power converter Refer to Running the Drive Controller From Control Power Only in chapter 5 for further information Two tests are available from the Autodiagnostic Screen Select either of the tests by scrolling with the A and W keys and pressing ENT 1 Memory 15 V Supply and Supply Frequency initiates a test on the ROM memory a confirmation of the presence of 15 V and a confirmation of the presence of supply frequency 2 Transistors Tests initiates a test sequence on the drive controller inverter bridge Note that the length of time required for this test varies with product size While the test is in progress the Result display will report In Process on line 2 There are three possible responses for each element of a test e OK indicates that the tested element is good e X indicates that the tested element is defective e 2 transistor test only indicates that the transistor could not be tested A WARNING UNINTENDED EQUIPMENT OPERATION Forcing drive controller logic and analog outputs may cause undesired activation of connected equipment Set the connected equipment to ignore the change of state Failure to follow thes
204. e performed Result Check the insulation and wiring of the DB Resistor or the motor Solution See Procedure 4 in chapter 5 GROUND FAULT ATV66D16N4 through ATV66C19N4 Incorrect motor cable wiring practice Excessive motor cable length Motor cable incompatible with application Motor cable submerged in water Cable wiring practices Cable length Cable type Cable environment Cable not installed as recommended in VD0CO06S304 Multiple controller motor cables housed in a single conduit Cable length exceeds length recommended in VD0C06S304_ Cable type incompatible with recommendations in VDO0C06S304_ Cable damp submerged in water Correct motor cable installation Install reactor on output of controller Replace cable with correct type Keep cable dry Internal drive controller fault Refer to chapter 4 to change Current transformer Power board Control basket Connections Figure 31 Ground Fault ATV66D16N4 through ATV66C19N4 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 3 Uorrecting tne Problem December 1996 Internal Fault Internal Fault The fault code only appears on a fault caused by the drive controller The internal fault is triggered e fthere is no 15 V 15 V power supply or if the power supply is less than 11 5 V 11 5 V The measurement is taken every millisec
205. e 213 11 Carefully pull the bus capacitor assembly up out of the drive chassis In the event that one capacitor goes bad at least two other capacitors will be damaged Therefore all of the capacitors should be replaced This procedure explains how to remove the bus capacitor assembly from the following drive controllers Drive Controller No Bus Capacitor Assembly No ATV66D54N4 VY1 ADC605 ATV66D64N4 VY1 ADC606 ATV66D79N4 VY1 ADC606 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Torque wrench set to 26 5 lb in 3 Nem e Power board procedure tool list page 203 Gate driver procedure tool list page 200 e Control basket procedure tool list page 193 1996 Square D All Rights Reserved 213 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66D54N4 to D79N4 December 1996 For
206. e DC bus fuse mounting washers and screws to 323 Ib in 36 5 Nem see Figure 118 on page 234 1996 Square D All Rights Reserved 307 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCU6S U1 ATV66C10N4 to C19N4 December 1996 308 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 CHAPTER 5 BASIC PROCEDURES PRECAUTIONS PROCEDURE 1 PROCEDURE 2 PROCEDURE 3 PROCEDURE 4 PROCEDURE 5 PROCEDURE 6 PROCEDURE 7 PROCEDURE 8 PROCEDURE 9 Cnapter 5 basic Procedures Contents Lng gies A cuta Va che inr sr edes hy eats e ORUM ale te A 310 BUS VOLTAGE MEASUREMENT sses esee ee eae 310 DISCHARGING STORED ENERGY IN CAPACITORS 311 INPUT LINE VOLTAGE MEASUREMENT 055 313 CHECKING PERIPHERAL EQUIPMENT 2 0005 313 VALIDATION AFTER REPAIR sssseseee eee 314 CHECKING FAN OPERATION 0 0000 e es 315 CLEANING HEAT SINKS AND AIR PASSAGES ss 316 RUNNING THE DRIVE CONTROLLER FROM CONTROL POWER ONLY 0 000 cee e nen 316 CHECKING THE SOFTWARE REVISION LEVEL 317 1996 Square D All Rights Reserved 309 Cnapter 5 basic Procedures Bulletin NO VDUCU6S UT Bus Voltage Measurement
207. e Overvoltage Measurement lisse eese eese 45 Line Overvoltage ooococcococncr eh 46 DC Bus Overvoltage Measurement 00000 cease 47 DC Bus Overvoltage ooococcocococc tees 48 Input Phase Loss Measurement 0000 eect eee eee 51 Input Phase LOSs c tees ee betas GERE dai 52 Motor Overload toi A PERRA dS 54 Drive Overtemperature Measurement 000 cece eee 55 Drive Overtemperature 0 0 0 cece eee 56 Loss Follower tens actos ions tn l a at trei cens 57 Output Phase Loss Measurement s n aranana nanne 58 Output Phase LOSS esse ett a a a snb pedet een Ts 59 Short Circuit Measurement 0 00 cee eee ee 61 Short Gireuits 2 28 cock needed des we eee Thee ge E NEN LEER eed 62 Ground Fault Measurement 000 ce eee ee eee 63 Ground Fault ATV66D16N4 through ATV66C19N4 64 Internal Faulty 5 rude t e Reed eR REC 65 Dynamic Brake Fault Measurement o ooocoocococcooco o 67 Review of Auto Ramp Adaptation lille 67 DB Resistor Overtemperature oooooccocococ eee 68 Power Part Electrical Schematic 0 000 eee eee eee 71 F4 Bus Fuse Test Procedure ATV66C10N4 to C19N4 72 Checking the Diode Bridge lssseseseeeele eee 73 Checking the Rectifier Bus lieseleeese sees 74 Checking the Capacitor and Inverter Bus ooooocoooo o 74 Checking the Inverter Bridge llle eee 75 Checking the IGB
208. e cable marked BR3 back out of the way see Figure 109 on page 206 5 Usinga hex key wrench loosen and remove the 12 screws which hold the bus bar to the bus capacitors see Figure 108 on page 206 The balancing resistors are mounted under these screws 6 Using a hex key wrench loosen and remove the two screws which hold the C and C cables to the bus bar Pull the cables back out of the way see Figure 108 on page 206 7 Remove the bus bar Braking IGBT module Figure 109 Drive Controller with Bus Bar Removed 8 Using a hex key wrench loosen and remove the four screws for the IGBT module to be removed see Figure 109 on page 206 9 Using a flat blade screw driver gently pry loose and remove the IGBT module O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the IGBT Module Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 There are three IGBT modules in this size of drive controller This procedure explains how to remove the IGBT module from the following drive controllers Drive Controller No IGBT Module No ATV66D54N4 VZ3 IM2150M1201 ATV66D64N4 VZ3 IM2200M1201 ATV66D79N4 VZ3 IM2300M1201 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or
209. e gate driver board Top IP20 protection cover Left side panel P P Right side panel Bottom IP20 protection cover Bottom panel Figure 83 Location of Various Covers 4 Using needle nose pliers carefully disconnect the J68 board fan connector from the power board see Figure 84 on page 153 and Figure 87 on page 158 J68 connection i qu on power board Board fan Figure 84 Board Fan Top Left Side of Drive Controller 5 Carefully pull the board fan leads out from underneath the gate driver board 6 Using the phillips or Torx screw driver loosen and remove the screw holding the board fan in place 7 Slide the old board fan down and remove it from the drive controller 8 Install the new board fan on the drive controller by sliding it up until the mounting holes are aligned Ensure the airflow direction arrow on the new board fan is away from the drive controller 9 Using needle nose pliers route and connect the fan leads under the gate driver board to the J68 connection on the power board see Figure 84 on page 153 and Figure 87 on page 158 10 Using a phillips or Torx screw driver install and tighten the screw for the board fan 11 Install the top IP20 protection cover Using a phillips screw driver install and tighten the four screws which hold the top IP20 protection cover in place 12 Install the left side panel Using a phillips or Torx screw driver install and tighten the fou
210. e ground screw at the top right corner of the power board to 17 7 Ib in 2 0 Nem NOTE On the power board the jacks are designated with a J whereas the corresponding connector plugs are designated with a P For example the P9 connector plug connects to the J9 jack on the power board and the J9 jack on the control basket 4 Using needle nose pliers install connector plugs P2 P10 and P11 at the top of the power board 5 Using needle nose pliers install connector plugs P1 P7 P8 and P15 at the bottom of the power board 6 Using needle nose pliers install connector plug P6 at the left side of the power board 245 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66C10N4 to C19N4 7 Using needle nose pliers install connector plugs P12 and P13 at the right side of the power board 8 Install the plastic mounting guard over the top half of the power board Using a hex key wrench install and tighten the three plastic guard mounting screws 9 Install a plastic tie wrap in place of the plastic rivet that was previously removed Snip the extra length from the tie wrap as close to the buckle as possible 10 Swing the hinged assembly back to the left Using a flat blade screw driver tighten the two screws 11 Install the control basket as described in the procedure on page 240 Removing the Snubber There are six snubber boards in the ATV66C10N4 to C19N4 d
211. e in the middle IGBT and the W cable over the mounting hole on the bottom IGBT 7 Usinga torque wrench with hex key attachment install the 12 hex head screws with the balancing resistors which connect the bus bar to the bus capacitors Tighten to 17 7 lb in 2 Nem Using a torque wrench with drive socket attachment install the nine mounting pins and washers which connect the bus bar or cables to the IGBT modules Tighten to 26 5 Ib in 3 Nem 8 Position the cable marked BR3 over the C1 terminal of the braking IGBT Using a torque wrench with phillips head attachment install and tighten the two braking IGBT screws to 17 7 lb in 2 Nem 9 Replace the bus bar isolating screen 10 Install the right side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the right side panel in place 11 Install the power board as described in the procedure on page 203 214 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D54N4 to D79N4 Removing the Filter Board This procedure explains how to remove the filter board from the following drive controllers Drive Controller No Filter Board No ATV66D54N4 ATV66D64N4 VX4 A66105 ATV66D79N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructi
212. e in the protection cover Using a phillips screw driver install and tighten the four screws which hold the top IP20 protection cover in place see Figure 104 on page 197 19 Install the left side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the left side panel in place see Figure 104 on page 197 20 Install the control basket as described in the procedure on page 193 Removing the Main Fan This procedure explains how to remove the main fan from the following drive controllers Drive Controller No Main Fan No ATV66D54N4 ATV66D64N4 VZ3 V665 ATV66D79N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved 223 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 224 Bulletin NO VDUCUOS U1 December 1996 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution
213. e instructions can result in death of serious injury Logic Input Test allows you to change the state of the logic inputs to check for good wiring connections When the Logic Input Test screen is active changes made to the inputs will change input bit status without affecting the state of the drive controller 1996 Square D All Rights Reserved 81 Cnapter 3 Correcting tne Problem Checking the Power Part of the Controller 82 Bulletin NO VDUCUOS U1 December 1996 Analog Input Test is similar to Logic Input Test When this screen is active you can change the state of the analog inputs to check for good wiring connections without affecting the state of the drive controller Logic Output Test allows you to change the state of the logic outputs to check for good wiring connections without affecting drive controller operation When the Logic Output Test screen is active all outputs are forced to low 0 state regardless of actual drive controller settings Changes then made to the outputs will alter bit status without affecting the state of the drive controller When you leave the Diagnostic Mode and return to the Main menu the logic outputs resume the programmed settings in place before the test sequence Analog Output Test allows you to change the value of the analog outputs to check for good wiring connections without a
214. e on the braking IGBT module Do not tighten until all of the hex head screws and mounting pins are started with any required cable connected Using a torque wrench and the appropriate socket tighten the mounting pins and screws except the braking IGBT module mounting pin to 17 7 Ib in 2 Nem The tightening torque for the braking IGBT module screw is 13 3 Ib in 1 5 Nem Red C cable from precharge resistor PA cables Two black C cables to be connected to left hand side of second capacitor down from the top Figure 71 Bus Bar Cable Locations 7 Remove static protective foam from IGBT module control terminals 8 Install the power board as described in the procedure on page 124 Removing the Braking This procedure explains how to remove the braking IGBT module from the IGBT Module following drive controllers Drive Controller No IGBT Module No ATV66D16N4 ATV66D23N4 VZ3 IM1025M1001 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D
215. e pages indicated in the table for spare part change out procedures For location of spare parts see Figure 118 on page 234 and Figure 119 on page 235 Table 15 Spare Parts for Drive Controllers ATV66C10N4 to C19N4 Description For Drive Catalog Number For Change Out Controllers Procedure See Control Kit ATV66C10N4 to C19N4 VX4 A66CK2 Pages 236 241 Control Terminal Blocks Kit ATV66C10N4 to C19N4 VZ3 NO06 Pages 241 242 Power Board ATV66C10N4 VX5 A66C10N4 Pages 243 246 ATV66C13N4 VX5 A66C13N4 ATV66C15N4 VX5 A66C15N4 ATV66C19N4 VX5 A66C19N4 Power Pole Kit ATV66C10N4 VZ3 IM1300M1206 Pages 247 255 ATV66C13N4 C15N4 VZ3 1M1400M1206 ATV66C19N4 VZ3 1M1500M1206 Diode Bridge Kit ATV66C10N4 C13N4 VZ3 DM2170M1601 Pages 257 260 ATV66C15N4 VZ3 DM2260M1601 ATV66C19N4 VZ3 DM2350M1601 Current Sensor Assembly ATV66C10N4 C13N4 VY1 A66106 Pages 261 263 ATV66C15N4 C19N4 VY1 A66107 Dynamic Braking Module Kit ATV66C10N4 to C19N4 VZ3 IM1300M1207 Pages 264 277 Thermal Switch Kit ATV66C10N4 to C19N4 VZ3 G003 Pages 277 280 Filter Board Assembly ATV66C10N4 to C19N4 VX4 A66106 Pages 280 282 Capacitor Assembly ATV66C10N4 to C19N4 VY1 ADC607 Pages 282 287 Control Power Transformer ATV66C10N4 to C19N4 VY1 ADA606 Pages 287 290 Stirring Fan ATV66C10N4 to C19N4 VZ3 V667 Pages 291 292 Fan and Capacitor ATV66C10N4 to C19N4 VZ3 V666 Pages 292 294 main cooling fan Dischar
216. e socket in the drive chassis see Figure 58 on page 109 Clip the fan leads on the controller side of the plug 12 Using needle nose pliers carefully remove the J6 connector located at the top of the power board Pull the wire attached to the J6 connector through the controller Discard the old fan bracket J6 connector and wiring Installing the Fan This procedure explains how to install the fan in the following drive controllers Drive Controller No Fan No ATV66U90N4 VZ3 V663 ATV66D12N4 VZ3 V663 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure 1996 Square D All Rights Reserved c 109 Cnapter 4 rquipment Change Out Bulletin NO VDUCUOS U1 December 1996 ATV66U90N4 and ATV66D12N4 110 The tools needed for this procedure are 1 4 drive metric socket set 5 5 to 14 mm Needle nose pliers Torque wrench set to 35 4 Ib in 4 Nem Flat blade screw drive sockets for torque wrench Control basket procedure tool list page 103 To install the
217. e surface temperatures of enclosures and conduits Damage to power or control conductor conduit e Unusual noise or odors from any of the equipment e Abnormal environmental conditions i e temperature humidity vibration etc e Other conditions which may adversely affect the operation of the equipment If external damage is apparent immediately inform operating personnel and assess the risk of leaving the drive system powered Outwardly visible signs of damage generally warrant shutdown thorough internal inspections and subsequent corrective action Table 5 on page 17 contains specific information for troubleshooting damaged equipment Once external inspection is complete maintenance personnel should consider using the controller s diagnostic features to help locate specific problems If the LED indicators and keypad on the front of the controller are accessible without exposing maintenance personnel to hazardous conditions a significant amount of status and fault trip information can be gathered Information available through the LED indicators and keypad display is described on pages 12 to 16 of this chapter If the controller is operational but not performing as expected proceed to Table 2 on page 14 for specific troubleshooting information based upon reported symptoms The keypad display can be used to gather status and operating parameter information to assist in the analysis If the controller has faulted and control power is s
218. e termination points located on the gate driver board see Figure 85 on page 155 8 Install the top IP20 protection cover Route the five control basket cables through the hole in the protection cover Using a phillips screw driver install and tighten the four screws which hold the top IP20 protection cover in place 9 Install the left side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the left side panel in place 10 Install the control basket as described in the procedure on page 149 Removing the Power Board This procedure explains how to remove the power board from the following drive controllers Drive Controller No Power Board No ATV66D33N4 VX5 A66D33N4 ATV66D46N4 VX5 A66D46N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Comp
219. e will be needed during the installation of the new power board Additionally remove the six gate driver board standoffs for use during installation of the new board NOTE Be sure the J5 ribbon cable has been released before pulling to avoid damage to the cable 11 Remove the power board This procedure explains how to install the power board in the following drive controllers Drive Controller No Power Board No ATV66D33N4 VX5 A66D33N4 ATV66D46N4 VX5 A66D46N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Torque wrench set to 17 7 lb in 2 Nem Gate driver procedure tool list page 156 e Control basket procedure tool list page 149 For the power board to be installed NOTE Make sure the bus bar isolating screen is in place between the bus bar and the power board see Figure 88 on page 160 1996 Square D All Rights Reserved L 159 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D
220. ecautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Aset of magnetized phillips screw drivers e Torque wrench set to 8 9 Ib in 1 0 Nem e Aset of phillips screw driver sockets for torque wrench For the control basket to be installed 1 Thread the three ribbon cables through the cable guides on the back of the control basket see Figure 61 on page 114 2 Place the control basket in the controller and ensure the mounting holes are aligned with the holes in the controller see Figure 61 on page 114 3 Insert the three screws that are not captive Using a torque wrench and phillips screw drive socket tighten the three screws and the one captive screw to 8 9 Ib in 1 0 Nem see Figure 61 on page 114 NOTE The captive mounting screw provides the grounding connection for the control basket and shield connection on J13 Ensure this screw is properly threaded and torqued 4 Snap the four connectors J9 J12 J13 and J32 into place see Figure 61 on page 114 NOTE The yellow keys in both the plugs and sockets are designed to prevent incorrect insertion of both J12 and J13 5 Make sure all three cable connectors are pulled out on connectors J3 J4 and J5 see Figure 62 on page 114
221. ect the jumper conductor between CL2 terminal of the controller and the user supplied L2 line side power fuse terminal 6 Replace the CL1 and CL2 jumpers refer to VDOC065304_ REMOVAL OF CL1 AND CL2 JUMPERS for location and replacement procedures if previously present in the controller For Class 8839 controllers replace the conductors previously connected to the CL1 and CL2 controller terminals 7 Replace the recommended user supplied power fuses in series with the L1 L2 and L3 line terminals of the controller from their respective fuse holders 8 Close the drive controller cover 9 Apply power to the controller 10 After the drive controller displays the keypad display I D screen go to the fault management screen menu 7 4 Change the In Phase Fail and Output Phase Flt to settings previously recorded 11 Press the F2 key to return to the controller keypad display I D screen NOTE If other controller settings were changed during testing return the settings to those recorded prior to testing PROCEDURE 9 To access the software version number on the chip CHECKING THE 1 Disconnect and verify that all power is removed from the drive controller SOFTWARE REVISION Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT on page 310 of LEVEL this manual 2 Wait one minute to allow the DC bus to discharge 3 Open the front cover of the drive controller 4 Locate the plastic cover over the software chip Software Chip Cover TERR e
222. ected to a Possible feeder whose utilization cause voltage level does not match the controller s voltage rating Short overvoltage 30 ms minimum Check the value of the UE line voltage on the keypad display performed Refer to chapter 3 section Drive Controller Internal Measurements Check and measure the voltage at terminals L1 L2 L3 Line voltage less than 544 VAC Line voltage greater than 544 VAC Result Refer to chapter 4 to change the Power board Filter board Control basket Refer to chapter 4 Control basket change out procedure to check for proper seating of control basket ribbon cables Install line reactors Check distribution upstream of controller System voltage setting Solution and expected range of variation Adjust or change as required Figure 17 Line Overvoltage O 1996 Square D All Rights Reserved Bulletin NO VDUCUO6S U1 Cnapter 3 Correcting the Problem December 1996 DC Bus Overvoltage DC Bus Overvoltage Figure 18 illustrates the measurement principle used for the DC bus overvoltage fault S Power board l Control basket Figure 18 DC Bus Overvoltage Measurement The measurement is taken from the capacitor terminals The voltage is compared to a threshold voltage of 850 VDC If the DC bus voltage is greater than 850 VDC the DC bus overvoltage fault is triggered The DC bus voltage can be displayed on the keypad display at the line
223. ed Bulletin NO VDUCUOS U1 December 1996 Installing the Current Sensor Assembly Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 6 Gently pull the current sensor out and then up Be aware of the signal cable connected to the lower right hand corner of the sensor When the sensor is removed sufficiently to reach the signal cable unplug it from the sensor using needle nose pliers pull on the connector not the wires Remove the sensor completely form the drive There are two current sensors in the ATV66C10N4 to C19N4 drive controllers The current sensor kit contains one current sensor This procedure how to install the current sensor assembly in the following drive controllers Drive Controller No Current Sensor No ATV66C10N4 VY1 A66106 ATV66C13N4 VY1 A66106 ATV66C15N4 VY1 A66107 ATV66C19N4 VY1 A66107 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Set of magnetized flat blade screw drivers Torque w
224. ed Trip 28 Cannot Start Motor a o x eres cya e ERAS qr BS ee tg UR 32 Cannot Stop Motor gt ai Acetate REIR E RR ERREUR ERE 37 Motor Turns in Wrong Direction llle 40 Drive Will Not Follow Speed Command 00 cece ete 41 Specific Drive Function Does Not Work as Expected Not at All 41 TRIPS RESETTABLE BY KEYPAD LI AUTOMATIC POWER CYCLE 43 Undervoltage 5 cess A RU RA LEUR NER eH 43 Line Overvoltage 2 2 s bepEnRB RPM ML p ELRPpIe baie Rd ees 45 DC Bus Overvoltage m e E n anoa mh 47 Input Phase Lo8s 5 eine dba 51 Motor OVerload ss ste eai kei mee a ete lee 53 Drive Overtemperature oooocccooco he 55 Loss of Follower acte i eer P US EP uU ARR AE PEZ 57 Output Phase Loss 0 0 cece eee mn 58 Sequence Time OUt tne edu e oe Dn E ii dde nre 60 Process Time Out seio RID A A ia s 60 Serial Link PAU ite i at ETC idv IU E epe Pet 60 TRIPS REQUIRES POWER TO BE CYCLED 0 0 0 cece eee eee 61 Short Circuits ii ia ReI ev E wie Oe ie ene eee eae Pie lh 61 Ground Fault oec il cda ore herent nae dees Beda RO 63 Internal Fault Ses EA IRR HM E unus 65 Internal Falt ccr A A uu Ede EE WIE erbe AA 66 Dynamic Brake Fault oooooocoocoror lene 67 Dynamic Brake Resistor Overtemperature 00 0 cece eee eee 68 Memory Failures 5 uei a an ERAS ek pon wae cea aon oe ane ash ab eee 69 Precharge Failures 12 bedi added arriba 69 lankeF
225. eeded for this procedure are e Aset of magnetized flat blade screw drivers With the drive controller door open 1 Using a flat blade screw driver push in on the keypad display tab and remove the keypad display see Figure 46 on page 87 2 Insert the new keypad display into the front of the control board Ensure the lip on the bottom of the keypad display is behind the tab on the control basket Key display tab RUN STOP cover Figure 46 ATV66U41N4 to U72N4 Front View 1996 Square D All Rights Reserved 87 Cnapter 4 Equipment Cnange Out ATV66U41N4 to ATV66U72N4 Removing the Control Basket 88 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to remove the control basket for the following drive controllers Drive Controller No Control Kit No ATV66U41N4 ATV66U54N4 VX4 A66CK1 ATV66U72N4 Before removing power note and record all the drive controller settings using the keypad display A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if in
226. eee 272 Removing the Dynamic Braking DB Diode Block oooooo 273 Installing the Dynamic Braking DB Diode Block oooooo 276 Replacing the Thermal Switches re 277 Replacing the Filter Board Assembly 000 00 e eee eee eee 280 Replacing the Capacitor Assembly 0 0000 cece eee eee eee 282 Removing the Control Power Transformer 0000 cece eee cence 287 Installing the Control Power Transformer 00 00 cee eee eee ee eeee 289 Replacing the Stirring Fan 0 0 0 cece 291 Removing the Main Fan 00 0 eee eee ee 292 Installing the Main Fan 0 eee eet 294 Replacing the Discharge Resistor 0000 cece eee eee eee 295 Replacing the Precharge Resistor 00c cece eee eee eee 296 Replacing the Contactor Auxiliary Contact Block oooooooooooo 298 Removing the Precharge Contactor 0 00 c cece tee 301 Installing the Precharge Contactor 0 0 cece ete 302 Replacing the Circuit Protector 305 Replacing the Control Fuses 0 0c eect tte tenes 306 Replacing the DC Bus Fuse 0 0 c cece tetas 306 1996 Square D All Rights Reserved 85 Cnapter 4 Equipment Cnange Out General GENERAL ATV66U41N4 to U72N4 86 Bulletin NO VUUCU6S U1 December 1996 A DANGER HAZARD
227. elation between the gate collector and emitter of each IGBT module The gate connection on ATV66C10N4 to ATV66C19N4 controllers is the upper right hand mounting screw on each of the six gate cards see Figure 128 on page 252 1996 Square D All Rights Reserved 75 Cnapter 3 Correcting tne Probiem Bulletin NO VDUCU6S UT Checking the Power Part of the Controller December 1996 ren 1 8V OL 0 30 0 45V 1 1 1 8V 1 4 2 1V 1 2 2 3V Figure 42 Checking the IGBT Modules NOTE All measurements referencing the G gate terminal will read OL if the gate lead is removed from the IGBT NOTE If an IGBT module is changed on drive controllers ATV66D16N4 through ATV66C19N4 the gate driver board must also be changed Checking the Braking IGBT Check the braking IGBT module as shown in Figure 43 for the resistance values Module shown Use a multimeter as recommended in LIST OF TOOLS AND INSTRUMENTS on page 5 Set the meter on the diode scale Refer to Figure 36 on page 71 for the relationship between the PB and terminals On ATV66U41N4 through ATV66D12N4 R OL Figure 43 Checking the Braking IGBT Module NOTE If a braking IGBT module is changed on drive controllers ATV66D16N4 through ATV66C19N4 the gate driver board must also be changed Checking the Braking IGBT Check the braking IGBT module freewheel diode as shown in
228. emoval installation instructions 4 Using a phillips screw driver carefully loosen and remove the two screws holding the controller top cover in place 5 Usinga flat blade screw driver carefully loosen and disconnect the J9 and J32 connectors located at the top left of the control basket see Figure 54 on page 102 EN mra Cable guides located on back of control AT basket Location of I O Extension Module if installed ELS Tm Captive mounting a Mounting screw screw J13 J12 9 Figure 54 Control Basket Connector Locations 6 Usinga flat blade screw driver carefully loosen and disconnect the J12 and J13 connectors located at the bottom of the control basket 7 Using two small flat blade screw drivers carefully pull out on each side of the cable clasps of J3 J4 and J5 to the release position see Figure 55 on page 102 Pull the ribbon cables from the sockets NOTE Be sure the ribbon cables have been released before pulling to avoid damage to the cables There are two versions of the cable clasps blue and white White Cable Clasp oe Ribbon Cable Ribbon Cable cele Circuit Board Circuit Board N a A ares i i Blue Cable Clasp Secure Position Secure Position White Cable Clasp Pull Out Pur ut ia Ribbon Cable BEN Ribbon Cable BES Circuit Board Circuit Board i Id AN p i j Blue Cable Clasp
229. emoved from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers 104 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Chapter 4 Equipment Change Out ATV66U90N4 and ATV66D12N4 With the drive controller door open or removed 1 Ze 1P20 Protection Cover Measure the bus voltage if not already performed as described in Chapter 5 of this manual Remove option module if present See User s Manual VDOCO061306 for removal installation instructions Identify and tag all field wiring for future re assembly Using a flat blade screw driver loosen the terminal screws on the J1 J12 and J13 connectors see Figure 56 on page 105 Pull the field wiring back out of the way Using a flat blade screw driver gently pry the J1 J12 and J13 field connectors away from the board side connectors Discard the old connectors Insert the new field side connectors into their associated board side connectors NOTE The yellow keys in both the plugs and sockets are designed to prevent incorrect in
230. en the four screws which hold the left side panel in place see Figure 104 on page 197 Install the control basket as described in the procedure on page 193 1996 Square D All Rights Reserved 229 Cnapter 4 rquipment Change Out Bulletin NO VDUCUbS UI ATV66D54N4 to D79N4 December 1996 Replacing the Auto This procedure explains how to replace the auto transformer for the following Transformer drive controllers Drive Controller No Main Fan No ATV66D54N4 ATV66D64N4 VY1 ADA604 ATV66D79N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction ca
231. ench set to 17 7 lb in 2 Nem e Current sensor assembly procedure tool list page 263 To install the dynamic braking snubber board 1 Align the mounting holes on the dynamic braking snubber board with the mounting posts in the controller see Figure 133 on page 266 2 Install the two mounting screws Using the torque wrench with a hex key socket tighten the two mounting screws to 17 7 Ib in 2 Nem 3 Connect the J2 connector on the dynamic braking snubber board 4 Ifinstalling a new snubber board install the jumper between J3 and JA 5 Replace both current sensor assemblies as described in the procedure on page 263 1996 Square D All Rights Reserved 267 Cnapter 4 rquipment Change vut Bulletin NO VDUCUOS UI ATV66C10N4 to C19N4 December 1996 Removing the Dynamic The dynamic braking module kit contains one gate driver board Braking DB Gate Driver y a q Board JPB This procedure explains how to remove the dynamic braking gate driver board from the following drive controllers Drive Controller No DB Module Kit No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 VZ3 IM1300M1207 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resultin
232. enes 191 Installing the Control Basket ocococcococccco teas 193 Replacing Control Terminal Blocks 00 0 cece eee 194 Replacing the Board Fan oocoocororocon a e 196 Removing the Gate Driver Board l i eese 198 Installing the Gate Driver Board liliis eese 200 Removing the Power Board l l tee 201 Installing the Power Board oooooccoccoo A 203 Removing the IGBT Module oo ooccccccccccco tetas 205 Installing the IGBT Module 2 0 0 0 cece III 207 Removing the Braking IGBT Module 0 000 cece eee eee 208 Installing the Braking IGBT Module 0 0 cece eee 210 Removing the Bus Capacitor Assembly 0 000 c cece eee ee eee 211 Installing the Bus Capacitor Assembly 000 cece eee eee 213 Removing the Filter Board 0 0 eee 215 Installing the Filter Board 0 0 tees 217 Removing the Diode Block 0 cee eee ees 219 Installing the Diode Block 0 00 0 cee eee ees 220 Replacing the Current Sensor 0 000 eee ee teas 221 Removing the Main Fan 0 cece eee n 223 Installing the Main Fan 0 eee 225 Replacing the Precharge Resistor 0 0 cece ett ees 226 Replacing the Discharge Resistor 0 cece eee ete 228 Replacing the Auto Transformer lise 230 ATV66C10N4 to C19N4 occ 233 Replacing the Keypad Display lsleleeee ee 236 Removing the Control Bas
233. ensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 1 4 drive metric socket set 5 5 to 14 mm e Torque wrench set to 26 5 Ib in 3N m e Metric hex key sockets for torque wrench 2 to 14 mm e Set of open end wrenches 5 5 to 19 mm e Thermal grease Thermalloy Thermalcote II Part No 349 or equivalent e Power board procedure tool list page 159 Gate drive procedure tool list page 156 e Control basket procedure tool list page 149 For the braking IGBT module to be installed 1 Clean the portion of the heatsink which will make contact with the new braking IGBT module 2 Evenly coat the bottom of the new braking IGBT module with a thin coating of thermal grease O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Bus Capacitors Unapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 3 Install the new braking IGBT module with the push on connectors towards the outside of the drive controller Using a torque wrench with a hex key socket install and tighten the two mounting screws to 26 5 Ib in 3 Nem see Figure 90 on page 163
234. ents may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Snubber board procedure tool list page 248 Gate driver procedure tool list page 251 With the drive controller door open or removed 1 Remove the gate driver boards as described in the procedure on page 250 NOTE To remove IGBT 2 3 5 or 6 it is necessary to loosen gate driver board mounted above it The gate driver board wiring may be left intact 2 Using a hex key wrench remove the mounting brackets for the metal can capacitors for the snubber board associated with IGBT being replace Remove the metal can capacitor see Figure 127 on page 249 3 Usingahexkey wrench loosen and remove the remaining bus terminal screw the other one was removed in the gate driver board removal procedure 4 Usinga hex key wrench loosen and remove the four IGBT mounting screws 5 Using a flat blade screw driver gently pry loose the IGBT module from the heat sink 6 Remove the IGBT module Ensure that all of the old Thermstrate foil is removed from the hea
235. er board 3 Position the gate driver board over the fixing pins on the power board and snap the gate driver board onto the fixing pins 4 Ifrequired re braid the twisted pair wires before connecting them to the IGBT modules 5 Using needle nose pliers carefully connect J20 1 J20_2 J21_1 J21_2 J22_1 J22 2 J23 1 J23_2 J24 1 J24 2 25 1 and J25_2 at the termination points located on the IGBT modules see Figure 106 on page 199 6 Using needle nose pliers carefully connect J26 1 J26 2 and J34 at the termination points located on the braking IGBT module see Figure 106 on page 199 7 Using needle nose pliers carefully connect J27 J28 J29 J30 J57 J58 J59 J60 and J61 at the termination points located on the gate driver board see Figure 105 on page 199 8 Install the top IP20 protection cover Route the five control basket cables through the hole in the protection cover Using a phillips screw driver install and tighten the four screws which hold the top IP20 protection cover in place 9 Install the left side panel by sliding it downward into position Using a phillips or Torx screw driver install and tighten the screws which hold the left side panel in place 10 Install the control basket as described in the procedure on page 193 Removing the Power Board This procedure explains how to remove the power board from the following drive controllers Drive Controller No Power Board No ATV66D54N4
236. er of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers With the drive controller door open 1 Usinga flat blade screw driver push in on the keypad display tab and remove the keypad display see Figure 53 on page 100 2 Insert the new keypad display into the front of the control board Ensure the lip on the bottom of the keypad display is behind the tab on the control basket Keypad display tab RUN STOP cover Figure 53 ATV66U90N4 and D12N4 Front View O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Control Basket Cnapter 4 Equipment Cnange Out ATV66U90N4 and ATV66D12N4 This procedure explains how to remove the control basket from the following drive controllers Drive Controller No Control Kit No ATV66U90N4 ATV66D12N4 VX4 A66CK1 Before removing power note and record all the drive controller settings using the keypad display A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if installed connectors Verif
237. er power supply connections are available on the J12 and J13 connectors of the main control board and if equipped with an I O Extension Module J22 and J23 connectors Check the following voltages using the multimeter recommended in LIST OF TOOLS AND INSTRUMENTS on page 5 of this manual 1 On J12 of the main control board check the voltage between COM and 24 terminals The voltage should be between 20 VDC to 30 VDC 2 OnJ13 of the main control board check the voltage between COM and 10 terminals The voltage should be between 9 5 VDC to 11 VDC 3 On J22 of the I O Extension board check the voltage between COM and 10 terminals The voltage should be between 9 5 VDC to 11 VDC 4 On J22 of the I O Extension board check the voltage between COM and 10 terminals The voltage should be between 9 5 VDC to 11 VDC 5 OnJ23 of the 24 VDC I O Extension board VW3A66201_ check the voltage between COM and 24 terminals The voltage should be between 20 VDC to 30 VDC If no or low voltage is present the user power supply may be overloaded due to the connected external load Remove the user connections from the terminals and retest If the voltage is now within limits check the user load connected to the ter minals to verify that an overload does not exist Refer to the VDOC065304_ and VD0C061306_ instruction manuals for rated output current of each supply 1996 Square D All Rights Reserved
238. er to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Snubber Board procedure tool list page 248 With the drive controller door open or removed 1 Remove the snubber board as described in the procedure on page 247 2 Using needle nose pliers carefully disconnect the P2 connector on the gate driver board see Figure 128 on page 252 3 Usinga hex key wrench loosen and remove the two mounting screws At the associated IGBT module use a hex key wrench to loosen and remove the top bus terminal screw and remove the gate driver wire landed underneath This wire is landed on the gate driver board by one of the following Soldered Connected by a zero force connector Connec
239. ermal switch Control basket Connections Refer to chapter 4 to change the precharge resistor Figure 15 Undervoltage 44 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 3 Correcting tne Problem December 1996 Overvoltage Overvoltage Figure 16 illustrates the measurement principle used for the overvoltage fault Connection is made through the filter board on the following models A n E ATV66D16N4 I ATV66D23N4 I ATV66D33N4 l ATV66D46N4 ATV66D54N4 ATV66D64N4 ATV66D79N4 ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Power board A et eae l Ea um ue ee a Figure 16 Line Overvoltage Measurement The line overvoltage fault appears when line supply voltage is too high The line voltage L1 L2 L3 is rectified and filtered Triggering occurs at the peak value The line overvoltage fault appears when line supply voltage is greater than 544 VRMS or 770 VAC peak The RMS value can be displayed on the keypad display O 1996 Square D All Rights Reserve 45 Cnapter 3 uorrecting tne Problem Overvoltage 46 Bulletin NO VDUCUOS U1 December 1996 Figure 17 illustrates the troubleshooting procedure when the line overvoltage fault is present LINE Fault Displayed OVERVOLTAGE Line voltage too high Controller conn
240. erminal Block Kit ATV66D33N4 D46N4 VZ3 N006 Pages 150 151 Board Fan ATV66D33N4 D46N4 VZ3 V6654 Pages 152 153 Gate Driver Board ATV66D33N4 VX5 A66105 Pages 154 157 ATV66D46N4 VX5 A66106 Power Board ATV66D33N4 VX5 A66D33N4 Pages 157 161 ATV66D46N4 VX5 A66D46N4 IGBT Module ATV66D33N4 VZ3 IM2100M1201 Pages 161 164 ATV66D46N4 VZ3 IM2150M1201 Braking IGBT Module ATV66D33N4 D46N4 VZ3 IM2050M1201 Pages 165 167 Bus Capacitor ATV66D33N4 D46N4 VY1 ADC472V450 Pages 167 170 Filter Board ATV66D33N4 D46N4 VX4 A66104 Pages 171 175 Diode Block ATV66D33N4 VZ3 DM2080M1606 Pages 175 177 ATV66D46N4 VZ3 DM2100M1601 Current Sensors 2 in kit ATV66D33N4 D46N4 VY1 A66104 Pages 178 180 Fan ATV66D33N4 D46N4 VZ3 V665 Pages 181 183 Discharge Resistor ATV66D33N4 D46N4 VZ3 R5KOW040 Pages 183 184 Auto Transformer ATV66D33N4 D46N4 VY1 ADA604 Pages 185 187 1996 Square D All Rights Reserved 145 Cnapter 4 Equipment Cnange vut ATV66D33N4 and ATV66D46N4 Replacing the Keypad Display 146 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to replace the keypad display for the following drive controllers Drive Controller No Control Kit No ATV66D33N4 ATV66D46N4 VX4 A66CK1 NOTE All ALTIVAR 66 drive controllers use the same model keypad display However the version of software present within the keypad display may be specific to the version of software present in
241. eter Pass the anemometer over the exhaust of each controller and compare the velocity readings Generally a controller with a damaged or blocked fan or air passage will have a significantly diminished flow rate which will be visible from the anemometer readings Stirring fans should be visually inspected Look for damaged impellers blocked or binding impellers or incorrect installation following repair check flow direction arrows 1996 Square D All Rights Reserve 315 Cnapter 5 basic Procedures Bulletin NO VDUCUOS UT Running the Controller from Control Power Only December 1996 PROCEDURE 7 CLEANING HEAT SINKSAND AIR PASSAGES PROCEDURE 8 RUNNING THE DRIVE CONTROLLER FROM CONTROL POWER ONLY 316 Cleaning heat sink passages generally requires some amount of controller disassembly All cleaning operations must be done with all power removed from the controller For ATV66U41 through ATV66D23 controllers follow the procedures for fan replacement found in chapter 4 to remove the rear cover of the controller to expose the heat sinks Use a compressed air jet applied to the exhaust openings of the heat sink to blow dirt and debris from the heat sink passages Use a vacuum hose to clean debris blown into the fan s For ATV66D16 through ATV66D79 controllers a compressed air jet should be applied to the exhaust opening of the contr
242. etthe voltmeter to the 1000 VDC scale Measure the bus capacitor voltage between the PA and terminals to verify the DC voltage is less than 45 V Do not short across capacitor terminals with voltage present 5 Ifthe bus capacitors are not fully discharged do not operate the drive controller 6 If controller is to be serviced refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS on page 311 Otherwise contact your local Square D representative 310 1996 Square D All Rights Reserved Bulletin NO VDUCUDGS U1 Unapter 5 Basic Procedures December 1996 Bus Voltage Measurement OD F4 BIESSE PEA z PA ATV66U41N4 to D12N4 o 9 Protective Switch GV2 olor 9 O O O OlsroJO O Ola ajo ojo of Ojololole ATV66C10N4 to C19N4 PA ATV66D16N4 to D79N4 Figure 147 Location of PA and Terminals ATV66U41N4 to C19N4 PROCEDURE 2 A DANGER DISCHARGING STO
243. ew driver install and tighten the three screws which hold the bottom IP20 protection cover in place see Figure 104 on page 197 11 Install the J1 terminal block see Figure 104 on page 197 12 Install the gate driver board as described in the procedure on page 200 201 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the IGBT Module Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 There are three IGBT modules in this size of drive controller This procedure explains how to remove the IGBT module in the following drive controllers Drive Controller No IGBT Module No ATV66D54N4 VZ3 IM2150M1201 ATV66D64N4 VZ3 IM2200M1201 ATV66D79N4 VZ3 IM2300M1201 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on
244. ews holding the controller top cover in place 5 Using a flat blade screwdriver carefully loosen and disconnect the J9 and J32 connectors located at the top left of the control basket see Figure 47 on page 89 Aw Li Cable guides located on back of control basket Location of I O Extension Module if installed AT cra i Captive mounting P ais N Mounting screw screw J13 J12 9 Figure 47 Control Basket Connector Locations 6 Usinga flat blade screw driver carefully loosen and disconnect the J12 and J13 connectors located at the bottom of the control basket 7 Using two small flat blade screw drivers carefully pull out on each side of the cable clasps of J3 J4 and J5 to the release position see Figure 48 on page 89 Pull the ribbon cables from the sockets NOTE Be sure the ribbon cables have been released before pulling to avoid damage to the cables There are two versions of the cable clasps blue and white White Cable Clasp n Ribbon Cable Ribbon Cable Lem Le Circuit Board a ES Circuit Board i e i ii Blue Cable Clasp Secure Position Secure Position White Cable Clasp Pull Out Pull Out N ra Ribbon Cable MELLE iren Cable i Circuit Board Circuit Board J N T i j Blue Cable Clasp Release Position Release Position White Cable Clasps Blue Cable Clasps Figure 48 Cable Con
245. f 74 3 b in 8 4 Nem NOTE Ensure that the bus bar spacing specifications are adhered to as described in the note on Figure 130 on page 258 Place the small RB cable over its mounting location on the RB bus bar Using a torque wrench with hex key socket install and tighten the mounting screw to a torque of 35 4 Ib in 4 Nem Place the small RB cable over its mounting location on the RB bus bar Using a torque wrench and hex key socket install and tighten the mounting screw to a torque of 35 4 Ib in 4 Nem See Figure 130 on page 258 Place the large RB cable over its mounting location on the RB bus bar Using a torque wrench with a hex key socket install and tighten the mounting screw to a torque of 70 Ib in 8 Nem Place the large RB cable over its mounting location on the RB bus bar Using a torque wrench and hex key socket install and tighten the mounting screw to a torque of 70 Ib in 8 Nem See Figure 130 on page 258 For ATV66C15N4 and C19N4 controllers replace the plastic cap on the middle diode block upper screw See Figure 130 on page 258 Reinstall plastic terminal block cover Swing the hinged assembly back to the left Using a flat blade screw driver tighten the two screws O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Current Sensor Assembly Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 There are two current sensors in the ATV66C10N4
246. f this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of Torx screw drivers e 4 Needle nose pliers Control Basket procedure tool list page 147 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 147 2 Using a phillips or Torx screw driver loosen and remove the four screws which hold the left side panel see Figure 83 on page 153 Two screws are located at the top and two screws are located at the bottom Remove the left side panel 151 __ 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D33N4 and ATV66D46N4 3 Using a phillips screw driver loosen and remove the four screws which hold the top IP20 protection cover in place Remove the top IP20 protection cover This allows access to the gate driver board 4 Using needle nose pliers carefully disconnect J27 J28 J29 J30 J57 J58 J59 J60 and J61 at the termination points located on the gate driver board see Figure 85 on page 155 Figure 85 Gate Driver Board Connection Locations 5 Using needle nose pliers carefully disconnect J20 1 20 2 J21 1 J21 2 22 1 J22_2 23 1 23 2 J24 1 J24 2 J25 1 and J25 2 at the termination points located on the IGBT modules see Figure 86 on page 155 Left Side of Drive Controller
247. fan 1 With the drive controller inverted thread the J6 connector from the new fan through the fan lead hole in the back of the drive controller see Figure 59 on page 110 Install the new twin fan Ensure the label side of the side of the twin fan is facing towards the heat sink Install the twin fan mounting bracket Install and tighten the two mounting screws With the drive controller returned to its upright position route the J6 connector and wire lead diagonally over to the right side of the controller see Figure 59 on page 110 J6 connector Fan lead routing Figure 59 Fan Lead Routing NOTE When routing the wire in the above step the J6 connector and attached fan leads are routed between the back of the heat sink and the underside of the printed circuit board 5 10 11 12 13 Continue to route the J6 connector and wire leads along the right side of the controller around the outside of the top right corner and under the voltage regulator heat sink bar Attach the J6 connector at the top of the power board See Figure 59 on page 110 Fit the drive controller chassis to the controller back cover Using a drive socket or a phillips screw driver as necessary tighten the four screws holding the drive controller chassis to the back cover Install the two side panels by sliding them towards the bottom of the controller until the mounting tabs lock into place Install the controller bottom cover Usi
248. ffecting drive controller operation When the Analog Output Test screen is active all output values are forced to 0 re gardless of actual drive controller settings Changes then made to the outputs will alter the setting without affecting the state of the drive controller When you leave the Diagnostic Mode and return to the Main menu the analog outputs resume the programmed settings in place before the test sequence O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 CHAPTER 4 EQUIPMENT CHANGE OUT PROCEDURES Cnapter 4 rquipment Change vut GENERAL RD e PM A Fate eres a rect d 86 ATV66U41N4 to U72N4 2 e e he e 86 Replacing the Keypad Display oooooooococororrn I 87 Removing the Control Basket eee 88 Installing the Control Basket 90 Replacing Control Terminal BlockS 0 0 00 eese 91 Replacing the Power Board 0 cece eee ene 92 Removing the Fan ue ei ee eels a RENE RUE EA E 94 Installingithe Fan ise pee Remp AA A 96 ATV66U90N4 and D12N4 occ 99 Replacing the Keypad Display oooooooococorocr 100 Removing the Control Basket eere 101 Installing the Control Basket 103 Replacing Control Terminal Blocks esee 104 Replacing the Power Board l i 106 Removing the Fani pinsi sealer Ata DRE D E REN KR Unete ch ERG 108 Installingithe Fan a AA a RAI ta es 109 ATV66D16N4 and D23N4 1 e rm e 111 Replacing the Keypad Display oooooocooccor
249. for the following drive controllers Drive Controller No Control Terminal Blocks No ATV66C10N4 ATV66C13N4 VZ3 N006 ATV66C15N4 ATV66C19N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if installed connectors Verify that all power has been removed from J1 J12 and J13 connectors If I O Extension Module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved L 241 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Bulletin NO VDUCUOS U1 December 1996 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are A set of magnetized flat blade screw drivers With the drive controller door open 1 J13 Measure the bus voltage if not already performed as described in chapter 5 of this manual Remove options module if present See User s Manual VD
250. g IGBT Module 000 cece e eee eee eee 76 Checking the Braking IGBT Module Freewheel Diode 76 Checkout of the Control Part of the Drive Controller oooooooo oo 77 Drive Controller Internal Measurements Check oooococcococccooo 78 Checking Fault History liliis 79 Checking the 24 VDC and 10 VDC User Power Supplies 79 Checking the Keypad Display lisseseleeee een 80 Diagnostic Mode keen ole RG SY be RG Re Rn RUE RUNE RD Bee 81 AULOCIAQNOSTICS dike bot eta Aid wrth ed dash ele i dala aos 81 Logic and Analog Input Output Tests 0000 e eee eee eee eee 81 GENERAL oia Re E RATER a Spy ad EH ii 86 ATV66U41N4 TO U72N4 2 0 ett eens 86 Replacing the Keypad Display lisse 87 Removing the Control Basket oooccococcccococ eh 88 Installing the Control Basket lilssssseeeee eee 90 Replacing Control Terminal Blocks 000 cece eee eee 91 Replacing the Power Board o oooccoccooc ne 92 Removing Te FAN RR ERE RERO RENS E 94 Installing the Fant i i ule od Serena a dodgy bed Bebe bog bees 96 ATV66U90N4 AND D12N4 occ 99 Replacing the Keypad Display 00 eee eet ete 100 Removing the Control Basket oooccocococccccoc 101 Installing the Control Basket 00 cect eee 103 Replacing Control Terminal Blocks 0 0 0 cece eee eae 104 Replacing the Power Board 0
251. g controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Set of open end wrenches 5 5 to 19 mm Filter board procedure tool list page 216 Gate driver procedure tool list page 198 e Control basket procedure tool list page 192 With the drive controller door removed 1 Remove the filter board as described in the procedure on page 215 2 Using an open end wrench loosen and remove the mounting post washers and incoming line cable for the diode block to be removed 1996 Square D All Rights Reserved 219 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66D54N4 to D79N4 December 1996 3 Using an open end wrench loosen and remove the two lower mounting posts and washers on the center diode block which attaches the diode block to the bus work and the filter board 4 Using a hex key wrench loosen and remove the four screws which hold the diode bridge bus work to the outside diode block modules Pull the L2P and L1P cables out of the way 5 Onthediode block to be removed use a hex key wrench to loosen and remove the two d
252. g in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter setto 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are DBSnubber board procedure tool list page 265 Current sensor assembly procedure tool list page 261 268 c 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Dynamic Braking DB Gate Driver Board Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 With the drive controlle
253. g the hinged assembly out to the right 4 Usinga hex key wrench or a drive socket loosen and remove the two bolts on either side of the bottom of the fan 5 Remove the old fan Transfer the finger guard from the old fan on the new fan MO Install the new fan with the airflow indicator pointing up Using a drive socket or hex key wrench install and tighten the two bolts on either side of the bottom of the fan 8 Using needle nose pliers carefully connect the two connectors on the right side of the fan This is an AC fan The two fan leads can be connected to either terminal 9 Swing the hinged assembly back to its normal position and using a flat blade screw driver tighten the two screws Removing the Main Fan This procedure explains how to remove the main fan and fan capacitor from the following drive controllers Drive Controller No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Fan and Capacitor No VZ3 V666 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter setto 1000 VDC scale If vol
254. ge Resistor ATV66C10NA to C19N4 VZ3 R640W135 Pages 295 296 Precharge Resistor Contactor Aux Contact Block ATV66C10N4 to C19N4 ATV66C10NA to C19N4 VZ3 R010W270 LA1DN04 Pages 296 298 Pages 298 299 Precharge Contactor ATV66C10N4 C13N4 ATV66C15N4 C19N4 VY1 A661C1010 VY1 A661C1510 Pages 301 305 Circuit Protector Kit Control Fuses ATV66C10NA to C19N4 ATV66C10N4 to C19N4 GV2M10 DF3CF00501 Page 305 Page 306 DC Bus Fuse ATV66C10N4 C13N4 ATV66C15N4 C19N4 O 1996 Square D All Rights Reserved VY1 ADF400V700 VY1 ADF450V700 Pages 306 307 233 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 DC Bus Fuse Power Poles Thermal Switch Capacitor Power Poles Assembly Typical of 3 Power Poles Thermal Switch Dynamic Braking
255. h 2 to 14 mm 4 Needle nose pliers Control basket procedure tool list page 193 With the drive controller door removed 1 2 10 11 12 Remove the control basket as described in the procedure on page 191 Using a phillips or Torx screw driver loosen and remove the four screws which hold the left side panel Remove the left side panel see Figure 104 on page 197 Using a phillips screw driver loosen and remove the four screws which hold the top IP20 protection cover in place Remove the top IP20 protection cover see Figure 104 on page 197 Using a phillips or TorxG screw driver loosen and remove the four screws which hold the right side panel Remove the right side panel see Figure 104 on page 197 Using a hex key wrench loosen the terminal screw on the J2 terminal block for the ground wires from the U T1 V T2 and W T3 cables see Figure 111 on page 216 Pull the ground wires out of the way Using a hex key wrench loosen the terminal screw for V T2 at the drive controller side of the J2 terminal block Pull the cable out of the way This allows for access to the mounting screws to the current sensors Using a hex key wrench loosen the terminal screw for U T1 or W T3 at the drive controller side of the J2 terminal block The terminal screw to be loosened will depend on which current sensor is to be replaced Pull the U T1 or W T3 cable back through the current sensor and out of the way see Figure 111 on page 216
256. harge resistor and end clamps 5 Install the new precharge resistor with end clamps Ensure the end clamps are properly secured to the precharge resistor 6 Using a torque wrench and phillips screw driver socket install and tighten the two screws to 13 3 Ib in 1 5 Nem Ensure the cables are properly connected see Figure 75 on page 138 7 Install the bus bar isolating screen see Figure 68 on page 124 8 Install the power board as described in the procedure on page 124 Removing the Fan This procedure explains how to remove the fan from the following drive controllers Drive Controller No Fan No ATV66D16N4 VZ3 V664 ATV66D23N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury 133 0 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by st
257. he Auto Transformer 0 cee eee 185 ATV66D54N4 TO D79N4 0 0 tte es 189 Replacing the Keypad Display o ooooocooorconcr eee 190 Removing the Control Basket ee 191 O 1996 Square D All Rights Reserved iii ALTIVAR 66 Service and Troubleshooting Manual Bulletin No VD0C06S701 Table of Contents December1996 Installing the Control Basket 2 0 0 0 cece e 193 Replacing Control Terminal Blocks 0 0 c cece eee 194 Replacing the Board Fan 1 cece ete 196 Removing the Gate Driver Board 1 0 0 cette 198 Installing the Gate Driver Board 0 2 0 eects 200 Removing the Power Board 0 cece tte tee 201 Installing the Power Board 0 cece tee 203 Removing the IGBT Module 0 00 cece teens 205 Installing the IGBT Module sssssseee III 207 Removing the Braking IGBT Module lesse sene 208 Installing the Braking IGBT Module oooococcccccoco e 210 Removing the Bus Capacitor Assembly 0000 cee eee eee eee 211 Installing the Bus Capacitor Assembly 0 000 cece eee ees 213 Removing the Filter Board 2 2 0 60 e eee ee ees 215 Installing the Filter Board lille tees 217 Removing the Diode Block 0 cece ee 219 Installing the Diode Block 0 0 eects 220 Replacing the Current Sensor
258. he tools needed for this procedure are e Aset of magnetized flat blade screw drivers With the drive controller door open 1 Using a flat blade screw driver push in on the top of the keypad display tab and remove the keypad display 2 Insert the new keypad display into the front of the control board Ensure the lip on the bottom of the keypad display is behind the tab on the control basket Keypad display tab Location of RUN STOP cover Figure 100 ATV66D54N4 to D79N4 Front View O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Control Basket Unapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 This procedure explains how to remove the control basket from the following drive controllers Drive Controller No Control Kit No ATV66D54N4 ATV66D64N4 VX4 A66CK1 ATV66D79N4 Before removing power note and record all the drive controller settings using the keypad display A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if installed connectors Verify that all power has been removed from J1 J12 and J13 connectors f I O Exten
259. hen identify the problem using the approaches in chapter 2 After the problem has been identified proceed to chapter 3 to find the cause and appropriate 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 WORK PRACTICE PRECAUTIONS Personnel Protection Precautions Chapter 1 Introduction Work Practice Precautions corrective action Where applicable use the procedures in chapter 4 to change out defective component s The procedures detailed in chapter 5 are to be used whenever they are referenced in other places in the manual For the protection of personnel and equipment a qualified maintenance person must perform the procedures detailed in this manual The maintenance person should e Be able to read interpret and follow instructions and precautions in this manual and the other manuals referenced e Beabletousethe tools listed on page 5 of this manual in a safe and technically correct manner e Beable to perform troubleshooting and equipment change out procedures while following the safety procedures recommended in ANSI NFPA 70E e Be trained on the operation and fundamentals of AC controllers and systems and be familiar with the associated hazards Review the sections below for personnel and equipment protection precautions before performing any troubleshooting or equipment change out procedures The drive controller contains elements which can be potentially hazardous to maintenance personnel
260. hrough ATV66C19N4 controller filter boards e IGBT snubber capacitors found on ATV66C10N4 though ATV66C19N4 controller power and snubber boards e IGBT voltage clamping capacitors found on ATV66C10N4 through ATV66C19N4 controllers When power is removed from an undamaged controller the stored energy in these capacitors is automatically discharged to nonhazardous levels However the discharge mechanisms in a damaged controller may not be operating properly and stored energy may be present If voltage is present across any power circuit capacitor in the controller use the following procedure to discharge stored energy e Capacitors whose capacitance is no greater than 10 microfarad Capacitors which are included in this category are line filter capacitors IGBT snubber capacitors and IGBT voltage clamping capacitors Use a voltmeter set to the 1000 vdc scale to discharge the capacitors It will take approximately 6 6 minutes for a 10 megohm input impedance voltmeter to discharge a 10 microfarad capacitor from 700v to less than to 50v It will take approximately 66 minutes for a 1 megohm input impedance voltmeter to discharge a 10 microfarad capacitor from 700v to less than 50v For snubber and voltage clamping capacitors found on the ATV66C10N4 through ATV66C19N4 controllers connect the voltmeter directly across the capacitor terminals to discharge the stored energy For line filter capacitors connect the voltmeter as indicated
261. hten the wire connection screws to 8 9 Ib in 1 0 Nem Replacing the Precharge This procedure explains how to replace the precharge resistor for the following Resistor drive controllers Drive Controller No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Precharge Resistor No VZ3 R010W270 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury 22 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers Torque wrench set to 35 4 Ib in 4 0 Nem e Metric hex key set 2 to 14 mm e Flat blade screw driver socket for torque wrench e Metric hex key sockets for torque wrench With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Using a flat blade screw driver loosen and remove the two wire connection screws on resistor R10 and the two wire connection screws on resistor R11 see Figure 1
262. ilter Board Connections 002 cece eee eee eee 282 Capacitor Assembly Mounting Diagram Front View 283 Capacitor Assembly Mounting Diagram Side View 285 Orientation of Capacitor Bus Bars Laminated Insulating Sheet 286 Transformer Contactor Assembly Front View 288 Transformer Contactor Assembly Side View 289 Wiring Diagram for Control Power Transformer Precharge Contactor amp Auxiliary Contact Block Precharge Resistors Discharge Resistors Circuit Protector and Ground Fault CT 0 00000 eee eae 296 Transformer Contactor Assembly Front View o o o o 297 Transformer Contactor Assembly Inside View 300 Location of PA and Terminals ATV66U41N4 to C19N4 311 1996 Square D All Rights Reserved ix ALTIVAR 66 Service and Troubleshooting Manual Bulletin No VD0C06S701 List of Figures amp Tables December 1996 X AAA 0 1996 Square D All Rights Reserved Bulletin No VD0C06S701 December 1996 ALTIVAR 66 Service and Troubleshooting Manual List of Figures amp Tables LIST OF TABLES Table 1 Table 2 Table 3 Table 4 Table 5 Table 6 Table 7 Table 8 Table 9 Table 10 Table 11 Table 12 Table 13 Table 14 Table 15 Table 16 ALTIVAR 66 Drive Controllers llle 2
263. in 0 76 Nem 177 bin 2 0 Nem SIEEEFIERIDBIREIRIR 26 5 Ib in M 26 5 Ib in 3 0 Nem Figure 93 J2 Terminal Block Torque Specs 9 Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the three screws which hold the bottom IP20 protection cover in place see Figure 83 on page 153 10 Reconnect the J1 connector see Figure 80 on page 148 174 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Diode Block Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 11 Install the right side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the right side panel in place Two screws are located at the top and two screws are located at the bottom see Figure 83 on page 153 12 Install the top IP20 protection cover Route the five control basket cables through the hole in the protection cover Using a phillips screw driver install and tighten the four screws which hold the top IP20 protection cover in place see Figure 83 on page 153 13 Install the left side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the left side panel in place Two screws are located at the top and two screws are located at the bottom see Figure 83 on page 153 14 Install the control basket as described in the procedure on page 149 There are three diode blocks on this s
264. in the Removing the Filter Board procedure found in Chapter 4 for the respective controller being serviced O 1996 Square D All Rights Reserved Bulletin NO VDUCUDGS U1 Cnapter 9 gt Basic Procedures December 1996 Input Line Voltage Measurement e Capacitors whose capacitance is greater than 10 microfarad Capacitors which are included in this category are the DC bus capacitors found on all controllers Discharge of these capacitors should occur automatically once power is removed from the controller The discharge means for controllers ATV66U41N4 through ATV66D12N4 is the controller switching power supply On larger controllers the discharge is augmented with discharge resistors that are switched onto the DC bus when power is removed from the controller The primary discharge means can discharge the DC bus to less than 50 V in 60 seconds If the primary discharge means is not operating a secondary discharge means consisting of balancing resistors can discharge the capacitors The balancing resistors should discharge the controller capacitor bank to less than 50 V in 15 minutes Inthe unlikely event that both the primary and secondary discharge means have failed the capacitor can be discharged using a load bank constructed by connecting seven 120 V 60 W lamps in series The load bank should be connected across the capacitor until the capacitor voltage has been reduced to less than 50 V PROCEDURE 3 To measure the input
265. in the procedure on page 88 2 Disconnect the J1 connector at the bottom of the power board see Figure 49 on page 92 3 Identify and tag all field wiring for future re assembly 4 Disconnect the field wiring on the J2 connector at the bottom of the power board See Figure 50 on page 94 5 Remove the IP20 protection cover see Figure 49 on page 92 6 Using a phillips screw driver loosen and remove the three screws holding the bottom cover in place Remove the bottom cover 7 Usinga phillips screw driver loosen and remove the two screws holding the top cover in place Remove the top cover 8 Slide the side covers towards the top of the controller until they release Remove the side covers 9 Using a drive socket or a phillips screw driver as necessary loosen the four screws holding the drive controller chassis to the controller back cover Lift the drive controller away from the back cover to gain access to the fan 1996 Square D All Rights Reserve 95 Cnapter 4 Equipment Cnange Out ATV66U41N4 to ATV66U72N4 Installing the Fan 96 Bulletin NO VDUCUOS U1 December 1996 Fan bracket mounting screws Figure 51 Fan Removal 10 11 12 Using a phillips screw driver loosen and remove the two screws holding the fan bracket see Figure 51 on page 96 Remove the fan bracket Pull the fan away fr
266. iode block mounting screws 6 Using a flat blade screw driver gently pry loose and remove the diode block Installing the Diode Block There are three diode blocks on this size of drive controller This procedure explains how to install the diode block in the following drive controllers Drive Controller No Diode Block No ATV66D54N4 ATV66D64N4 VZ3 DM2160M1606 ATV66D79N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Torque wrench set to 26 5 Ib in 3 Nem e Thermal grease Thermalloy Thermalcote II Part No 349 or equivalent Filter board procedure tool list page 217 Gate driver procedure tool list page 200 e Control basket procedure tool list page 193 For the diode block to be installed 1 Clean the portion of the heatsink which will make contact with the diode block 2 Evenly coat the bottom of the diode block with a thin coat of thermal grease 3 Install the diode block Using a torque w
267. ion White Cable Clasps Blue Cable Clasps Figure 122 Cable Connector Secure and Release Positions 8 Using a phillips screw driver and hex key wrench loosen the four corner screws on the control basket Remove the control basket from the drive controller As the control basket is removed pull the three ribbon cables out of the guide on the back of the control basket 9 Replace the old keypad per the procedure on page 236 1996 Square D All Rights Reserved 239 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Installing the Control Basket 240 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to install the control basket in the following drive controllers Drive Controller No Control Kit No ATV66C10N4 ATV66C13N4 ATV66C15N4 VX4 A66CK2 ATV66C19N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure
268. ipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric drive sockets for torque wrench e Metric hex key set 2 to 14 mm DBsnubber board procedure tool list page 267 Current sensor assembly procedure tool list page 263 To install the dynamic braking diode block 1 Install a new Thermstrate foil from the kit on the back of the new diode block Remove the paper backing from the Thermstrate foil Do not remove white contact grease coating NOTE If the Thermstrate foil is damaged i e wrinkled coating gaps gt 1 8 round discard the Thermstrate foil Obtain new foil 2 Place the new diode block on the heat sink with R11 terminal toward outer edge of controller and align the mounting holes Using a torque wrench with hex key socket install and tighten the two diode block mounting screws see Figure 135 on page 275 Initially tighten to 6 0 9 0 Ib in 0 7 1 0 Nem The final torque is 35 4 Ib in 4 Nem 3 Align the dynamic braking diode block connector over the DM4 2 and DM4 3 mounting holes in the dynamic braking diode block Align the DM4 2 cable over the DM4 2 mounting hole see Figure 135 on page 275 Using a torque wrench and a hex key socket install and tighten the mounting screw in DM4 2 mounting hole to 17 7
269. is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure 1996 Square D All Rights Reserved 91 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66U41N4 to ATV66U72N4 December 1996 The tools needed for this procedure are e Aset of magnetized flat blade screw drivers With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Remove options module if present See User s Manual VDOCO6T306 for removal installation instructions 3 Identify and tag all field wiring for future re assembly 4 Using a flat blade screw driver loosen the terminal screws on the J1 J12 and J13 connectors see Figure 49 on page 92 Pull the field wiring back out of the way 5 Using a flat blade screw driver gently pry the J1 J12 and J13 field connectors away from the board side connectors Discard the old connectors 6 Insert the new field side connectors into their associated board side connectors NOTE The yellow keys in both the plugs and sockets are designed to prevent incorrect inse
270. it in the controller The 3 phase average RMS value of line voltage is available on menu 4 1 of the keypad display This voltage can be compared to the 3 phase average voltage measured at L1 L2 and L3 of the controller with the multimeter recommended in LIST OF TOOLS AND INSTRUMENTS on page 5 of this manual NOTE The accuracy ofthe controller line voltage measurement can be affected by the presence of voltage waveform distortion at the controller terminals As a result a comparison of keypad display values to direct measurements with the recommended test apparatus can differ by as much as 10 Line frequency is measured on the CL1 CL2 terminals of the control supply by the controller on each power up Absence of a frequency measurement will result in CONTROL SUPPLY fault being displayed on the keypad display The value of frequency measured is not available on the keypad display However if serial link mode is used the range of the value detected is available in word register 2203 Voltage measurement of the DC bus is performed with an impedance isolated circuit in the controller The average value of the DC bus voltage is available on menu 4 1 of the keypad display This voltage can be compared to the average DC bus voltage measured at PA and of the controller with the multimeter recommended in LIST OF TOOLS AND INSTRUMENTS on page 5 of this manual Motor current is measured by two sensors placed on the T1 U and T3 W output phases
271. it on the input wiring of the controller Using a drive socket install and tighten the two mounting nuts and lock washers SOs OEGI O le a a a a a O O a O O gf Fan capacitor Filter board assembly mounting screws Figure 137 Filter Board and Fan Capacitor Assembly Locations 1996 Square D All Rights Reserved 281 Cnapter 4 rquipment Change Out Bulletin NO VDUCUOS UT ATV66C10N4 to C19N4 December 1996 S P Tp EN o0 eo Sn sns e y oz G ii 3 sss s ds E md am a Top View Filter Board Assembly Figure 138 Filter Board Connections Replacing the Capacitor There are either two or three capacitor assemblies in the drive controller The VY1 Assembly ADC607 Capacitor Assembly Kit contains 6 capacitors This kit will also be used to replace the upper capacitor assembly on the ATV66C13N4 drive controller which assembly contains 4 capacitors This procedure explains how to replace an individual capacitor assembly for the following drive controllers Drive Controller No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Capacitor Assembly No VY1 ADC607 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these ins
272. iver board 5 Using needle nose pliers carefully disconnect J27 J28 J29 J30 J57 J58 J59 J60 and J61 at the termination points located on the gate driver board see Figure 105 on page 199 6 Using needle nose pliers carefully disconnect J20 1 20 2 21 1 J21 2 22 1 J22_2 23 1 J23_2 J24 1 J24 2 J25 1 and J25 2 at the termination points located on the IGBT modules see Figure 106 on page 199 J27 J3 J28 J57 J29 Board fan Gate driver board Figure 105 Gate Driver Board Connection and Board Fan Locations Left Side of Drive Controller J37 Blu EO fe s nas ii J20 i E BiG Red J20_2 e IGBT Module Red J21 2 9 EM J21 AA J86 Grn aX S4 Gate Wht 422 1 7 ss Gate wnt J22 smi gt E 333 Red J22 2 O IGBT Module di Re J23 2 ve S J23 H E S6 G 2 SAO ae 335 Yel Ls E pu 3324147 ssGat v J24 aires f EE 1253 Red J24 2 IGBT Module S Red 3 J25 2 Grn J25 a il um a S2 Gate W J34 Bed Red Bed Power Board J26
273. ize of drive controller This procedure explains how to remove a diode block from the following drive controllers Drive Controller No Diode Block No ATV66D33N4 VZ3 DM2080M1606 ATV66D46N4 VZ3 DM2100M1601 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage 1996 Square D All Rights Reserved 175 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D33N4 and ATV66D46N4 December 1996 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performi
274. k 5 Remove the dynamic braking IGBT module Remove all of the old Thermstrate foil from the heatsink The dynamic braking module kit contains one IGBT module This procedure explains how to install the dynamic braking IGBT module in the following drive controllers Drive Controller No DB Module Kit No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 VZ3 IM1300M1207 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Torque wrench set to 26 5 Ib in 3 Nem DB gate driver board procedure tool list page 269 DBsnubber board procedure tool list page 267 Current sensor assembly tool list page 263 To install the dynamic braking IGBT module 1 Install a new Thermstrate foil on the back of the new dynamic braking IGBT module Ensure the paper backing is removed from the Thermstrate foil Do not remove the white contact grease coating NOTE If the Thermstrate foil is damaged i e wrinkled
275. k of the control basket NOTE Be sure the ribbon cables have been released before pulling to avoid damage to the cables There are two versions of the cable clasps blue and white White Cable Clasp RENE DEP a Been Cable Ribbon Cable Circuit Board Ob Circuit Board wee E Blue Cable Clasp Secure Position Secure Position White Cable Clasp Pull Out Pull Out p Ribbon Cable rd Cable Circuit Board aa Circuit Board Blue Cable Clasp Release Position Release Position White Cable Clasps Blue Cable Clasps Figure 62 Cable Connector Secure and Release Positions 114 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Control Basket Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 This procedure explains how to install the control basket in the following drive controllers Drive Controller No Control Kit No ATV66D16N4 ATV66D23N4 VX4 A66CK1 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic pr
276. ket 0 0 0 0 cece eee 237 Installing the Control Basket 0 0 0 0c cece tenes 240 Replacing Control Terminal Blocks 00 00 c eee eee 241 Removing the Power Board 0 cece eee 243 Installing the Power Board 00 cece tees 246 Removing the Snubber Board oooccccccoccco teas 247 Installing the Snubber Board 0 000 cece etna 249 Removing the Gate Driver Board 1 0 0 0 0 cece tetas 250 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 rquipment Change Out Installing the Gate Driver Board ooocoocccccococo ee 252 Removing the IGBT Module oooocoocccccccco tee 253 Installing the IGBT Module ooccocccccccoc IA 255 Removing the Diode Block oo ooooooccoccrr tees 257 Installing the Diode Block ooooooooccoccn BRA 259 Removing the Current Sensor Assembly 000 cece eee eee eee 261 Installing the Current Sensor Assembly 0 000 eee eee eee eee 263 Removing the Dynamic Braking DB Snubber Board 2 005 264 Installing the Dynamic Braking DB Snubber Board 00 0 00 267 Removing the Dynamic Braking DB Gate Driver Board o 268 Installing the Dynamic Braking DB Gate Driver Board 0 269 Removing the Dynamic Braking DB IGBT Module 00 271 Installing the Dynamic Braking DB IGBT Module 00 0 ee
277. king Drive Running at speed Jog Operation No Run Permissive Forward Direction Reverse Direction Resistance Braking Accelerating Serial Link Command Decelerating Fault SPEED REFER 47 2 Hz T C RUNL Status Code Figure 3 Display Screen Status Code Location The up down arrow keys on the keypad display may be used to select and view the following measurements from the Display screen e Speed reference Hz e Output frequency Hz Output current A e Motor torque e Output power W e Motor thermal state Drive thermal state 7o ATV66D16N4 through ATV66C19N4 Line voltage V Output voltage V e DC bus voltage V e Elapsed time H and Min O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 October 1997 I O Map LOGIC INPUT MAP ANALOG INPUT MAP LOGIC OUTPUT MAP ANALOG OUT MAP amp ENT to select Figure 4 I O Map 1996 Square D All Rights Reserved Cnapter 2 investigating tne Problem Return to Main menu 2 l L GIC INPUT MAP IM ASSIGNMENT 5 LIZ RUN FORWARD LIS RUN REVERSE LI4 JOG Ali SPEED REF 1 RI2 SPEED REF 2 A 3 L11 RUN PERMISSIVE m 2 2 ANALOG_ INPUT MAP gt 1N ASSIGNMENT WALA ESC __ 2 3 LOGIE OUTPUT MAP QUT ASSIGNMENT LOL AT SPEED LOZ CURRENT LIMIT R1 FAULT STATE R2
278. l Rights Reserved 209 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 Installing the Braking IGBT Module 210 Bulletin NO VDUCUO6S U1 December 1996 This procedure explains how to install the braking IGBT module in the following drive controllers Drive Controller No Braking IGBT Module No ATV66D54N4 VZ3 IM2100M 1201 ATV66D64N4 VZ3 IM2150M 1201 ATV66D79N4 VZ3 IM2150M1201 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Torque wrench set to 26 5 lb in 3 Nem e Thermal grease Thermalloy Thermalcote II Part No 349 or equivalent e Power board procedure tool list page 203 Gate driver procedure tool list page 200 e Control basket procedure tool list page 193 For the braking IGBT module to be installed 1 Clean the portion of the heatsink which will make contact with the ne
279. lace the wiring knockout panel can be detached from the bottom panel in the next step Remove the bottom panel screws and remove the bottom panel Precharge resistor Precharge resistor mounting bracket Figure 115 Precharge Resistor 7 Using a drive socket loosen and remove the two nuts holding the bottom mounting bracket for the precharge resistor and remove the bottom bracket 8 Slide the precharge resistor downwards to give better access to the terminals 9 Using a hex key and open end wrench carefully disconnect the wires connected to the terminals of the precharge resistor 10 Remove the old precharge resistor 11 Install the new precharge resistor 12 Using a hex key and open end wrench carefully connect the wires to the precharge resistor Use a torque wrench and drive socket to tighten the terminal connections to 17 7 Ib in 2 Nem 13 Fit up the precharge resistor to the top mounting bracket and install the bottom bracket Using a drive socket install and tighten the two nuts on the bottom mounting bracket 14 Install the bottom panel see Figure 104 on page 197 15 Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the three screws for the bottom IP20 protection cover see Figure 104 on page 197 16 Install the J1 terminal block see Figure 104 on page 197 17 Install the right side panel Using a phillips or Torx screw driver install and tighten the four
280. le nose pliers carefully reconnect the T1 sensing wire see Figure 131 on page 262 7 Install the plastic shield in front of the line and motor terminals Tighten the thumb screws 8 Swing the hinged assembly back to its normal position Using a flat blade screw driver tighten the two screws The dynamic braking module kit contains one snubber board This procedure explains how to remove the snubber board from the following drive controllers Drive Controller No DB Module Kit No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 VZ3 IM1300M1207 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66C10N4 to C19N4 A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter set to 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in de
281. lem Checking the Power Part of the Controller Measure the ohmic value of the precharge resistor between the and PA terminals It must correspond to the values in Table 7 Table 7 Checking the Precharge Resistor Rp 50Q ATV66U41N4 Rp 33Q ATV66U54N4 ATV66D12N4 ATV66U72N4 ATV66D16N4 ATV66U90N4 ATV66D23N4 Rp 10Q ATV66D33N4 ATV66C10N4 ATV66D46N4 ATV66C13N4 ATV66D54N4 ATV66C15N4 ATV66D64N4 ATV66C19N4 ATV66D79N4 NOTE ATV66C10N4 to ATV66C19N4 controllers are equipped with a series thermal cut off switch to protect the precharge resistor in the event of a bus short circuit If the thermal cut off switch has tripped reset the switch prior to making a precharge resistor resistance measurement Check the inverter bridge as shown in Figure 41 This should be done for each phase of the motor output with respect to the PA and terminals of the drive controller Use a multimeter as recommended in LIST OF TOOLS AND INSTRUMENTS on page 5 Set the meter on the diode scale In the event of any problem disconnect the IGBT modules and test them directly on their terminals Figure 41 Checking the Inverter Bridge Check each IGBT module as shown in Figure 42 on page 76 for the resistance val ues shown Use a multimeter as recommended in LIST OF TOOLS AND INSTRU MENTS on page 5 Set the meter on the diode scale Refer to Figure 36 on page 71 Figure 66 on page 119 Figure 86 on page 155 and Figure 106 on page 199 to deter mine the corr
282. ler No Current Sensor No ATV66D54N4 ATV66D64N4 VY1 A66105 ATV66D79N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved L 221 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 222 Bulletin NO VDUCUOS U1 December 1996 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are A set of Torx screw drivers Metric hex key set 2 to 14 mm Torque wrench set to 170 Ib in 19 Nem Metric hex key sockets for torque wrenc
283. llers or 105 6 Ib in 12 Nem for ATV66C15N4 C 19N4 controllers In some cases it may be necessary to attach the L bracket to the diode block before it is installed into the drive controller Install the power fuse or shorting bar and the two mounting screws to the L bracket and the line power terminal Using a torque wrench and a hex key socket tighten the fuse or shorting bar screws to 141 Ib in 16 Nem Install the two bus bar pieces Using a torque wrench with hex key socket install and tighten the six bus bar screws to a torque of 53 Ib in 6 Nem for ATV66C10N4 C13N4 controllers or 105 6 Ib in 12 Nem for ATV66C15N4 C 19N4 controllers The top screw on the bus bar extension piece is the longest of the six See Figure 130 on page 258 Ensure that the bus bar spacing specifications are adhered to as described in the note in Figure 130 on page 258 NOTE On ATV66C10N4 and C13N4 controllers install spacer blocks under bus bars NOTE If installing the far right diode block it is necessary to first install the bus bar extension piece Position the bus bar extension piece mounting hole over the corresponding hole on the terminal block Using a torque wrench and hex key socket install the extension piece mounting screw and tighten to a torque of 141 Ib in 16 Nem Using a torque wrench with hex key socket install and tighten the screw which holds the bus bar extension piece to the RB bus bar Tighten to a torque o
284. lletin NO VDUCUOS U1 To Order Replacement Parts December 1996 32 c 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 A ACC 14 air passages 316 analog input test 82 analog output test 82 auto transformer replacing 185 230 autodiagnostics 81 board fan replacing 152 196 braking IGBT module 76 installing 131 166 210 removing 129 165 208 BRK 14 bus capacitor 312 installing 143 169 213 removing 141 167 211 voltage measuring voltage 310 bus voltage measurement 310 C capacitor assembly replacing 282 capacitors DC bus 310 replacing 71 282 checking peripheral equipment 313 circuit protector replacing 305 CL1 CL2 78 cleaning heat sinks 316 CLI 14 contactor auxiliary contact block replacing 298 installing 302 removing 301 control power transformer installing 289 removing 287 AL IIVAH 66 Service and IroubDiesnooting Manual replacing fuses 306 terminal blocks replacing 91 104 116 150 194 241 control basket installing 90 103 115 149 193 240 removing 88 101 113 147 191 237 current sensors installing 263 removing 261 replacing 178 221 D DB dynamic braking diode module installing 276 removing 273 gate driver board installing 269 removing 268 IGBT module installing 272 removing 271 resistor 314 snubber board installing 267 removing 264 DC bus 73 310 DCB 14 LEDs 310 measuring voltage 78 310 replacing fuse 306 DEC 14 diag
285. lletin number VD0C065305 for controller configuration programming If the controller is a part of a larger system refer to the specific programming instructions provided by the system builder If the controller configuration program was saved in a PCMCIA Memory Card reload the program If the program was manually recorded reload the program through the keypad If problems persist after performing the recommended procedures then factory service may be required Have the following information available Controller part number O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 October 1997 Drive System De energized Power Removed Unapter 2 Investigating tne Problem Drive System De Energized e Controller input voltage Controller power rating e Controller software version see PROCEDURE 9 CHECKING THE SOFTWARE REVISION LEVEL on page 317 in chapter 5 Description of any physical damage or defect Operating environment e Application e Any LED status light s illuminated e Any fault message display on the keyboard screen Contact your local Square D field office to arrange service It is not uncommon for the maintenance person to find that the drive controller has been de energized and tagged out locked out by operations or other maintenance personnel The controller may have been removed from service for a number of reasons such as Drive system or process not performing as expected Drive
286. lling 134 173 217 removing 132 171 215 replacing 280 freewheel diode 76 fuses DC bus 72 G gate driver board installing 120 156 200 252 removing 117 154 198 250 IGBT modules 75 installing 128 163 207 255 removing 126 161 205 253 snubber capacitors 312 voltage clamping capacitors 312 input line voltage measurement 313 instruments and tools 5 inverter bridge 75 J JOG 14 K keypad display 12 replacing 87 100 112 146 190 236 L LEDs 9 70 310 line voltage measuring 78 logic input test 81 logic output test 82 M measurements DC bus voltage 78 line voltage 78 output current 78 output frequency 78 output voltage 79 power part schematic 78 measuring voltage 310 motor cannot start 32 cannot stop 37 overheating 22 slow deceleration 25 turns in wrong direction 40 nameplate data 8 NEMA standard MG 1 313 NLP 14 NRP 14 P PA terminals 311 power board installing 124 159 203 246 removing 121 157 201 243 replacing 92 106 input line 313 precautions equipment protection 4 operating equipment 9 personnel protection 3 personnel qualifications 77 work practice 3 precharge resistor 75 replacing 137 226 296 R ramp time 315 RDY 14 revision level 317 RUN 14 S schematic power part 71 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 SLC 14 slow acceleration 22 snubber board installing 24
287. lling the Braking IGBT Module 166 Bulletin NO VDUCUOS U1 December 1996 4 Using a phillips screw driver loosen and remove the two screws which attach the bus bar to the braking IGBT module The BR3 cable is connected to the C1 terminal of the braking IGBT module Pull the BR3 cable back out of the way see Figure 90 on page 163 5 Usinga hex key wrench loosen and remove the eight screws which hold the bus bar to the bus capacitors The balancing resistors are mounted under these screws Note the location of all cables connected to the bus bar to assist during the re installation of the bus bar see Figure 89 on page 162 6 Remove the bus bar 7 Using a phillips screw driver loosen and remove the screw at the C2E1 terminal of the braking IGBT module The BR1 cable is connected at this terminal Pull the BR1 cable back out of the way see Figure 90 on page 163 8 Using a hex key wrench loosen and remove the two mounting screws for the braking IGBT module see Figure 90 on page 163 9 Using a flat blade screw driver gently pry loose and remove the braking IGBT module This procedure explains how to install the braking IGBT module in the following drive controllers Drive Controller No IGBT Module No ATV66D33N4 ATV66D46N4 VZ3 IM2050M1201 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static S
288. llle 221 Fan Mountlng eig A EU NE 224 Precharge Resistor ooooooooooonoro e 227 Discharge Resistor 0 000 eee ee eens 229 Auto TransforMer oooocccoco eee 231 Spare Parts Location Diagram Front View 5 234 Spare Parts Location Diagram Side View oooo oo ooo 235 ATV66C10N4 to C19N4 Front View 00 eee eee 236 Control Basket Connector Locations 0 00e essen 239 Cable Connector Secure and Release Positions 239 Location of J1 J12 and J13 Connectors 0 eee ee 242 Front View of Hinged Assembly ooooooocococoo eee 244 Power Board CONMNectiONS o ooooooococo eee eee 245 View of Snubber Boards 0 000 cece eee eee ees 248 Snubber Board Connector and Capacitor Locations 249 Gate Driver Board Locations 0 0 c eee eee eee 252 IGBT Module Locations 0200 cece ee 255 Removing the Diode Block ATV66C10N4 and C13N4 shown 258 Current Sensor Assembly 00 0 cece eee eee eee 262 Dynamic Braking Snubber Board 000 cee eee eee 266 Dynamic Braking Snubber Board Gate Driver Board IGBT Diode 266 Top View of Dynamic Braking Module o oo o oooo 275 Side View of Dynamic Braking Module 0 005 275 Thermal Switch Locations 0 0 00 cece eee eee eee 279 Filter Board and Fan Capacitor Assembly Locations 281 F
289. ls needed for this procedure are e Aset of magnetized flat blade screw drivers Torque wrench set to 35 4 Ib in 4 0 Nem Flat blade screw driver sockets for torque wrench Metric hex key set 2 to 14 mm e Metric hex key sockets for torque wrench With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Using a flat blade screw driver loosen and remove the two wire connection screws on resistor R7 and the two wire connection screws on resistor R8 see Figure 145 on page 297 3 Using a hex key wrench loosen the two precharge resistors mounting screws see Figure 145 on page 297 Remove the two precharge resistors still stacked together Record the arrangement of washers and use this as a guide when assembling the new precharge resistor assembly 4 Stack the two new precharge resistors in the arrangement noted from step 2 5 Place the new discharge resistor assembly in the drive controller with the white laminated insulating paper behind the assembly Orient assembly with wire connection tabs on left NOTE Be careful not to scratch white laminated insulating paper when installing discharge resistor assembly If the paper is torn or scratched do not operate drive controller Replace insulating paper 1996 Square D All Rights Reserved
290. m 1996 Square D All Rights Reserved 217 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 218 Bulletin NO VDUCUOS U1 December 1996 Using needle nose pliers carefully connect J38 blue J39 white J40 red J53_1 blue and J53 2 white on the power board see Figure 107 on page 202 Route the wires as necessary Connect the J42A and J42 B connector on the power board Install the J2 terminal block assembly see Figure 111 on page 216 Using a hex key wrench install and tighten the two screws holding the terminal block assembly in place Install the cables and wires for L1 L2 L3 PA PB U T1 V T2 W T3 CL1 CL2 L21 L22 and the ground connection at both the field side and drive controller side of the J2 terminal block Ensure the U T1 and W T3 cables are routed through their respective current sensors located in front of the J2 terminal block see Figure 111 on page 216 Using a torque wrench and appropriate attachment tighten the terminal screws as shown in Figure 112 on page 218 6 73 lb in 0 76 Nem 26 5 Ib in 3 Nem EISE 170 Ib in 19 Nem 26 5 Ib in 3 0 Nem Figure 112 J2 Terminal Block Torque Specs 9 10 11 12 Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the three screws which hold the bottom IP20 protection co
291. mic braking module kit contains one gate driver board This procedure explains how to install the dynamic braking gate driver board in the following drive controllers Drive Controller No DB Module Kit No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 VZ3 IM1300M1207 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm 1996 Square D All Rights Reserved 269 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 DB Snubber board procedure tool list page 267 e Current sensor assembly procedure tool list page 263 To install the dynamic braking gate driver board 1 Align the mounting holes on the dynamic braking gate driver board with the mounting holes on the dynamic braking IGBT module see Figure 133 on page 266 2 I
292. mperature is greater than 110 C In addition to the thermal probe thermal switches are provided to shut down the drive controller should heatsink temperatures exceed certain levels 1996 Square D All Rights Reserve 55 Cnapter 3 Correcting tne Probiem Bulletin NO VDUCU6S UT Drive Overtemperature December 1996 Figure 24 illustrates the troubleshooting procedure when the drive overtempera ture fault is present DRIVE Fault Displayed OVERTEMPERATURE Heatsink temperature too high Drive controller fault Possible cause Ambient temperature Refer to Checking Fan Check Operating cycle Operation in chapter 5 to be Heatsink fins clogged performed with dirt Operating altitude Little or no air movement Result Decrease controller Refer to chapter 4 to Change the ambient temperature if change the fan Connections Solution 40 C Temperature probe Drive controller incorrectly Power board positioned in the enclosure Control basket or ventilation opening Thermal switches blocked Increase air movement around controller Air conditioning required Refer to Cleaning Heatsink and Air Passages in chapter 5 Derate for operating altitude Figure 24 Drive Overtemperature 55 1996 Square
293. n resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Torque wrench set to 35 4 Ib in 4 Nem e Flat blade screw driver sockets for torque wrench e Control basket procedure tool list page 103 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 101 2 Remove the IP20 protection cover See Figure 56 on page 105 3 Usinga phillips screw driver loosen and remove the two screws holding the controller top cover in place Remove the top cover 4 Usinga phillips screw driver loosen and remove the four screws holding the controller bottom cover in place Remove the bottom cover 5 Disconnect the J1 connector at the bottom of the power board 6 Identify and tag all field wiring for future re assembly 1 1996 Square D All Rights Reserved Bulletin
294. n cover in place 10 Reconnect the J1 connector 11 Connect J42A J42B J43 at the termination points located on the power board see Figure 87 on page 158 NOTE Ifcontroller does not contain a board fan Figure 84 on page 153 the J68 jack will be left empty 12 Using needle nose pliers carefully connect J7 J8 J16_1 J17_1 black J17_2 black J68 board fan leads J33 J38 blue J39 white J40 red J53_1 blue and J53_2 white at the termination points located on the power board see Figure 87 on page 158 NOTE Ensure J53_1 and J53_2 are routed away from the power resistors located next to the J53 connection on the power board 160 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the IGBT Module Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 13 Install the right side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the right side panel in place Two screws are located at the top and two screws are located at the bottom 14 Install the gate driver board as described in the procedure on page 156 There are three IGBT modules in this size of drive controller This procedure explains how to remove the IGBT module from the following drive controllers Drive Controller No IGBT Module No ATV66D33N4 VZ3 IM2100M1201 ATV66D46N4 VZ3 IM2150M1201 A DANGER HAZAR
295. n result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of Torx screw drivers e 4 Needle nose pliers e Control basket procedure tool list page 193 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 191 2 Using a phillips or Torx screw driver loosen and remove the four screws which hold the right side panel Remove the right side panel see Figure 104 on page 197 3 Remove the J1 terminal block see Figure 104 on page 197 230 c 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 4 Unapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place see Figure 104 on page 197 Remove the bottom IP20 protection cover Mounting screws Auto transformer Figure 117 Auto Transformer 5 Using needle nose pliers carefully disconnect the four wires connected to the terminals of the auto transformer see Table 14 on page 231 Table 14 Auto Transformer Connections Auto Transformer Connection Wire Color 1 Black 3 Red 5 White 7 Blue 6 Using a phillips screw driver loosen the two screws holding the auto 10
296. n the mounting screws for the affected gate driver board see procedure on page 252 7 Using a torque wrench with a hex key socket install the metal can capacitor that was removed in the IGBT removal procedure see Figure 127 on page 249 Torque mounting screws to 12 lb in 1 3 Nem 8 Install the gate driver boards as described in the procedure on page 252 25 _ _ _ _____________________ __ _______________________ 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Diode Block Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 There are three diode blocks in the ATV66C10N4 to C19N4 drive controllers The diode bridge kit contains three diode blocks This procedure explains how to remove an individual diode block from the following drive controllers Drive Controller No Diode Bridge Kit No ATV66C10N4 VZ3 DM2170M1601 ATV66C13N4 VZ3 DM2170M1601 ATV66C15N4 VZ3 DM2260M1601 ATV66C19N4 VZ3 DM2350M1601 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presen
297. n the protection cover Using a phillips screw driver install and tighten the four screws which hold the top IP20 protection cover in place see Figure 83 on page 153 Install the left side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the left side panel in place Two screws are located at the top and two screws are located at the bottom Install the control basket as described in the procedure on page 149 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D33N4 and ATV66D46N4 Removing the Fan This procedure explains how to remove the fan from the following drive controllers Drive Controller No Fan No ATV66D33N4 VZ3 V665 ATV66D46N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedu
298. nector Secure and Release Positions 1996 Square D All Rights Reserve 89 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66U41N4 to ATV66U72N4 December 1996 8 Using a phillips screw driver loosen the two screws at the bottom of the control basket see Figure 47 on page 89 Pull down on the control basket and remove it from the drive controller As the control basket is removed pull the three ribbon cables out of the guides on the back of the control basket Installing the Control This procedure explains how to install the control basket for the following drive Basket controllers Drive Controller No Control Kit No ATV66U41N4 ATV66U54N4 VX4 A66CK1 ATV66U72N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Aset of magnetized phillips scre
299. nents Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 1 4 drive metric socket set 5 5 to 14 mm e Set of open end wrenches 5 5 to 19 mm e Torque wrench set to 17 7 Ib in 2 Nem e Metric hex key sockets for torque wrench 2 to 14 mm e Power board procedure tool list page 159 Gate driver procedure tool list page 156 e Control basket procedure tool list page 149 1996 Square D All Rights Reserved 169 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D33N4 and ATV66D46N4 December 1996 For the bus capacitors to be installed 1 Attach to the new capacitors the mounting brackets removed from the old capacitors Do not tighten the hardware until proper alignment of capacitors is verified 2 Install the new capacitors Ensure that the polarity matches the polarity marking on the bus bar The terminal of a capacitor should be towards the outer right side of the drive controller see Figure 88 on page 160 NOTE The capacitor mounting brackets are properly installed when the capacitor rests on the bottom of the drive controller and a line drawn through the two ca
300. ng screws from the diode block being removed 12 Using a flat blade screw driver gently pry loose the diode block from the heat sink 13 Remove the diode block Ensure that all of the old ThermstrateM foil is removed from the heatsink Plastic Cap If present Small RB d mall RB Bus Bar RB Bus Bar Large RB Cable Large RB Cable Small RB Cable Diode Blocks Bus Bar Bus Bar Extension Piece Extension Piece NOTE Maintain a 3 8 9 5 mm spacing between RB and RB bus bars and non insulated connectors Figure 130 Removing the Diode Block ATV66C10N4 and C13N4 shown O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Diode Block Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 There are three diode blocks in the ATV66C10N4 to C19N4 drive controllers The diode bridge kit contains three diode blocks This procedure explains how to install an individual diode block in the following drive controllers Drive Controller No Diode Bridge Kit No ATV66C10N4 VZ3 DM2170M1601 ATV66C13N4 VZ3 DM2170M1601 ATV66C15N4 VZ3 DM2260M1601 ATV66C19N4 VZ3 DM2350M1601 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drive
301. ng a phillips screw driver tighten the four screws holding the bottom cover in place Install the IP20 protection cover see Figure 56 on page 105 Install the controller top cover Using a phillips screw driver tighten the two screws holding the top cover in place Connect J1 at the bottom of the power board Using a torque wrench and a flat blade screw driver socket install and tighten the field wiring on the termination points on connector J2 See Receiving and Installation Manual VDOCO065304 for torque specifications Install the control basket as described in the procedure on page 103 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange vut ATV66D16N4 and ATV66D23N4 ATV66D16N4 and This section contains spare part information and change out procedures for drive D23N4 controllers e ATV66D16N4 e ATV66D23N4 Table 10 lists the spare parts Refer to the pages indicated in the table for spare part change out procedures Table 10 Spare Parts for Drive Controllers ATV66D16N4 and D23N4 Description For Drive Catalog Number For Change Out Controllers Procedure See Control Kit ATV66D16N4 D23N4 VX4 A66CK1 Pages 112 116 Control Terminal Block Kit ATV66D16N4 D23N4 VZ3 N006 Pages 116 117 Gate Driver Board ATV66D16N4 VX5 A66103 Pages 117 121 ATV66D23N4 VX5 A66104 Power Board ATV66D16N4 VX5 A66D16N4 Pages 121 125 ATV66D23N4 VX5 A66D23N4 IGBT Module
302. ng any maintenance or troubleshooting procedure The tools needed for this procedure are e Set of open end wrenches 5 5 to 19 mm Filter board procedure tool list page 172 e Control basket procedure tool list page 147 With the drive controller door removed 1 Remove the filter board as described in the procedure on page 171 2 Using an open end wrench loosen and remove the top mounting post and incoming line cable for the diode block to be removed Filter board Filter board Capacitors Diode blocks Figure 94 Diode Block Bottom left side view of controller NOTE For the following steps keep all washers with their respective screws or pins Washers are used as spacing devices to level controller components 3 Using an open end wrench loosen and remove the two lower mounting posts on the center diode block which attaches the module to the bus work and the filter board see Figure 94 on page 176 4 Using a hex key wrench loosen and remove the four screws which hold the diode bridge bus work to the outside diode blocks Pull the bus work and cables out of the way 5 For the diode block to be removed use a hex key wrench to loosen and remove the two mounting screws 6 Remove the diode block 17 6 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the Diode Block Cnapter 4 E
303. ning between the heatsink and the six voltage regulators Using the clip pliers install the six clips which hold the voltage regulators on the heatsink Using needle nose pliers carefully connect J6 J16 J17 J33 J38 blue J39 white J40 red J66 blue and J67 white at the termination points located on the power board see Figure 67 on page 123 If installing a new power board perform the following step Carefully insert the J4 and J5 cable saved earlier into their connectors on the power board with the silver leads facing the top of the controller Ensure the connector is in the release position before inserting the cable see Figure 62 on page 114 Once the cables are inserted push the ribbon cable connectors to their secure position Install the right side panel Using a phillips screw driver install and tighten the three mounting screws for the right side panel Install the gate driver board as described in the procedure on 120 1996 Square D All Rights Reserved 125 Cnapter 4 rquipment Change Out Bulletin NO VDUCUbS UI ATV66D16N4 and ATV66D23N4 December 1996 Removing the IGBT Module There are three IGBT modules in this size of drive controller This procedure explains how to remove the IGBT modules from the following drive controllers IGBT Module No VZ3 IM2050M1201 VZ3 IM2075M1201 Dri
304. nitude Refer to VDOC06S305_ Stopping or holding brake if used not working correctly May be expected operation Drive system may be misapplied Solution Figure 11 Cannot Stop Motor O 1996 Square D All Rights Reserved CANNOT STOP MOTOR Controller start command signals still present or are corrupted Control parameters incorrectly set Check logic input map menu 2 for presence of run command Check setting of IR Compensation and Voltage Boost menu 1 Run command or run enable still present Refer to VDOCO6SS305 to choose correct settings Check wiring and external control circuitry Refer to VD0C06S305 to choose correct settings 37 Cnapter 3 Uorrecting tne Problem Bulletin NO VDUCUOS UT Cannot Stop Motor December 1996 Cannot Stop Motor continued 2 of 3 If DB option is present Controller motor are Too high load inertia for incorrectly sized for desired deceleration rate Possible expected load Overhauling load cause condition Braking torque DC bus voltage level Check Check DB option for on keypad display to be damage Braking torque performed Braking torque required Braking energy required exceeds capability of DB exceeds drive capability Result option Braking torque required DB option inoperative exceeds motor capability tripped damaged or not at given speed connected If possible red
305. nnected see Figure 71 on page 129 Using a torque wrench and phillips screw driver socket install and tighten the four screws to the bus capacitor brackets to 6 2 Ib in 0 7 Nem Fit up the drive controller chassis to the back cover Using a phillips screw driver install and tighten the four corner screws Install the bottom cover Using a phillips screw driver install and tighten the two screws which hold the bottom cover in place Install the power board as described in the procedure on page 124 Using a torque wrench and a flat blade screw driver socket install and tighten the field wiring on the termination points on connector J2 See Receiving and Installation Manual VDOC06S304_ for torque specifications PA terminal terminal Figure 78 Bus Capacitor PA and Terminals O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 ATV66D33N4 and D46N4 Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 This section contains spare part information and change out procedures for the following drive controllers e ATV66D33N4 e ATV66D46N4 Table 11 lists the spare parts Refer to the pages indicated in the table for spare part change out procedures Table 11 Spare Parts for Drive Controllers ATV66D33N4 and D46N4 Description For Drive Catalog Number For Change Out Controllers Procedure See Control Kit ATV66D33N4 D46N4 VX4 A66CK1 Pages 146 150 Control T
306. nostic mode 81 diode bridge 73 installing 136 177 220 259 removing 135 175 219 257 discharge resistor replacing 183 227 295 documentation list 5 drive status codes 14 F factory service 10 12 factory settings 314 fan checking operation 315 O 1996 Square D All Rights Reserved Index installing 96 109 140 182 225 294 removing 94 108 138 181 223 292 fault analysis external damage 9 inspections 11 faults cannot start motor 32 36 cannot stop motor 37 39 causes 8 DC bus overvoltage 47 50 drive does not work as expected not at all 41 42 drive overtemperature 55 56 drive system energized 9 drive will not follow speed command 41 dynamic brake resistor overtemperature 67 68 excessive motor temperature 22 24 FLT 14 ground 63 64 history 79 input phase loss 51 52 inspections 10 11 internal 65 66 line overvoltage 45 46 link fault 69 loss of follower 57 memory failure 69 motor accelerates too slowly 25 27 motor decelerates too slowly over speeds 28 motor overload 53 54 motor turns in wrong direction 40 output phase loss 58 59 overview 8 poor speed stability 20 21 precharge failure 69 process time out 60 sequence time out 60 serial link 60 severity 8 short circuit 61 supply fault 69 undervoltage 43 44 with drive system de energized 11 with external damage 70 with no external damage 70 321 AL IIVAH 66 Service and lroublesnooting Manual Index filter board insta
307. ns how to remove the control basket from the following drive controllers Drive Controller No Control Kit No ATV66D33N4 ATV66D46N4 VX4 A66CK1 Before removing power note and record all the drive controller settings using the keypad display A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if installed connectors Verify that all power has been removed from J1 J12 and J13 connectors If I O Extension Module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshoo
308. ns module if present See User s Manual VDOC06T306_ for removal installation instructions Identify and tag all field wiring for future re assembly Using a flat blade screw driver loosen the terminal screws on the J1 J12 and J13 connectors see Figure 103 on page 195 Pull the field wiring back out of the way Using a flat blade screw driver gently pry the J1 J12 and J13 terminal blocks away from the board side connectors Discard the old terminal blocks Insert the new field side connectors into their associated board side connectors NOTE The yellow keys in both the plugs and sockets are designed to prevent incorrect insertion of both J12 and J13 Install the field wiring on the new terminal blocks for J1 J12 and J13 Using a flat blade screw driver tighten the terminal screws for the field wiring installed Reinstall options module if previously present See User s Manual VDOC06T306_ for removal installation instructions J12 J13 Figure 103 Location of J1 J2 J12 and J13 Connectors 1996 Square D All Rights Reserved 195 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 Replacing the Board Fan 196 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to replace the board fan for the following drive controllers Drive Controller No Board Fan No ATV66D54N4 ATV66
309. nstall the two mounting screws Using the torque wrench and a hex key socket tighten the two mounting screws to 17 7 Ib in 2 Nem NOTE Always use the J1 lead provided with the replacement gate driver board DO NOT reuse the existing J1 lead 3 Atthe dynamic braking IGBT module Q7 C terminal install and tighten the terminal screw with the Q7 C power control and jumper cables landed underneath Using a torque wrench and hex key socket tighten the screw to 26 5 Ib in 3 Nem 4 Install the bus bar extension piece see Figure 130 on page 258 Using a torque wrench and hex key socket install and tighten the two mounting screws Tighten the bottom screw to 164 Ib in 18 5 Nem and the top screw to 74 3 lb in 8 4 Nem 5 Using needle nose pliers carefully connect the P2 connector on the DB gate driver board 6 Install the DB gate driver board bus bar bracket see Figure 135 on page 275 Using the torque wrench and a hex key socket install and tighten the mounting screw to 17 7 Ib in 2 Nem 7 Align the mounting hole for the current sensor mounting bracket with the mounting hole inside the controller Using a hex key wrench install and tighten the mounting screw 8 Install the T2 power cable at the back of the T2 terminal block and install the mounting screw Using the torque wrench and a hex key socket tighten the screw to 164 Ib in 18 5 Nem 9 Using needle nose pliers carefully reconnect the T2 sensing wire see Figure
310. ntrol basket as described in the procedure on page 147 Using a phillips or Torx screw driver loosen and remove the four screws which hold the left side panel Two screws are located at the top and two screws are located at the bottom Remove the left side panel see Figure 83 on page 153 Using a phillips screw driver loosen and remove the four screws which hold the top IP20 protection cover in place Remove the top IP20 protection cover see Figure 83 on page 153 Using a phillips or Torx screw driver loosen and remove the four screws which hold the right side panel Two screws are located at the top and two screws are located at the bottom Remove the right side panel see Figure 83 on page 153 Disconnect the J1 connector This will allow the bottom IP20 protection cover to be removed see Figure 82 on page 151 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place Remove the bottom IP20 protection cover see Figure 83 on page 153 Using a hex key wrench loosen the terminal screws for L1 L2 L3 U T1 V T2 and W T3 at both the field side and drive controller side of the J2 terminal block Pull the cables and wires out of the way Identify and tag all field wiring for future re assembly see Figure 82 on page 151 Using a flat blade screw driver loosen the terminal screws for CL1 CL2 L21 L22 PA PB and the ground connections at both the field side
311. o follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of Torx screw drivers e 4 Needle nose pliers e Control basket procedure tool list page 149 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 147 2 Using a phillips or Torx screw driver loosen and remove the four screws which hold the left side panel see Figure 83 on page 153 Two screws are located at the top and two screws are located at the bottom Remove the left side panel O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D33N4 and ATV66D46N4 3 Using a phillips screw driver loosen and remove the four screws which hold the top IP20 protection cover in place see Figure 83 on page 153 Remove the top IP20 protection cover This allows access to th
312. oblem Bulletin NO VDUCUOS U1 December 1996 Checking the Power Part of the Controller Checking Fuses in The ATV66C10N4 through ATV66C19N4 controllers are equipped with a DC bus ATV66C10N4 to C19N4 fuse to minimize damage in the event of an inverter failure Use the following controllers procedure to check the DC bus fuse Step 3 Protective Switch GV2 9 9 LL PA Figure 37 F4 Bus Fuse Test Procedure ATV66C10N4 to C19N4 1 72 Set a voltmeter to the 1000 VDC scale Measure the bus capacitor voltage between the PA and terminals to verify that the DC voltage is less than 10 V Do not short across capacitor terminals with voltage present If the bus capacitors are not fully discharged refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS on page 311 Once the capacitor energy has been dissipated continue with this procedure Measure the voltage between the PA terminal and both sides of fuse F4 to verify the voltage is less than 10 V If the voltage is not less than 10 V refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS on page 311 Once the capacitor energy has been dissipated continue with this procedure Check condition of the fuse with an ohmmeter If the fuse is blown this indicates that inverter or capacitor bank components may be damaged O 1996 Square D All Rights Reserved Bulletin NO VD
313. ocoocoooo 267 Removing the Dynamic Braking DB Gate Driver Board 268 Installing the Dynamic Braking DB Gate Driver Board llus 269 Removing the Dynamic Braking DB IGBT Module ooocoocoooo 271 Installing the Dynamic Braking DB IGBT Module ooococcococoo 272 Removing the Dynamic Braking DB Diode Block o ooo oooo 273 Installing the Dynamic Braking DB Diode Block ooo ooooooo 276 Replacing the Thermal Switches oooccoccocccccco eee 277 Replacing the Filter Board Assembly oooooocoooccrc eee 280 Replacing the Capacitor Assembly ooocoocooocoo eee ees 282 1996 Square D All Rights Reserved Bulletin No VD0C06S701 ALTIVAR 66 Service and Troubleshooting Manual December 1996 Table of Contents Removing the Control Power Transformer 000 cece eee eee 287 Installing the Control Power Transformer 20 000 cece eee e eee 289 Replacing the Stirring Fan 0 cette eae 291 Removing the Main Fan 0 0 cee tenets 292 Installing the Main Fan 0 eee RII 294 Replacing the Discharge Resistor 0 0 cece eee eee 295 Replacing the Precharge Resistor 0c cece eee eee 296 Replacing the Contactor Auxiliary Contact Block ooooo ooooooo 298 Removing the Precharge Contactor o oocccccocccccoc tee ae 301 Installing the Precharge Contactor 0 0 cece 302
314. of the controller The information is conveyed to the power and control cards of the controller The 3 phase average RMS value of current is available on menu 4 1 of the keypad display This current can be compared to O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Checking Fault History Checking the 24 VDC and 10 VDC User Power Supplies Cnapter 3 Correcting tne Problem Checking the Power Part of the Controller the 3 phase average current measured at T1 U T2 V and T3 W of the controller with the multimeter and current probe recommended in LIST OF TOOLS AND INSTRUMENTS on page 5 of this manual 5 The voltage of each output phase is measured using a galvanically isolated circuit in the controller The 3 phase average fundamental value of output voltage is available on menu 4 1 of the keypad display Due to the harmonic content of the waveform a comparison of the absolute values of the keypad display value and the 3 phase average voltage measured at T1 U T2 V and T3 W of the controller with a multimeter is not recommended the measurement error can approach 20 However the relative balance of the output voltages as measured by multimeter can be checked and should be within 3 as defined in NEMA ICS 7 The last eight faults stored by the drive controller and run status at time of fault can be displayed on menu 3 on keypad display Refer to Table 2 on page 14 of this manual for run status codes Us
315. oller see Figure 118 on page 234 6 Using a drive socket install and tighten the three main fan mounting screws 7 Route the three main fan wires through the fan access hole into the drive controller If a black wire grommet is present tighten grommet 8 Install the blue black and brown wires into the right side of terminal blocks 1 2 and 3 respectively of TB1 Using a flat blade screw driver tighten the three terminal see Figure 118 on page 234 9 Install the bottom drive controller cover Using a drive socket install and tighten the ten bottom cover mounting screws 29 9 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Replacing the Discharge Resistor Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 This procedure explains how to replace the discharge resistor for the following drive controllers Drive Controller No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Discharge Resistor No VZ3 R640W135 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The too
316. oller to blow dirt and debris from the heat sink passages back through the fan For ATV66C10 through ATV66C19 controllers cleaning of the heat sink air passages is generally not required due to the normal operating velocity of the air However if cleaning is required the main fan should be removed Follow the procedures for fan replacement found in chapter 4 to remove the fan Use a compressed air jet applied to the exhaust opening of the controller to blow dirt and debris from the heat sink passages Debris blown into the fan cavity can be removed with a vacuum hose To run the drive controller from control power only 1 e 10 11 12 Disconnect and verify that all power is removed from the drive controller Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT on page 310 of this manual Wait one minute to allow the DC bus to discharge Open the front cover of the drive controller Remove the CL1 and CL2 jumpers refer to VDOC06S304_ REMOVAL OF CL1 AND CL2 JUMPERS for location and removal procedures if present in the controller For Class 8839 controllers remove the conductors connected to the CL1 and CL2 controller terminals Insulate and tape the disconnected conductors Remove the recommended user supplied power fuses in series with the L1 L2 and L3 line terminals of the controller from their respective fuse holders Connect a 10 AWG 600 V insulation jumper conductor between CL1 terminal of the controller and the use
317. olution DB switch Power board Driver board Figure 35 DB Resistor Overtemperature 68 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Memory Failure Precharge Failure Link Fault Control Supply Fault Cnapter 3 Correcting tne Problem Memory Failure The fault only appears if there is a fault when writing to the EEPROM If the fault OCCUIS Reset the controller to the factory settings e If the fault persists change out the control card When the unit is powered up the capacitor charging is monitored When the capacitor voltage reaches 450 VDC a 500 msec for drive controllers ATV66U41N4 through ATV66D12N4 or 1500 msec for drive controllers ATV66D16N4 through ATV66C19N4 timer is triggered While the timer is running the voltage to the capacitor terminals must remain sta ble for 100 msec otherwise a precharge failure fault is triggered During operation if the charging relay opens when RUN LI1 is validated a pre charge failure fault is triggered The check is made every millisecond If a precharge failure occurs possible causes are e Failure of precharge relay contactor or its associated coil drive circuitry e Control card ribbon cable incorrectly connected e Excessive mains voltage distortion The link fault covers several possible causes As a general rule it is a stop in the communication task between the key
318. om the controller until the plug that is attached to the fan leads pulls out of the socket in the drive chassis see Figure 51 on page 96 Clip the fan leads on the controller side of the plug Using needle nose pliers carefully remove the J6 connector located at the top of the power board see Figure 52 on page 97 Pull the wire that is attached to the J6 connector through the controller Discard the old fan bracket J6 connector and wiring This procedure explains how to install the fan in the following drive controllers Drive Controller No Fan No ATV66U41N4 VZ3 V661 ATV66U54N4 VZ3 V661 ATV66U72N4 VZ3 V662 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Torque wrench set to 17 4 Ib in 1 96 Nem Flat blade screw driver sockets for torque wrench 1 4 drive metric socket set 5 5 to 14 mm 4 Needle nose pliers Control Basket procedure tool list page 90 O 1996 Square D All Rights Reserved Bulletin NO
319. omponents Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of open end wrenches 5 5 to 19 mm e Asetof Torx screw drivers e Torque wrench set to 17 7 lb in 2 Nem e 1 4 drive metric socket set 5 5 to 14 mm e Metric hex key set 2 to 14 mm e Control basket procedure tool list page 193 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 191 2 Using a phillips or Torx screw driver loosen and remove the four screws which hold the left side panel Remove the left side panel see Figure 104 on page 197 226 z _ _ _ _ _ _ 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 Using a phillips or Torx screw driver loosen and remove the four screws which hold the right side panel Remove the right side panel see Figure 104 on page 197 Remove the J1 terminal block see Figure 104 on page 197 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place Remove the bottom IP20 protection cover see Figure 104 on page 197 NOTE If repairing the controller with field wiring in p
320. on Cnapter 3 Correcting the Probiem Motor currents voltages are unstable Check controller settings under menus 1 7 11 7 12 and 7 13 Controller improperly tuned Refer to VD0C06S305 to choose correct settings Motor Accelerates Too Slowly Motor currents voltages are unbalanced or unstable Motor Controller Load side conductors overloads switchgear contactors etc Motor controller or other equipment damage Refer to Checking Peripheral Equipment in chapter 5 27 Cnapter 3 Correcting tne Problem Bulletin NO VDUCUOS UT Motor Decelerates Too Slowly Overspeeds Overspeed Trip December 1996 Motor Decelerates Too Figure 9 illustrates the troubleshooting procedure when the motor is decelerating Slowly Overspeeds too slowly Overspeed Trip MOTOR DECELERATES TOO SLOWLY OVERSPEEDS OVERSPEED TRIP Operating Condition Application requires Controller being Controller deceleration holding torque at zero commanded to decelerate ramps incorrectly set Possible speed as observed cause Speed reference Check command to be Ramp type selected performed menu 7 12 Ramp selected menu 7 12 Ramp rates of speed reference signal sent to Result controller incorrect Wrong ramp type selected Wrong ramp selected Holding brake required Modify speed reference Modify deceleration FVC controller required ramp
321. ond and triggering occurs if the fault is present for 5 msec terminal block J9 on the control board e If the controller rating information has not been recognized correctly on power up Figure 32 details the troubleshooting procedure when an internal fault is present INTERNAL Fault Displayed FAULT Main control board may Drive controller fault Rating not recognized require hard reset after Incompatible components Possible software change installed cause e Has software been Drive controller Check changed identification menu 6 to be performed Fault condition Display unit compatibility experienced directly after Result changing software Consult factory Refer to chapter 4 Refer to chapter 4 to i control basket change out change the Solution procedure to check for Control basket proper seating of control Driver board 1 basket ribbon cables Power board 2 1 2 ATV66D33N4 ATV66D64N4 ATV66U41N4 ATV66D16N4 ATV66D46N4 ATV66D79N4 ATV66U54N4 ATV66D23N4 ATV66D54N4 ATV66U72N4 ATV66C10N4 ATV66U90N4 ATV66C13N4 ATV66D12N4 ATV66C15N4 ATV66C19N4 Figure 32 Internal Fault O 1996 Square D All Rights Reserve 65 Cnapter 3 Uorrecting tne Problem Internal Fault Internal Fault continued 2 of 2 66 Possible cause Check to be performed Result Solution 15 V
322. onents on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage 1996 Square D All Rights Reserved 157 Cnapter 4 rquipment Cnange Out ATV66D33N4 and ATV66D46N4 158 Bulletin NO VDUCUOS U1 December 1996 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Gate driver procedure tool list page 154 e Control basket procedure tool list page 147 With the drive controller door removed 1 Remove the gate driver board as described in the procedure on page 154 2 Using a phillips or Torx screw driver loosen and remove the four screws which hold the right side panel see Figure 83 on page 153 Two screws are located at the top and two screws are located at the bottom Remove the right side panel 3 Using needle nose pliers carefully disconnect J7 J8 J16 1 J17 1 black J17 2 black J68 board fan leads J33 J38 blue J39 white J40 red J53 1 blue and 53 2 white at the termination points located on the power board see Figure 87 on page 158 NOTE On older versions of ATV66D33N4 and ATV66D46NA4 controllers a board fan and J
323. onnector cable and J5 18 connector cable connectors Ensure the silver leads of the cables are facing outwards from the controller 7 Push the three ribbon cable connectors to their secure position 8 Apply multi lingual hazard labels supplied with kit to control basket as required 9 Reinstall options module if previously present See User s Manual VDOCO061306 for removal installation instructions 10 Install the controller top cover Tighten the two screws using a phillips screw driver 11 Install the keypad display as described in the procedure on page 87 12 Reprogram the user settings as previously noted during the control basket removal Replacing Control Terminal This procedure explains how to replace the control terminal blocks for the Blocks following drive controllers Drive Controller No Control Terminal Block Kit No ATV66U41N4 ATV66U54N4 VZ3 N006 ATV66U72N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if installed connectors Verify that all power has been removed from J1 J12 and J13 connectors If I O Extension Module is installed verify that all power
324. ons will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on large tubular capacitors on filter board assembly see Figure 111 on page 216 Always check for presence of voltage between terminals L1 L2 and L3 on J2 terminal block see Figure 111 on page 216 using voltmeter set to 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage 1996 Square D All Rights Reserved 215
325. ons will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if installed connectors Verify that all power has been removed from J1 J12 and J13 connectors If I O Extension Module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Aset of magnetized phillips screw drivers 1996 Square D All Rights Reserved 113 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D16N4 and ATV66D23N4 December 1996 With the drive controller doo
326. ooor eee 152 Removing the Gate Driver Board 0 0 cece ett 154 Installing the Gate Driver Board 0 0 0 ects 156 Removing the Power Board 0 ccc eet tte 157 Installing the Power Board IR 159 Removing the IGBT Module oooccoccccccoccoco tee 161 1996 Square D All Rights Reserved 83 Cnapter 4 rquipment Change vut 84 Bulletin NO VDUCUOS U1 December 1996 Installing the IGBT Module sssesseee III 163 Removing the Braking IGBT Module 0 0 e eee eae 165 Installing the Braking IGBT Module 2 0 cece eee 166 Removing the Bus Capacitors 0 cece eta 167 Installing the Bus Capacitors 0 0 0 cece tetas 169 Removing the Filter Board 0 0 eet eee 171 Installing the Filter Board 1 0 tee 173 Removing the Diode Block 0 0 cece eee 175 Installing the Diode Block lseleeee IR 177 Replacing the Current Sensor 0 000 eee ete eee 178 Removing the Ean x iii Ep i IRA E bra up PRECOR UR 181 Installing th FaMo 2r AIL io a we IE EM 182 Replacing the Discharge Resistor lille 183 Replacing the Auto Transformer o coccoocoocro ee 185 ATV66D54N4 to D79N4 cerd in e e m0 189 Replacing the Keypad Display 0oooooooocooocorrr ee 190 Removing the Control Basket ooooccococccccco t
327. or example some of the controller components are sensitive to the method of handling or mounting In addition many fasteners require specific torque settings for proper operation Follow the guidelines listed below and throughout the manual when performing change out procedures Be sure to install thermal grease or the supplied Thermstrate foil when mounting components which use the heat sink for dissipating heat i e voltage regulators and power semiconductor devices Always torque semiconductor components using the method described in the applicable equipment change out procedure When disconnecting the J3 J4 and J5 connectors from the control basket or printed circuit board ensure that the cable connectors are in their released position Never operate the controller after performing equipment change out procedures without verifying that the J3 J4 J5 J9 and J32 cables are properly connected to the printed circuit board and to the control basket If the controller is removed from its permanent mounting location for performing troubleshooting equipment change out procedures ensure that it is properly secured in an upright position before reenergizing During maintenance do not block impede or otherwise diminish cooling air flow over or through the controller A number of printed wiring board assemblies are equipped with non volatile memory and will require programming if replaced Existing or factory default programs within a
328. or removed 1 Remove the control basket as described in the procedure on page 101 2 Disconnect the J1 connector at the bottom of the power board 3 Identify and tag all field wiring for future re assembly 4 Disconnect the field wiring on the J2 connector at the bottom of the power board see Figure 56 on page 105 Remove the IP20 protection cover see Figure 56 on page 105 6 Usinga phillips screw driver loosen and remove the four screws holding the controller bottom cover in place Remove the bottom cover g 108 s 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66U90N4 and ATV66D12N4 7 Usinga phillips screw driver loosen and remove the two screws holding the controller top cover in place Remove the top cover 8 Slide the side covers towards the top of the controller until they release Remove the side covers 9 Usinga drive socket or a phillips screw driver as necessary loosen the four screws holding the drive controller chassis to the controller back cover Lift the drive controller chassis away from the back cover to gain access to the fan Mounting bracket screw Mounting bracket screw Plug Figure 58 Fan Removal 10 Using a phillips screw driver loosen and remove the two screws holding the fan bracket see Figure 58 on page 109 11 Pull the fan away from the controller until the plug that is attached to the fan leads pulls out of th
329. or this procedure are e Snubber board procedure tool list page 250 Gate driver procedure tool list page 253 To install an IGBT module 1 Install a new Thermstrate foil on the back of the new IGBT module Remove the paper backing from the Thermstrate foil but do not remove the white contact grease coating NOTE If the Thermstrate foil is damaged i e wrinkled coating gaps gt 1 8 round discard Thermstrate foil Obtain new foil 2 Place the new IGBT module behind the bus bar and align the mounting holes 3 Install the four mounting screws the wire from J1 on the gate driver board on the top bus terminal screw and the two bus terminal screws 4 Using the torque wrench with a hex key socket initially tighten the four mounting screws in the sequence shown below to 6 0 9 0 Ib in 0 7 1 0 Nem Final torque is 26 5 Ib in 3 Nem Oo oQ y 0 0 5 Using the torque wrench with a hex key socket tighten the two bus terminal screws to 26 5 lb in 3 Nem Ensure that the non insulated portion of the J1 wire and the attached connector have a minimum of 3 8 9 5 mm spacing from the lower bus bar NOTE Always use the J1 lead provided with the replacement gate driver board DO NOT reuse the existing J1 lead 6 If the adjacent gate driver board was loosened in the IGBT module removal procedure see note on page 254 tighte
330. oup phone 919 217 6535 FAX 919 217 6508 for ATV66 troubleshooting support When placing a call having the following information will be very helpful 1 Drive catalog number available from nameplate on drive heatsink or from drive identification screen on keypad display example ATV66D16NAU 2 Ifdrive was enclosed by Square D provide catalog number from enclosure nameplate Example of freestanding enclosure 8839 66UFA4VF A11 MO9 A16 G16 L16 P16 R16 T16 Example of MCC enclosure 8898 M6BVV7 6AU M09 A16 AG16 T2 P16 T16 N16 3 Information on how the drive is applied type of load motor power distibution etc Drive installation environment enclosure type ambient temperature etc Control wiring diagrams All user s installation and configuration manuals This service and troubleshooting manual Listing of how drive is configured SC RPND DA Listing of last eight faults from fault history menu 10 History of drive and difficulties experienced 11 Information on troubleshooting steps already taken To arrange for your drive to be repaired at our factory call your local Square D Distributor To arrange for a factory trained repair technician to repair your drive at your site call Square D s Field Service Organization at 1 800 634 2003 1996 Square D All Rights Reserve 319 Appenaix Bu
331. ove the right side panel 3 Ifreplacing the power board perform the following step Using two small flat blade screw drivers carefully pull out on each side of the cable connectors for J4 and J5 on the power board to the release position see Figure 62 on page 114 Pull the ribbon cables from the connectors Save for use on a new power board NOTE Be sure the ribbon cables have been released before pulling to avoid damage to the cables 4 Using needle nose pliers carefully disconnect J6 J16 J17 J33 J38 blue J39 white J40 red J66 blue and J67 white at the termination points located on the power board see Figure 67 on page 123 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D16N4 and ATV66D23N4 J17 J38 Blue J39 White J40 Red Braking IGBT E ee Sigh Location of one nut for module nuts 9 JJ capacitor bank DR2 cable termination Voltage regulators U cable termination i i Hall Effect sensors V cable termination REED Y J66 Blue W cable termination UE EA J67 White U Cable SEA ANA Termination V Cable NG Detail A OA Termination Hall Effect sensors W Cable Termination ae Figure 67 Connector Wire and Nut Locations on Power Board 5 Using a drive socket loosen and remove the five nuts on the power board for the IGBT modules see Figure 67 on page
332. over the four mounting holes While supporting the transformer contactor assembly with one hand install the two bottom transformer contactor assembly mounting screws see Figure 142 on page 288 with your other hand Use a drive socket with a 12 extension to tighten the two screws While still supporting the top of the assembly with one hand use the other hand to put one of the pieces of tape across the socket at the end of the 12 extension piece the tape will help hold the screw in the socket Insert one of the mounting screw heads into the socket Thread the 12 extension piece with socket and screw through the upper left opening in the transformer contactor assembly Using the drive socket install and tighten the transformer contactor assembly mounting screw see Figure 142 on page 288 Perform step 13 again for the upper right transformer contactor assembly mounting screw Using a torque wrench a 12 socket extension and a metric socket torque the four transformer contactor assembly mounting screw to 35 4 Ib in 4 0 Nem Using a torque wrench and hex key socket install and tighten the power wire connection screws for the DCB and DCB power cables to 164 Ib in 18 5 Nem see Figure 139 on page 283 Using a torque wrench and hex key socket install and tighten the power wire connection screws for the RB and RB power cables to 40 7 Ib in 4 6 Nem see Figure 139 on page 283 Position the two DCB control wires
333. ower before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if installed connectors Verify that all power has been removed from J1 J12 and J13 connectors f I O Extension Module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage 1996 Square D All Rights Reserved 237 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 238 Bulletin NO VDUCUOS U1 December 1996 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for
334. owing drive controllers Drive Controller No Filter Board No ATV66D54N4 ATV66D64N4 VX4 A66105 ATV66D79N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm Torque wrench set to 170 Ib in 19 Nem e Metric drive sockets for torque wrench e Metric hex key sockets for torque wrench 2 to 14 mm e Flat blade screw driver sockets for torque wrench e Gate driver procedure tool list page 200 e Control basket procedure tool list page 193 For the filter board to be installed 1 Ifinstalling a new filter board connect the J41 connector from the yellow green ground wire to the new board 2 Install the filter board in the drive controller and align the seven mounting holes 3 Using a torque wrench and drive socket install and tighten the five nuts to 17 7 lb in 2 Nem 4 Using a torque wrench and hex key socket install and tighten the two mounting screws to 7 7 lb in 1 Ne
335. p00000022 20020200 5 Inserta small electrically insulated screw driver in the notch of the plastic cover While applying slight upward pressure pull out to remove cover 6 Record the software revision number from the chip 7 Replace the plastic cover over the software chip 8 Close the drive controller cover If your drive controller contains a software version other than 1 6IE21 1 61E22 or 2 0IE23A or newer contact your local field sales office for a software upgrade 1996 Square D All Rights Reserved 317 Cnapter 5 basic Procedures Bulletin NO VDUCU6S UT Running the Controller from Control Power Only December 1996 315 c 1996 Square D All Rights Reserved Bulletin NO VDUCU6S U1 December 1996 APPENDIX TO ORDER REPLACEMENT PARTS LOCAL SUPPORT FACTORY TELEPHONE SUPPORT FACTORY REPAIR ON SITE REPAIR Appenaix To Order Replacement Parts If you need more assistance Call your local Square D Distributor with the catalog numbers referenced in this manual Distributor Name Distributor Phone Number Call your local Square D Field Office for drive application assistance as well as price and delivery information on replacement equipment For a list of phone numbers see back cover of the Square D Digest Field Office Phone Number Call Square D s AC Drives Product Support Gr
336. pacitor posts would be perpendicular to the side of the drive controller 3 When mounting brackets are properly installed tighten the mounting bracket hardware Using a phillips screw driver install and tighten the eight capacitor mounting bracket screws 4 Install the current sensor mounting bracket Using a hex key wrench install and tighten the two current sensor mounting screws 5 Position the bus bar and align the mounting holes NOTE When executing steps 6 through 9 perform the following checks Ensure the red C cable from the contactor is connected to the terminal of the top capacitor Ensure the black C cable is connected to the terminal of the third capacitor from the top of the controller Ensure the BR3 cable is connected to the C1 terminal of the braking IGBT module Ensure the U V and W cables are connected to the C2E1 terminals of their respective IGBT modules as labeled on the bus Do not tighten any one screw or mounting pin until all of the hex head screws phillips head screws and mounting pins are started with all required cables connected 6 Using a hex key wrench install the eight bus capacitor hex head screws with the balancing resistors see Figure 89 on page 162 7 Using a drive socket or open end wrench install the six mounting pins with two washers which connect the bus bar to the IGBT modules see Figure 89 on age 162 sing a phillips screw driver install the two screws which attach the
337. pad Ll Automatic Runs Does Not Perform as Expected Severity of Fault Other AFDI SS Application Environmental E TS Installation Cause of Fault Figure 1 Typical Causes and Severity of Faults RECOMMENDED This chapter contains procedures for detecting faults and faulty operating TROUBLESHOOTING conditions in the drive controller Before attempting the procedures read the INSTRUCTIONS precaution statement on the inside front cover of this manual and the Work Practice Precautions section in chapter 1 Also if directed to the equipment change out procedures in chapter 4 of this manual read all applicable instructions and precautions before beginning work Always record the drive controller motor and auxiliary apparatus nameplate data For the drive controller this should include part number date code voltage rating power rating and software revision number See page 317 in chapter 5 for checking software revision level Obtaining nameplate information generally requires de energizing the controller Discussions with operating personnel can yield a wealth of information about symptoms and possible root causes of reported problems Itis extremely important for maintenance personnel to gather as much information as possible from operation personnel Some questions to ask may include When was the problem 8 AAA 0 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 October 1997
338. pad display and the control basket or a software corruption caused by external influences In the case of a software corruption reset the unit by totally disconnecting the line power supply Wait for the keypad display to fade before restarting This type of fault occurs e If control power is supplied separately and if the L1 L2 L3 terminals are powered before the CL1 and CL2 terminals e If the shunts between CL1 L1 and CL2 L2 are missing and separate control power is not supplied e If the frequency is not between 48 1 and 52 1 for a 50 Hz line supply and between 56 8 and 62 1 Hz for a 60 Hz line supply 1996 Square D All Rights Reserve 69 Cnapter 3 Uorrecting tne Problem Bulletin NO VDUCUOS U1 Keypad Display is Off December 1996 EQUIPMENT DAMAGE When the drive controller is powered up and the keypad display is not active Keypad Display 3 04 If the LEDs are not lit check the unit supply or control card connections J9 ribbon cable 5 V between 7 and 8 If the LEDs are lit check that the keypad display is properly connected to the con trol card For controllers equipped with a cable between the keypad display and main control board check continuity of cable assembly External Signs of Look for any sign of physical damage to the exterior of the drive controller Equipment Damage specifically e Cracked ch
339. phase for t 2 1 sec Possible cause Check to be performed Result Reset by removing the input line power wait until the keypad display fades Refer to Checking Refer to chapter 4 to Peripheral Equipment in check the connections chapter 5 Control basket Check the controller Power board input line fuses Filter board 1 Check the input line Solution 1 ATV66D16N4 ATV66D64N4 ATV66C19N4 ATV66D23N4 ATV66D79N4 ATV66D33N4 ATV66C10N4 ATV66D46N4 ATV66C13N4 ATV66D54N4 ATV66C15N4 Figure 21 Input Phase Loss 52 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Motor Overload Cnapter 3 Correcting tne Problem Motor Overload Using the signals provided by the T1 and T3 current sensors the load status is calculated in relation to the thermal current Ith and the type of protection programmed in Fault Management menu 7 4 e Fan cooled motor Force cooled motor Manual adjustment Two time constants are taken into account Short constant copper temperature rise motor overload e Long constant iron temperature rise motor load status When the motor thermal state reaches 100 there is a thermal early warning and the yellow LED blinks The motor overload fault is triggered if the thermal state reaches 11876 The motor overload thermal state percent can be displayed on the keypad display at the MOTOR THERMAL STATE line 199
340. phillips screw driver loosen the two screws holding the auto transformer in place see Figure 99 on page 186 Using needle nose pliers carefully disconnect the wires connected to the terminals of the auto transformer Remove the old auto transformer Install the new auto transformer Using needle nose pliers carefully connect the wires to the auto transformer in accordance with Table 12 on page 187 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 Table 12 Auto Transformer Connections Auto Transformer Connection Wire Color 1 Black 3 Red 5 White 7 Blue 16 Install the auto transformer Using a phillips screw driver install and tighten 17 18 19 20 21 22 23 24 25 the two screws Install the J2 terminal block assembly Using a hex key wrench install and tighten the two screws holding the terminal block assembly in place Install the cables and wires for L1 L2 L3 U T1 V T2 W T3 CL1 CL2 L21 L22 PA PB and ground at both the field side and drive controller side of the J2 terminal block Using a torque wrench and appropriate attachment tighten the terminal screws as shown in Figure 93 on page 174 Ensure that the U T1 cable passes through the left current sensor and that the W T3 cable passes through the right current sensor Install the bottom panel Using a phillips or To
341. pliers carefully connect the J1 J2 J3 and J4 connectors on the snubber board see Figure 127 on page 249 4 Swing the hinged assembly back to its normal position Using a flat blade screw driver tighten the two screws Removing the Gate Driver There are six gate driver boards in the ATV66C10N4 to C19N4 drive controllers Board The power pole kit contains two gate driver boards NOTE Replace the gate driver boards in horizontal pairs see Figure 128 on page 252 GD1 and GD4 GD6 and GD3 GD5 and GD2 This procedure explains how to remove an individual gate driver board from the following drive controllers Drive Controller No Power Pole Kit No ATV66C10N4 VZ3 IM1300M1206 ATV66C13N4 VZ3 IM1400M1206 ATV66C15N4 VZ3 IM1400M1206 ATV66C19N4 VZ3 IM1500M1206 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury 20 c O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66C10N4 to C19N4 A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter set to 1000 VDC scale If voltage is present allow voltmet
342. quipment Cnange Out ATV66D33N4 and ATV66D46N4 There are three diode blocks on this size of drive controller This procedure explains how to install the a diode block in the following drive controllers Diode Block No VZ3 DM2080M1606 VZ3 DM2100M1601 Drive Controller No ATV66D33N4 ATV66D46N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Torque wrench set to 26 5 lb in 3 Nem e 1 4 drive metric socket set 5 5 to 14 mm e Thermal grease Thermalloy Thermalcote II Part No 349 or equivalent Filter board procedure tool list page 173 e Control basket procedure tool list page 149 For the diode bridge to be installed 1 Clean the portion of the heatsink which will make contact with the diode block 2 Evenly coat the bottom of the diode block with a thin coating of thermal grease 3 Install the diode block Orient the diode block so that terminal 3 is located next to the fan Using a torque
343. r see Figure 144 on page 296 Using a torque wrench and a flat blade screw driver socket tighten the terminal screws to 15 Ib in 1 7 Nem 1996 Square D All Rights Reserved 305 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 Replacing the Control This procedure explains how to replace the control fuses for the following drive Fuses controllers Drive Controller No Control Fuses No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 DFSCF00501 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual Pull FU5 and FU6 fuse holders from their sockets see Figure 118 on page 234 Remove the two fuses from their fuse holders Install the two new fuses into the FU5 and FU6 fuse holders Insert the FU5 and FU6 fuse holders into their sockets see Figure 118 on page 234
344. r corner screws to 8 9 Ib in 1 0 Nem see Figure 101 on page 192 NOTE The captive mounting screw provides the grounding connection for the control basket and shield connection on J13 Ensure this screw is properly threaded and torqued 1996 Square D All Rights Reserved c 193 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66D54N4 to D79N4 December 1996 2 Snap the four connectors J9 J12 J13 and J32 into place see Figure 101 on page 192 NOTE The yellow keys in both the plugs and sockets are designed to prevent incorrect insertion of both J12 and J13 3 Make sure all three cable connectors are pulled out on connectors J3 J4 and J5 see Figure 102 on page 193 4 Carefully insert the three ribbon cables into the white cable connectors at the J3 seven connector cable J4 six connector cable and J5 18 connector cable connectors Ensure the silver leads of the cables are facing outwards from the controller 5 Push the three ribbon cable connectors to their secure position 6 Apply multi lingual hazard labels supplied with kit to control basket as required 7 Reinstall options module if previously present See User s Manual VDOCO061306 for removal installation instructions 8 Install the keypad display as described in the procedure on page 190 9 Reprogram the user settings as previously noted during the control basket removal Replacing Control Terminal This procedure explains how to replace
345. r door open or removed 1 Remove the dynamic braking snubber board as described in the procedure on page 264 2 Using needle nose pliers carefully disconnect and pull back out of the way the T2 sensor wire see Figure 131 on page 262 3 Using a hex key wrench loosen and remove the screw at the back of the T2 terminal block Pull the T2 power cable back out of the way 4 Using a hex key wrench loosen and remove the current sensor mounting bracket screw 5 Using a hex key wrench loosen and remove the remaining mounting screw for the dynamic braking snubber board bus bar bracket see Figure 133 on page 266 Remove the bracket 6 Disconnect the P2 connector on the dynamic braking gate driver board 7 Using a hex key wrench loosen and remove the two mounting screws for the bus bar extension piece see Figure 130 on page 258 Remove the bus bar extension piece 8 Usingahexkey wrench remove the screw located at the Q7 C terminal of the dynamic braking IGBT module see Figure 133 on page 266 This frees the Q7 C control wire which is attached to the dynamic braking gate driver board at the J1 location 9 Using a hex key wrench loosen and remove the two mounting screws Remove the dynamic braking gate driver board and wire NOTE If the J1 wire landed on the gate driver board is connected with a detachable terminal connector or zero force connector be sure to discard the wire and DO NOT reuse on new board The dyna
346. r is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter setto 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved 273 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 274 Bulletin NO VDUCUOS U1 December 1996 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 1 4 drive metric socket set 5 5 to14 mm DBsnubber board procedure tool list page 265 Current sensor assembly procedure tool list page 261 With
347. r leakage Internal drive reactance high efficiency controller fault motor multi motor applications Electrical noise induced into motor cables During operation when Conduct autodiagnostic does short circuit fault transistor test occur Keypad display shows short circuit Incorrect wiring practice utilized on motor cables Fault occurs during acceleration or current limit operation Place a reactor at the Refer to chapter 4 to drive controller output change the Correct motor cable IGBT module 1 installation Refer to Gate driver board VD0CO06S304 Power board Control basket Connections O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 3 Correcting tne Problem December 1996 Ground Fault Ground Fault Figure 30 illustrates the measurement principle used for the ground fault Current transformer 4 N 4 Y Filter board ATV66D16N4 ATV66D64N4 ATV66D23N4 ATV66D79N4 ATV66D33N4 ATV66C10N4 ATV66D46N4 ATV66C13N4 ATV66D54N4 ATV66C15N4 I ATV66C19N4 f Power board Control basket Figure 30 Ground Fault Measurement For drive controllers ATV66U41N4 through ATV66D12N4 there is no ground fault The output short circuit fault provides similar protection For drive controllers ATV66D16N4 through ATV66C19N4 the ground fault is trig gered on a threshold of the current from the current transformer if the motor or the dynamic brake resistor are connected
348. r open 1 Measure the bus voltage if not already performed as described in Chapter 5 of this manual 2 Remove the keypad display as described on page 112 3 Remove options module if present See User s Manual VDOC06T306_ for removal installation instructions 4 Using a flat blade screw driver carefully loosen and disconnect the J9 and J32 connectors located at the top left of the control basket see Figure 61 on page 114 5 Using a flat blade screw driver carefully loosen and disconnect the J12 and J13 connectors located at the bottom of the control basket see Figure 61 on page 114 J9 J32 J4 J3 J5 wWounting screw Mounting screw JA E Cable guides located Fr i on back of control basket Location of I O Extension Module If installed a Captive mounting 5 screw E Mounting screw WBHZEHREN KEAN J13 J12 Figure 61 Control Basket Connector Locations 6 Usingtwo small flatblade screw drivers carefully pull out on each side of the cable clasps may be either blue or white of J3 J4 and J5 to the release position see Figure 62 on page 114 Pull the ribbon cables from the sockets 7 Using a phillips screw driver loosen the four corner screws on the control basket The bottom left screw is a captive screw see Figure 61 on page 114 8 Remove the control basket from the drive controller As the control basket is removed pull the three ribbon cables out of the guide on the bac
349. r screws which hold the left side panel in place 13 Install the control basket as described in the procedure on page 149 1996 Square D All Rights Reserved L 153 Cnapter 4 rquipment Change Out Bulletin NO VDUCUbS UI ATV66D33N4 and ATV66D46N4 December 1996 Removing the Gate Driver This procedure explains how to remove the gate driver board from the following Board drive controllers Gate Driver Board No VX5 A66105 VX5 A66106 Drive Controller No ATV66D33N4 ATV66D46N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover o
350. r supplied L1 line side power fuse terminal Connect a 10 AWG 600V insulation jumper conductor between CL2 terminal of the controller and the user supplied L2 line side power fuse terminal Close the drive controller cover Apply power to the controller After the drive controller displays In Phase Fail on the keypad display screen press Enter on the keypad display Go to the fault management screen menu 7 4 Record the setting of the In Phase Fail and Output Phase Flt functions Change the In Phase Fail and Output Phase Flt to No Remove and reapply power to clear fault condition The controller is now ready for operation with control power applied NOTE If controller settings are changed during testing record the original settings for restoration after completion of testing O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Unapter 5 basic Procedures Running the Controller from Control Power Only To restore the drive controller once testing is complete 1 Disconnect and verify that all power is removed from the drive controller Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT on page 310 of this manual 2 Wait one minute to allow the DC bus to discharge 3 Open the front cover of the drive controller 4 Disconnect the jumper conductor between CL1 terminal of the controller and the user supplied L1 line side power fuse terminal 5 Disconn
351. rd and using the needle nose pliers carefully disconnect J35 blue J36 white and J37 red at the termination points located on the power board underneath the gate driver board see Figure 86 on page 155 9 Remove the gate driver board 10 If the gate driver board is to be replaced loosen the J3 and J4 cable connectors and remove the cables see Figure 81 on page 149 and Figure 85 on page 155 These cables will be needed during the installation of the new gate driver board Remove and save the ferrite cores from cables J28 J29 and J30 for use on the new board NOTE Be sure the ribbon cables have been released before pulling to avoid damage to the cables This procedure explains how to install the gate driver board in the following drive controllers Drive Controller No Gate Driver Board No ATV66D33N4 VX5 A66105 ATV66D46N4 VX5 A66106 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of Torx screw
352. rd in the following drive controllers Drive Controller No Gate Driver Board No ATV66D54N4 VX5 A66107 ATV66D64N4 VX5 A66108 ATV66D79N4 VX5 A66109 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of Torx screw drivers e 4 Needle nose pliers e Control basket procedure tool list page 193 For the gate driver board to be installed 1 Loosen the J3 and J4 cable connectors see Figure 102 on page 193 Insert the J3 and J4 cables with the silver leads facing towards the top of the gate driver board Push the connectors to the secure position Install the ferrite cores saved earlier onto cables J28 J29 and J30 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D54N4 to D79N4 2 Using needle nose pliers carefully connect J21 3 black J23_3 yellow J25_3 green J35 blue J36 white and J37 red at the termination points located on the pow
353. rd to the diode bridge bus work see Figure 92 on page 173 14 Carefully remove the filter board This procedure explains how to install the filter board in the following drive controllers Drive Controller No Gate Driver Board No ATV66D33N4 anes NN A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of Torx screw drivers Flat blade screw driver sockets for torque wrench e Metric hex key set 2 to 14 mm e Torque wrench set to 26 5 lb in 3 Nem e Metric hex key sockets for torque wrench 2 to 14 mm e 4 Needle nose pliers Control basket procedure tool list page 149 1996 Square D All Rights Reserved 173 Cnapter 4 rquipment Cnange Out ATV66D33N4 and ATV66D46N4 Bulletin NO VDUCUOS U1 December 1996 For the filter board to be installed 1 Install the new filter board in
354. re The tools needed for this procedure are e Aset of magnetized phillips screw drivers e 4 Needle nose pliers e Aset of thin shaft Torx screw drivers e Metric hex key set 2 to 14 mm With the drive controller door removed 1 Using a phillips or Torx screw driver loosen and remove the four screws which hold the left side panel see Figure 83 on page 153 Two screws are located at the top and two screws are located at the bottom Remove the left side panel 2 Disconnect the J1 connector This will allow the bottom IP20 protection cover to be removed see Figure 82 on page 151 3 Using a phillips screw driver loosen and remove the three screws which hold the bottom IP20 protection cover in place see Figure 83 on page 153 Remove the bottom IP20 protection cover NOTE If repairing the controller with field wiring in place the wiring knockout panel can be detached from the bottom panel in the next step 4 Using a phillips or Torx screw driver loosen and remove the five screws which hold the bottom panel in place see Figure 83 on page 153 Remove the bottom panel 1996 Square D All Rights Reserved 181 Cnapter 4 rquipment Cnange Out ATV66D33N4 and ATV66D46N4 Installing the Fan 182 Bulletin NO VDUCUOS U1 December 1996 5 Using needle nose pliers carefully disconnect the two
355. re D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the IGBT Module Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Torque wrench set to 26 5 lb in 3 Nem e Snubber board procedure tool list page 250 To install a gate driver board 1 Atthe associated IGBT module land the wire from terminal J1 on the gate driver board underneath the top bus terminal screw Ensure that the non insulated portion of this wire and the attached connector have a minimum of 3 8 9 5 mm spacing from the lower bus bar NOTE Always use the J1 lead provided with the replacement gate driver board DO NOT reuse the existing J1 Lead 2 Using the torque wrench and a hex key socket tighten the bus terminal screw to 26 5 lb in 3 Nem 3 Align the mounting holes on the gate driver board with the mounting posts in the controller see Figure 128 on page 252 4 Install the two mounting screws Using the torque wrench with a hex key socket tighten the two mounting screws to 17 7 Ib in 2 Nem 5 Using needle nose pliers carefully connect the P2 connector on the gate driver board 6 Install the snubber board as described in the procedure on page 249 There are six IGBT modules in the ATV66C10N4 to C19N
356. re non sinusoidal To ensure consistent measurement results always use the recommended test apparatus found in LIST OF TOOLS AND INSTRUMENTS on page 5 of this manual 1996 Square D All Rights Reserved 77 Cnapter 3 Correcting the Problem Checking the Power Part of the Controller Drive Controller Internal Measurements Check 78 Bulletin NO VDUCUOS U1 December 1996 Figure 45 shows the measurements performed by the drive controller on the vari ous power conversion stages Incorrect operation of any sensor can affect overall performance of the controller Anumber of monitored parameters are available for observation from the keypad display By comparing the keypad values to those measured with appropriate test apparatus the operation of the sensor circuits can be checked Measuring the ground fault current ATV66D16N4 to f i ATvesci9N4 Measuring Measuring the Measuring the l the DC bus motor current motor voltage Measuring voltage U and W phases 9 the line Measuring the line voltage frequency at power up Figure 45 Drive Controller Power Part Measurements The following checks should be performed Refer to VDOC065305_ for additional information on the use of the keypad display 1 Line voltage is measured by a 3 phase rectifier bridge and a impedance isolated circu
357. red charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e 4 Needle nose pliers e Metric hex key set 2 to 14 mm e 1 4 drive metric socket set 5 5 to 14 mm With drive controller door open or removed refer to Figure 119 on page 235 for location of fan NOTE Do not disturb white laminated insulating paper around stirring fan If disturbed be sure to replace in original position Do not operate drive controller if paper is damaged or scratched If sheet is damaged replace 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Using needle nose pliers carefully disconnect the two connectors on the right side of the fan 1996 Square D All Rights Reserved 291 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 3 Using a flat blade screw driver loosen the two screws holding the hinged assembly in place Swin
358. rench set to 164 Ib in 18 5 Nem e Metric hex key sockets for torque wrench 2 to 14 mm e 4 Needle nose pliers e Set of magnetized phillips screw drivers To install the right current sensor NOTE Do not alter the factory set current sensor adjustment settings 1 Gently pull the right current sensor signal cable labeled CT3 out from the drive just enough to attach it to the socket on current sensor using a needle nose pliers pull on the wires not the connector 2 Install the current sensor into the drive positioning the bottom mounting hole of the sensor over the fixed screw in the mounting bracket and aligning the top mounting hole of the sensor over the top screw hole in the mounting bracket With a phillips screw driver reinstall and tighten the mounting screw 3 Install the copper center cylinder into the center of the current sensor 4 While holding the T3 power cable and current sensor connector in place beside the right current sensor install the center cylinder screw see Figure 131 on page 262 Using the torque wrench and a hex key socket tighten the center cylinder screw to 164 lb in 18 5 Nem 1996 Square D All Rights Reserved 263 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Removing the Dynamic Braking DB Snubber Board 264 Bulletin NO VDUCUOS U1 December 1996 5
359. rench with a hex key socket install and tighten the two mounting screws to 17 7 Ib in 2 Nem Position the cables over their respective mounting location see Figure 113 on page 221 220 lt lt 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D54N4 to D79N4 NW L L Two ring Lip4 Lop 4 isp M mounting post O L1P Ox C Our O O ect post Vid Figure 113 Diode Bridge Mounting 4 Usinga torque wrench with a hex key socket install and tighten the four screws and washers which hold the diode bridge bus work to the outside diode blocks Tighten to 17 7 Ib in 2 Nem sing a torque wrench and drive socket install and tighten the two mounting osts with three rings and washers see Figure 113 on page 221 on the center iode block Tighten to 26 5 Ib in 3 Nem sing a torque wrench and drive socket install and tighten the mounting post with two rings washers see Figure 113 on page 221 and incoming line cable on the diode block that was replaced Tighten to 26 5 Ib in 3 Nem 7 Install the filter board as described in the procedure on page 217 al am a o c Replacing the Current There are two current sensors in this size of drive controller This procedure Sensor explains how to replace the current sensors for the following drive controllers Drive Control
360. resence and correct directional sense of tachometer encoder signal Scaling of speed feedback signal Bidirectional characteristic of tachometer encoder velocity feedback device Feedback signal absent wrong directional sense incorrectly scaled Repair or replace the tachometer encoder device Correct directional sense of velocity feedback device Refer to VDOCO6S306_ Replace unidirectional velocity feedback device with bidirectional velocity feedback device O 1996 Square D All Rights Reserved Cnapter 3 Correcting the Problem Motor Decelerates Too Slowly Overspeeds Overspeed Trip Motor deceleration under current limit or regeneration torque limit Current limit setting menu 7 11 Regeneration torque limit setting menu 7 11 Motor current during deceleration Current limit set too low Regeneration torque limit set too low If motor current and torque are less than the setting of the controller current and torque limits then controller is not capable of producing sufficient deceleration torque Increase current limit setting Increase regeneration torque limit setting Add Dynamic Braking Resistor Kit so that controller can produce deceleration torque Current limit already set to maximum value Regeneration torque limit already set to maximum value f motor current and torque are less than the setting of the controller current and torq
361. rew drivers e Torque wrench set to 8 9 Ib in 1 0 Nem e Aset of phillips screw driver sockets for torque wrench For the control basket to be installed 1 Thread the three ribbon cables through the cable guides on the back of the control basket see Figure 54 on page 102 2 Place the control basket in the controller and slide it up until the two bottom mounting holes are aligned with the holes in the controller Ensure the two ears at the top of the control basket are behind the tabs on the drive controller see Figure 54 on page 102 3 Insert the bottom screw that is not captive and using a torque wrench with a phillips screw drive socket tighten both screws to a torque of 8 5 Ib in 1 0 Nem NOTE The captive mounting screw provides the grounding connection for the control basket and shield connection on J13 Ensure this screw is properly threaded and torqued 4 Snap the four connectors J9 J12 J13 and J32 into place see Figure 54 on page 102 NOTE The yellow keys in both the plugs and sockets are designed to prevent incorrect insertion of both J12 and J13 5 Make sure all three cable connectors are pulled out on connectors J3 J4 and J5 see Figure 55 on page 102 6 Carefully insert the three ribbon cables into the cable connectors at the J3 seven connector cable J4 six connector cable and J5 18 connector cable 1996 Square D All Rights Reserved L 103 Cnapter 4 Equipment Cnange Out Bulletin NO V
362. rforming any of the following procedures From the drive initialization mode reset the unit to the factory settings Perform the following a Set the following LM 1 run LI2 1 forward All AL 0 V reference The motor should remain stationary b Set the following LM 1 run LI 1 forward All 0 to 10 V reference The motor accelerates up to 60 Hz c Set the following LM 0 run LI 1 forward All 10 V reference The motor should freewheel to a stop d Set the following LM 1 run LI3 1 reverse All 10 V reference The motor accelerates up to 60 Hz in reverse e Set the following LM 1 run O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 PROCEDURE 6 CHECKING FAN OPERATION Cnapter 9 gt Basic Procedures Checking Peripheral Equipment LI2 1 forward LI3 1 reverse Al 10V reference The motor speed remains constant f Set the following LN 1 run LI 1 forward LI3 0 reverse AI 10 V reference The motor slows down and accelerates in the other direction g Set the following LM 1 run LI2 0 forward LI3 0 reverse All 10 V reference The motor should stop in accordance with the deceleration ramp 1 Reduce the ramp time to 0 1 seconds acceleration and deceleration
363. ripheral Equipment Bulletin NO VDUCU6S U1 December 1996 PROCEDURE 5 Conduct the validation after repair to ensure the drive controller is working VALIDATION AFTER properly prior to returning it to service REPAIR 1 Connect the controller to a test bench consisting of the following devices 314 A power source of appropriate current voltage and frequency for the controller The test bench power source should be equipped with a disconnect switch dimensioned for the power source and recommended input fuses of a type and current rating as indicated on the controller nameplate Atest motor whose voltage and frequency match the controller output rating The motor power rating should be greater than 20 but not exceeding 100 of the controller power rating A means for switching the logic inputs and providing an analog reference to the controller as described in VDOC06S304_ A dynamic braking resistor selected according to the selection chart in VDOC06S304_ The test bench should be constructed in accordance with NFPA 70 and OSHA standards In the event that a test bench is not available it may be possible to use the actual controller installation for check out of the controller using some or all of the following procedures Check the suitability of the actual installation prior to performing any procedures Read the WORK PRACTICE PRECAUTIONS in chapter 1 and the precaution statement on the inside cover of this manual before pe
364. rive controllers Drive Controller No Thermal Switch No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 VZ3 G003 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter setto 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved 277 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 278 Bulletin NO VDUCUOS U1 December 1996 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components F
365. rive controllers The Board power pole kit contains snubber boards with four different part numbers When replacing a snubber board match the part number of the replacement board with the part number of the board to be replaced NOTE Replace the snubber boards in horizontal pairs SB1 and SB4 SB6 and SB3 SB5 and SB2 see Figure 127 on page 249 This procedure explains how to remove an individual snubber board from the following drive controllers Drive Controller No Power Pole Kit No ATV66C10N4 VZ3 IM1300M1206 ATV66C13N4 VZ3 IM1400M1206 ATV66C15N4 VZ3 IM1400M1206 ATV66C19N4 VZ3 IM1500M1206 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter set to 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved
366. roller bonding and ground system and ensure that the controller is properly grounded per applicable codes and recommendations found in the Receiving Installation and Start Up manual bulletin number VD0C06S304_ e Check the integrity of insulation and connections of all incoming and outgoing wiring both power and ground e Check the wiring method and routings Make sure that wiring is as recommended in the Receiving Installation and Start Up manual bulletin number VD0C06S304_ e Check that the voltage present on the line side of the controller disconnect is within the controller specifications as listed on the controller nameplate Conduct the voltage test with a properly rated voltage sensing device 1996 Square D All Rights Reserved 11 Cnapter 2 Investigating tne Problem Bulletin NO VDUCUOS U1 LEDs October 1997 Refer to Table 6 on page 17 when checking for controller damage Follow referenced troubleshooting and repair procedures as required Upon completion of any recommended repairs the following should be performed e Refer to the Receiving Installation and Start Up manual bulletin number VD0C06S304_ and follow all procedures for checking the integrity of the drive controller and for reinstalling if necessary and starting up the controller e After the controller is re installed and powered up perform P
367. rollers Procedure See Control Kit ATV66U90N4 D12N4 VX4 A66CK1 Pages 100 104 Control Terminal Block Kit ATV66U90N4 D12N4 VZ3 N006 Pages 104 105 Power Board ATV66U90N4 VX5 A66U90N4 Pages 106 107 ATV66D12N4 VX5 A66D12N4 Fan ATV66U90N4 D12N4 VZ3 V663 Pages 108 110 O 1996 Square D All Rights Reserved 99 Cnapter 4 Equipment Cnange Out ATV66U90N4 and ATV66D12N4 Replacing the Keypad Display 100 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to replace the keypad display for the following drive controllers Drive Controller No Control Kit No ATV66U90N4 ATV66D12N4 VX4 A66CK1 NOTE All ALTIVAR 66 drive controllers use the same model keypad display However the version of software present within the keypad display may be specific to the version of software present in the control basket Mixing incompatible versions of keypad display and control basket software can result in non recognition of the keypad display by the drive controller or garbled message displays Therefore keypad displays are not supplied as separate kitted items Keypad displays are supplied with control kits Keep keypads with their associated control basket Do not mix keypads and control baskets The keypad display is mounted on the control basket for drive controllers ATV66U90N4 and ATV66D12NA see Figure 53 on page 100 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cov
368. rs Torque wrench set to 141 Ib in 16 Nem e Metric hex key sockets for torque wrench 2 to 14 mm To install a diode block 1 Install a new Thermstrate foil from the kit on the back of the new diode block Remove the paper backing from the Thermstrate foil Do not remove the white contact grease coating NOTE If Thermstrate foil is damaged i e wrinkled coating gaps gt 1 8 round discard foil Obtain new Thermstrate foil 2 Place the new diode block on the heat sink and align the mounting holes Using a torque wrench with hex key socket install and tighten the two or four diode mounting screws as described below For drive controllers ATV66C10N4 and C13N4 Initially torque the two screws to 6 0 9 0 Ib in 0 7 1 0 Nem The final torque is 53 Ib in 6 Nem Q Q For drive controllers ATV66C15N4 and C19N4 initially torque the four screws in the sequence shown to 6 0 9 0 Ib in 0 7 1 0 Nem The final torque is 53 Ib in 6 Nem Qo oQ 3 0 O 1996 Square D All Rights Reserved 259 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 260 10 11 Bulletin NO VDUCUOS U1 December 1996 Install the L bracket and mounting screw to the bottom power connection on the diode block Using a torque wrench and hex key socket tighten the L bracket screw to a torque of 53 Ib in 6 Nem for ATV66C10N4 C13N4 contro
369. rs Discard the old terminal blocks Insert the new terminal blocks into their associated board side connectors NOTE The yellow keys in both the plugs and sockets are designed to prevent incorrect insertion of both 12 and J13 Install the field wiring on the new terminal blocks for J1 J12 and J13 Using a flat blade screw driver tighten the terminal screws for the field wiring installed Reinstall options module if previously present See User s Manual VDOC06T306_ for removal installation instructions Figure 82 Location of J1 J2 J12 and J13 Connectors 1996 Square D All Rights Reserved _ __ _ _ 151 Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 Replacing the Board Fan 152 Bulletin NO VDUCUOS U1 December 1996 This procedure explains how to replace the board fan for the following drive controllers NOTE Older versions of ATV66D33N4 and ATV66D46N 4 controllers do not contain a board fan Drive Controller No Board Fan No ATV66D33N4 ATV66D46N4 VZ3 V6654 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure t
370. rtion of both 12 and J13 7 Install the field wiring on the new connectors for J1 J12 and J13 Using a flat blade screw driver tighten the terminal screws for the field wiring installed 8 Reinstall options module if previously present See User s Manual VDOCO061306 for removal installation instructions IP20 Protection Cover J13 Ji Figure 49 Location of J1 J2 J12 and J13 Connectors Replacing the Power Board For drive controllers ATV66U41N4 to U72N4 the power board and drive controller chassis come as one replacement part This procedure explains how to replace the power board and chassis in the following drive controllers Drive Controller No Power Board No ATV66U41N4 VX5 A66U41N4 ATV66U54N4 VX5 A66U54N4 ATV66U72N4 VX5 A66U72N4 2 j 0 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66U41N4 to ATV66U72N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENS
371. rx screw driver install and tighten the three screws for the bottom panel see Figure 83 on page 153 Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the three screws for the bottom IP20 protection cover see Figure 83 on page 153 Reconnect the J1 connector see Figure 82 on page 151 Install the top IP20 protection cover Route the five control basket cables through the hole in the protection cover Using a phillips screw driver install and tighten the four screws for the top IP20 protection cover see Figure 83 on page 153 Install the right side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the right side panel in place Two screws are located at the top and two screws are located at the bottom see Figure 83 on page 153 Install the left side panel Using a phillips or Torx amp screw driver install and tighten the four screws which hold the left side panel in place Two screws are located at the top and two screws are located at the bottom see Figure 83 on page 153 Install the control basket as described in the procedure on page 149 1996 Square D All Rights Reserved 187 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D33N4 and ATV66D46N4 December 1996 133 ANAM 1996 Square D All Rights Reserved
372. s e Set of Torx screw drivers e 1 4 drive metric socket set 5 5 to 14 mm e 2 1 4 drive socket extension e 12 1 4 drive socket extension e Metric hex key set 2 to 14 mm e Regular hex key set 1 4 to 9 16 e Metric ball end hex key set 2 to 14 mm Clip pliers Catalog No VY1 ADV608 e Torque wrench 4 4 to 352 lb in 0 5 to 40 Nem e Metric hex key sockets for torque wrench e Metric drive sockets for torque wrench Phillips screw driver sockets for torque wrench e Flat blade screw driver sockets for torque wrench e 4 Needle nose pliers e Antistatic wrist strap e Antistatic carpet ground connection e Thermal grease Thermalloy Thermalcote II Part No 349 or equivalent e Set of open box end wrenches 5 5 to 19 mm e Wire cutters Plastic tie wraps 8 length Multimeter 0 1000 V Fluke 87 or equivalent e Clamp On Current Probe 0 600 A Fluke 80i 600A or equivalent English hex wrenches 5 16 and 3 8 e Electrical tape DOCUMENTATION The following ALTIVAR 66 drive controller documents are available LIST Instructions for Safe Handling Installation Operation and Maintenance of Electrical Control Equipment 30072 200 50_ latest revision e Enclosed ALTIVAR 66 Drive Controllers Class 8839 50006 523 07 latest revision e Receiving Installation and Start Up VD0C065304 latest revision e Level 1 amp 2 Configuration VD0C06S305_ latest revision e I O Extension Module and Level 3
373. s carefully connect J20 1 J20 2 J21 1 21 2 J22 1 J22 2 23 1 J23 2 J24 1 J24 2 J25 1 and J25 2 at the termination points located on the IGBT modules see Figure 66 on page 119 7 Using needle nose pliers carefully connect J26 J27 J28 J29 J30 J31 and J34 at the termination points located on the power board 8 Install theleft side panel Using a phillips screw driver install and tighten the three screws which hold the left side panel in place 9 Install the top cover Using a phillips screw driver install and tighten the two screws which hold the top cover in place 10 Install the bottom IP20 protection cover Using a phillips screw driver install and tighten the two screws which hold the bottom IP20 protection cover in place 11 Install the top IP20 protection cover Using a phillips screw driver install and tighten the two screws which hold the top IP20 protection cover in place 12 Connect the J1 connector on the power board 13 Install the control basket as described in the procedure on page 115 Removing the Power Board This procedure explains how to remove the power board from the following drive controllers Power Board No VX5 A66D16N4 VX5 A66D23N4 Drive Controller No ATV66D16N4 ATV66D23N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause
374. s route and connect the fan leads under the gate driver board to the J68 connection on the power board see Figure 107 on page 202 12 Install the top IP20 protection cover Route the five control basket cables through the hole in the protection cover Using a phillips screw driver install and tighten the four screws which hold the top IP20 protection cover in place 13 Install the left side panel by sliding it downward into position Using a phillips or Torx screw driver install and tighten the screws which hold the left side panel in place 14 Install the control basket as described in the procedure on page 193 1996 Square D All Rights Reserved L 197 Cnapter 4 rquipment Change vut Bulletin NO VDUCUbS UI ATV66D54N4 to D79N4 December 1996 Removing the Gate Driver This procedure explains how to remove the gate driver board from the following Board drive controllers Drive Controller No Gate Driver Board No ATV66D54N4 VX5 A66107 ATV66D64N4 VX5 A66108 ATV66D79N4 VX5 A66109 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instruc
375. s each on the other three posts Using a torque wrench and drive socket tighten the mounting pins to 13 3 Ib in 1 5 Nem 5 Install the power board as described in the procedure on page 124 This procedure explains how to remove the filter board from the following drive controllers Drive Controller No Filter Board No ATV66D16N4 VX4 A66103 ATV66D23N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metri
376. s manual 2 Usinga drive socket loosen and remove the two plexiglass shield screws see Figure 139 on page 283 Remove the plexiglass shield 3 Using a flat blade screw driver loosen the right side terminal screws on TB3 see Figure 145 on page 297 Remove the right side control wires from the terminal block assembly 4 Using a hex key wrench loosen and remove the DCB and DCB control wire connection screws Figure 139 on page 283 Pull the wires back out of the way 5 Using a hex key wrench loosen and remove the DCB DCB RB and RB power wire connection screws see Figure 139 on page 283 6 While supporting the transformer contactor assembly use a drive socket with a 12 extension to loosen and remove the four transformer contactor assembly mounting screws see Figure 145 on page 297 Remove the assembly 7 Using a flat blade screw driver remove the screws which connect the R11 A and R8 A wires to the resistors see Figure 145 on page 297 8 Usinga hex key wrench loosen and remove the bolt holding the large PCC 1 cable at the bottom of the precharge contactor Pull the large PCC 1 cable through the wire tie in the back of the transformer contactor assembly see Figure 145 on page 297 1996 Square D All Rights Reserved 301 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N
377. s observed Operating Condition Motor temperature is actually within the normal EXCESSIVE MOTOR TEMPERATURE Ambient operating temperature of motor is Motor load power requirements exceed Possible temperature operating exceeded motor rated power during cause range all or part of operating Speed range Motor continuous torque envelope exceeded during all or part of operating Speed range Motor base speed not matched to load base speed Check motor insulation Check ambient air around F Check output current of Check class motor controller on keypad to be Check motor temperature Check ambient display performed rise via thermocouple or temperature rating of motor Check load and motor resistance of stator refer Check motor insulation base speed to NEMA MG1 for class temperature limits Check motor temperature rise via thermocouple or resistance of stator refer to NEMA MG1 for temperature limits f both absolute If ambient temperature Steady state output temperature and is within limits of motor current of controller Result temperature rise are within check other possible exceeds FLA rating of acceptable levels no causes of excessive motor further action is required temperature Motor and load base speed mismatched Apply motor with a Apply motor with higher ambient higher FLA or power Solution temperature rating rating Cons
378. screws 5 While still supporting the top of the assembly with one hand use the other hand to put one of the pieces of tape across the socket at the end of the 12 extension piece the tape will help hold the screw in the socket Insert one of the mounting screw heads into the socket Thread the 12 extension piece with socket and screw through the upper left opening in the transformer contactor assembly Using the drive socket install and tighten the transformer contactor assembly mounting screw Figure 142 on page 288 6 Perform step 5 again for the upper right transformer contactor assembly mounting screw 7 Usinga torque wrench a 12 socket extension and a metric socket torque the 4 transformer contactor assembly mounting screws to 35 4 Ib in 4 Nem 8 Usingatorque wrench and hex key socket install and tighten the power wire connection screws for the DCB and DCB power cables to 164 Ib in 18 5 Nem see Figure 139 on page 283 9 Using a torque wrench and hex key socket install and tighten the power wire connection screws for the RB and RB power cables to 74 3 Ib in 8 4 Nem see Figure 139 on page 283 10 Position the two DCB control wires over their mounting hole on the capacitor bus bar plate Using a torque wrench and hex key socket install and tighten the mounting screw to 40 7 lb in 4 6 Nem see Figure 139 on page 283 11 Position the one DCB control wire over its mounting hole on th
379. screws holding the large RB and RB cables in place on the left side of the bus bar see Figure 130 on page 258 6 Using a hex key wrench loosen and remove the screws holding the small U RB and RB cables in place on the left side of the bus bar see Figure 130 on page 258 7 Usinga hex key wrench loosen and remove the screw which holds the bus bar extension piece to the RB bus bar Remove the bus bar extension piece see Figure 130 on page 258 8 Using a hex key wrench loosen and remove the remaining six bus bar screws Remove the two bus bar pieces see Figure 130 on page 258 NOTE On ATV66C10N4 and C13N4 controllers there are spacer blocks between the two bus bars and the diode blocks Before removal note their orientation Save them for reinstallation NOTE To remove the far right diode block it is necessary to also remove the 4 bus bar extension piece from the drive controller Do this by removing the bus bar extension piece screw from the 4 terminal block with a hex key wrench 9 Using a hex key wrench loosen and remove the screws which attach the large power fuse or shorting bar is fuses not present associated with the diode block being removed Remove the fuse or shorting bar 10 Using a hex key wrench loosen and remove the screw at the bottom power connection of the diode block Pull L bracket out of the way 11 Using a hex key wrench remove the four or two diode block mounti
380. sertion of J12 and J13 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Replacing Control Terminal Blocks Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 5 Ensure that all three cable clasps are pulled out on J3 J4 and J5 see Figure 122 on page 239 6 Carefully insert the three ribbon cables into the cable clasps at J3 seven wire cable J4 six wire cable and J5 18 wire cable Ensure that the silver leads of the cables are facing outwards from the controller and are seated firmly against the bottom of the jacks before engaging clasps 7 Push the three ribbon cable clasps to their secure position 8 Install the connector for the remote LED status indicators Use tie wraps as needed to remove any slack from the cable see Figure 119 on page 235 9 Install the connector for the remote keypad display Using a flat blade screw driver tighten the two screws on the connector Use tie wraps as needed to remove any slack from the cable see Figure 119 on page 235 10 Apply multi lingual hazard labels supplied with kit to control basket as required 11 As required install the I O Extension Module Install the J22 J23 and J24 connectors See User s Manual VDOC06T306_ for removal installation instructions 12 Reprogram the user settings as previously noted during the control basket removal This procedure explains how to replace the control terminal blocks J1 J12 and J13
381. sertion of both J12 and J13 Install the field wiring on the new connectors for J1 J12 and J13 Using a flat blade screw driver tighten the terminal screws for the field wiring installed Reinstall option module if previously present See User s Manual VDOC06T306_ for removal installation instructions J13 J2 Figure 56 Location of J1 J2 J12 and J13 Connectors 1996 Square D All Rights Reserved 105 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66U90N4 and ATV66D12N4 December 1996 Replacing the Power Board For drive controllers ATV66U90N4 and ATV66D12N4 the power board and drive controller chassis come as one replacement part This procedure explains how to replace the power board and chassis on the following drive controllers Power Board No VX5 A66U90N4 VX5 A66D12N4 Drive Controller No ATV66U90N4 ATV66D12N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or bur
382. settings menus 1 and Solution Change ramp type 7 12 menu 7 12 Select correct ramp menu 7 12 Figure 9 Motor Decelerates Too Slowly Not at All Overspeeds Overspeed Trip 28 _ ____________________ 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Motor Decelerates Too Slowly Overspeeds Overspeed Trip continued 2 of 4 Wrong torque type or control type is selected Possible for the application cause Check settings under Check menus 6 and 7 13 to be performed Result Refer to VD0C06S305 to choose correct settings Solution Refer to SC100 R5 95 for more information O 1996 Square D All Rights Reserved Cnapter 3 Correcting the Problem Motor Decelerates Too Slowly Overspeeds Overspeed Trip If DB option is present Braking torque Check DB option for damage Braking torque required exceeds capability of DB option DB option inoperative tripped damaged or not connected If possible reduce resistance for DB resistors Refer to VDOCO6N908__ for more information Refer to SC100 R5 95 for more information Controller motor are incorrectly sized for expected load DC bus voltage level on keypad display Braking torque Braking energy required exceeds drive capability Braking torque required exceeds motor capability at given speed Add a DB option Refer to VDOCO6S201_ to determine required
383. shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved L 121 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 122 Bulletin NO VDUCUOS U1 December 1996 A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Clip pliers Catalog No VY1 ADV608 e 1 4 drive metric socket set 5 5 to 14 mm e Gate driver board procedure tool list page 118 e Control basket procedure tool list page 113 With the drive controller door removed 1 Remove the gate driver board as described in the procedure on page 117 2 Using a phillips screw driver loosen and remove the three screws which hold the right side panel in place Rem
384. sion Module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure 1996 Square D All Rights Reserved 191 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66D54N4 to D79N4 December 1996 The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Aset of magnetized phillips screw drivers With the drive controller door removed 1 Measure the bus voltage if not already performed as described in Chapter 5 of this manual 2 Remove the keypad display as described on page 190 3 Remove options module if present See User s Manual VDOC06T306_ for removal installation instructions J9 J32 J4 J3 J Mounting screw Pd Mounting scre
385. ssemblies may not be suitable for the specific application Always check the controller for the appropriate software configuration after replacing removing or swapping printed wiring board assemblies Static Sensitive Observe the following precautions when handling electrostatic sensitive Components components circuit boards IGBT s etc Keep static producing material plastic upholstery carpeting etc out of immediate work area Leave electronic sensitive assemblies in protective packaging when they are not installed in drive controller Do not handle assembly or remove from protective package until assembly and wrist strap are properly grounded see next precaution Wear a conductive wrist strap connected through a minimum of one megohm resistance to the host device If the host device such as printed wiring board assembly has no grounding point place it on a grounded conductive surface and connect the wrist strap through a minimum of one megohm to the conductive surface O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 1 Introauction December 1996 List of Tools and Equipment e Avoid touching exposed conductors and component leads with skin or clothing LIST OF TOOLS AND The tools and instruments required for performing maintenance and replacing INSTRUMENTS components on the drive controllers are listed below e Set of magnetized flat blade screw drivers e Set of magnetized phillips screw driver
386. stalled connectors Verify that all power has been removed from J1 J12 and J13 connectors If I O Extension Module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screwdrivers e Aset of magnetized phillips screwdrivers 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66U41N4 to ATV66U72N4 With the drive controller door open 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Remove the keypad display as described on page 87 3 Remove options module if present See User s Manual VDOC06T306_ for removal installation instructions 4 Usinga phillips screwdriver carefully loosen and remove the two scr
387. supply problem Autodiagnostics test the supply Refer to chapter 4 to change the Control basket Power board Driver board O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Bulletin NO VDUCUOS UT Cnapter 3 Correcting the Problem December 1996 Dynamic Brake Fault Dynamic Brake Fault Figure 33 shows the measurement principle used for the dynamic brake fault PA PB l k C Figure 33 Dynamic Brake Fault Measurement During power up the dynamic brake IGBT is operated and the voltage at the PA and terminals is checked to determine if the DB Resistor is present The dynamic brake fault appears if it has been selected in the Fault Management menu and the resistor is missing broken or has too low of a resistance value see Figure 34 be low Two conditions are needed to control the DB Resistor e DC bus voltage is greater than 750 VDC DCbus voltage minus the peak line voltage multiplied by the square root of 2 1 414 is greater than 20 V Controller Minimum Review of the auto ramp adaptation model resistance number ohms Presence of DB resistor menu 7 4 factory fault setting ATV66 el m ramp auto Deceleration D16N4 D adaptation on a ramp D23N4 0 D33N4 ra ramp auto Dynamic D46N4 adaptation braking D54M4 E D54N4 S Figure 34 Review of Auto Ramp Adaptation 1996 Square D All Rights Reserved
388. t ATV66U41N4 to U72N4 VZ3 N006 Pages 91 92 Power Board ATV66U41N4 VX5 A66U41N4 Pages 92 94 ATV66U54N4 VX5 A66U54N4 ATV66U72N4 VX5 A66U72N4 Fan ATV66U41N4 to U54N4 VZ3 V661 Pages 94 97 ATV66U72N4 VZ3 V662 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Replacing the Keypad Display Cnapter 4 Equipment Cnange Out ATV66U41N4 to ATV66U72N4 This procedure explains how to replace the keypad display for the following drive controllers Drive Controller No Control Kit No ATV66U41N4 ATV66U54N4 VX4 A66CK1 ATV66U72N4 NOTE All ALTIVAR 66 drive controllers use the same model keypad display However the version of software present within the keypad display may be specific to the version of software present in the control basket Mixing incompatible versions of keypad display and control basket software can result in non recognition of the keypad display by the drive controller or garbled message displays Keypad displays are not supplied as separate kitted items Keypad displays are supplied with control kits Keep keypads with their associated control basket Do not mix keypads and control baskets The keypad display is mounted on the control basket for drive controllers ATV66U41N4 through ATV66U72N4 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools n
389. t all power sources which feed the controller are deenergized and locked and tagged out before opening the controller door or performing any equipment change out procedures Never assume the power is off Always check for voltage with a properly rated voltage sensing device 9 Inspect the drive controller bonding and ground system and ensure that the drive controller is properly grounded per the applicable codes and recommendations in the drive controller instruction manual 1996 Square D All Rights Reserve MMMM 3 Cnapter 1 Introduction Work Practice Precautions Bulletin NO VDUCUOS U1 December 1996 10 Ensure that the controller door is closed and secured by the applicable latches 11 before energizing a controller If you must work on energized equipment a number of safety rules must be followed Use personal protective equipment and follow procedures to prevent accidental contact between tools and energized equipment If contact Occurs arcing faults can be created lonized gas and a shower of high temperature particles will be generated which can cause death and severe burns Further information can be found in OSHA 29 CFR Part 1910 Electrical Safety Related Work Practices Equipment Protection The drive controller uses a complex system of interrelated subsystems and Precautions specialized components to achieve rated performance during operation Many devices and components in the controller require special attention F
390. t block locks into place see Figure 146 on page 300 Install the three saved jumpers on the auxiliary contact block AUX 51 AUX 61 jumper AUX 71 AUX 81 jumper and AUX 62 AUX 72 jumper The jumpers should be installed into their marked locations on the auxiliary contact block Install the AUX 52 and AUX 82 control wires into their marked locations on the auxiliary contact block see Figure 144 on page 296 and Figure 145 on page 297 Replace the resistor plate assembly into its mounting location on the front of the transformer contactor assembly Using a torque wrench with a drive socket install and tighten the five mounting screws to 35 4 lb in 4 0 Nem see Figure 145 on page 297 Align the R11 A and R8 A wire connectors over their mounting locations on the two resistors Using a torque wrench and flat blade screw driver socket install and tighten the two mounting screws to 8 9 Ib in 1 0 Nem see Figure 144 on page 296 and Figure 145 on page 297 1996 Square D All Rights Reserved 299 Cnapter 4 rquipment Change Out Bulletin NO VDUCUOS UT ATV66C10N4 to C19N4 December 1996 PCC 2 Cables Precharge Contactor Aux Contact Block Small PCC 1 Cable O Drive Controllers ATV66C10N4 and C13N4 PC
391. t is moni tored continuously The following conditions trigger the output phase loss fault e One phase is missing for 0 5 seconds e The measured current is less than the nominal drive controller current divided by 32 In constant torque there is no detection if the motor frequency is less than 1 Hz In variable torque there is no detection if the motor frequency is less than 20 Hz Output phase loss is automatically disabled when the bypass application function is enabled 5 gt gt gt 0 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 3 Correcting tne Problem December 1996 Output Phase Loss Figure 27 illustrates the troubleshooting procedure when the output phase loss fault is present OUTPUT PHASE Fault Displayed LOSS Phase loss between Motor undersized in drive controller and motor relation to the Possible drive controller cause Read the I output ibd on the keypad display o be performed In drive In drive Result motor controller motor controller 32 32 Refer to chapter 4 to change the Power board Gate driver board 1 Control basket Connections Check the U T1 V T2 Check the motor drive W TS wiring to the motor controller compatibility Solution If there is a contactor at the drive controller output check for proper sequence and electrical continuity of ihe contacts 1 ATV66D16N
392. tage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure 292 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 The tools needed for this procedure are 4 Needle nose pliers A set of magnetized flat blade screw drivers 1 4 metric drive socket set 5 5 to 14 mm With the drive controller door open or removed and with access to the bottom of the drive controller 1 10 Measure the bus voltage if not already performed as described in chapter 5 of this manual Using needle nose pliers disconnect the C34 A and C34 B connectors from the left side of the fan capacitor assembly see Figure 118 on page 234 Using a flat blade screw driver loosen the left side terminal connectors 2 and 3 on terminal block TB1 Remove the blue wire from terminal 2 and the black wire from terminal 3 see Figure 118 on page 234 Using a flat blade screw driver loosen the right side terminal connectors 1 2 and 3 on terminal block TB1 Remove the blue
393. tch Using a phillips screw driver loosen and remove the two mounting screws on the thermal switch Remove the old thermal switch Place the new thermal switch on the heatsink and align the mounting holes Using a phillips screw driver install and tighten the two mounting screws Using needle nose pliers carefully connect the two connectors to the new thermal switch Replace P2 connector on the GD 2 gate driver board Install the dynamic braking snubber board as described in the procedure on page 267 1996 Square D All Rights Reserved 279 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 To replace the thermal switch located on the heat sink behind the GD4 gate driver board see Figure 136 on page 279 1 Remove the GD4 gate driver board as described in the procedure on page 250 Do not loosen IGBT bus terminal screw and remove J1 wire 2 Using needle nose pliers carefully disconnect the two connectors from the thermal switch 3 Using a phillips screw driver loosen and remove the two mounting screws on the thermal switch 4 Remove the old thermal switch 5 Place the new thermal switch on the heatsink and align the mounting holes Using a phillips screw driver install and tighten the two mounting screws 6 Using needle nose pliers carefully connect the t
394. ted by a detachable terminal connector 4 Remove the gate driver board and wire NOTE If the J1 wire landed on the gate driver board is connected with a detachable terminal connector or zero force connector be sure to discard the wire and DO NOT reuse on new board 1996 Square D All Rights Reserved 251 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUO6S U1 ATV66C10N4 to C19N4 December 1996 Gate Driver Board typical of 6 IGBT Module typical of 6 Figure 128 Gate Driver Board Locations Installing the Gate Driver There are six gate driver boards in the ATV66C10N4 to C19N4 drive controllers Board The power pole kit contains two gate driver boards This procedure explains how to install an individual gate driver board in the following drive controllers Drive Controller No Power Pole Kit No ATV66C10N4 VZ3 IM1300M1206 ATV66C13N4 VZ3 IM1400M1206 ATV66C15N4 VZ3 IM1400M1206 ATV66C19N4 VZ3 IM1500M1206 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage 52 0 1996 Squa
395. testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Torque wrench 26 5 Ib in 3 Nem e Thermal grease Thermalloy Thermalcote II Part No 349 or equivalent e Power board procedure tool list page 203 Gate driver procedure tool list page 200 e Control basket procedure tool list page 193 For the IGBT module to be installed 1 Clean the portion of the heatsink which will make contact with the new IGBT module 2 Evenly coat the bottom of the new IGBT module with a thin coating of thermal grease 3 Install the new IGBT module Using a torque wrench and hex key socket install and tighten the four mounting screws to 26 5 lb in 3 Nem Torque screws in the sequence shown Q Y P di 3 _ _ _ 4 Position the bus bar and align the mounting holes 2 O 5 Position the C cable over the bus bar terminal and the C cable over the bus bar terminal see Figure 108 on page 206 Using a torque wrench with hex key attachment install and tighten the two screws which hold the C and C cables to the bus bar to 17 7 lb in 2 Nem 1996 Square D All Rights Reserved
396. that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved 211 Cnapter 4 rquipment Change Out Bulletin NO VDUCUOS U1 December 1996 ATV66D54N4 to D79N4 212 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Power board procedure tool list page 202 Gate driver procedure tool list page 198 e Control basket procedure tool list page 192 With the drive controller door removed 1 Remove the power board as described in the procedure on page 201 Using a phillips or Torx screw driver loosen and remove the four screws which hold the right side panel Remove the right side panel 3 Remove the bus bar isolating screen NOTE In order to keep the proper spacing for
397. the bottom IP20 protection cover Using a phillips screw driver install and tighten the three screws for the bottom IP20 protection cover see Figure 83 on page 153 5 Reconnect the J1 connector see Figure 82 on page 151 6 Install the left side panel Using a phillips or Torx screw driver install and tighten the four screws which hold the left side panel in place Two screws are 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Replacing the Discharge Resistor Cnapter 4 Equipment Cnange Out ATV66D33N4 and ATV66D46N4 located at the top and two screws are located at the bottom see Figure 83 on page 153 7 Install the bottom panel Using a phillips or Torx screw driver install and tighten the five screws for the bottom panel see Figure 83 on page 153 This procedure explains how to replace the discharge resistor from the following drive controllers Drive Controller No Fan No ATV66D33N4 VZ3 R5KOW040 ATV66D46N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock
398. the bus capacitors Tighten to 17 7 lb in 2 Nem Using a torque wrench with drive socket attachment install the nine mounting pins and washers which connect the bus bar or cables to the IGBT modules Tighten to 26 5 Ib in 3 Nem 8 Position the cable marked BR1 over the C2E1 terminal of the braking IGBT module and the cable marked BR3 over the C1 terminal of the braking IGBT module Using a torque wrench and phillips head attachment install and tighten the three screws to 17 7 lb in 2 Nem 9 Replace the bus bar isolating screen 10 Remove the static protective foam from the braking IGBT module control terminals 11 Install the power board as described in the procedure on page 203 Removing the Bus In the event that one capacitor goes bad at least two other capacitors will be Capacitor Assembly damaged Therefore all of the capacitors should be replaced This procedure explains how to remove the bus capacitor assembly from the following drive controllers Drive Controller No Bus Capacitor Assembly No ATV66D54N4 VY1 ADC605 ATV66D64N4 VY1 ADC606 ATV66D79N4 VY1 ADC606 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify
399. the capacitor assembly to be installed 1 Carefully install the new bus capacitor assembly into the drive chassis aligning the bracket holes on the two right hand corners with the mounting posts in the drive and fitting the lip on the left side of the assembly into the channel on the heat sink assembly 2 Using a torque wrench and the appropriate socket install the two nuts in the right hand corners of the bus capacitor assembly Tighten to 17 7 Ib in 2 Nem 3 Usinga torque wrench with a phillips screw driver socket install the two screws in the left hand corners of the bus capacitor assembly Tighten to 17 7 Ib in 2 Nem 4 Position the bus bar and align the mounting holes Make sure wire leads from the capacitor assembly fan are free to be connected to the power board 5 Position the C cable over the bus bar terminal and the C cable over the bus bar terminal see Figure 108 on page 206 Using a torque wrench and hex key socket install and tighten the two screws which hold the C and C cables to the bus bar to 17 7 Ib in 2 Nem NOTE To ensure that the power board is mounted level make sure that each mounting pin has two washers mounted under it and that the red end of the pins are facing up Also the three pins with the stripe s are to be used for connecting the U V and W cables to the IGBT modules 6 Position the U cable over the mounting hole in the top IGBT Position the V cable over the mounting hol
400. the control terminal blocks for the Blocks following drive controllers Drive Controller No Control Terminal Block Kit No ATV66D54N4 ATV66D64N4 VZ3 N006 ATV66D79N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on control basket power board and I O Extension Module if installed connectors Verify that all power has been removed from J1 J12 and J13 connectors f I O Extension Module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure 194 ___ gt gt xx 22 gt 0 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 The tools needed for this procedure are A set of magnetized flat blade screw drivers With the drive controller door open 1 Measure the bus voltage if not already performed as described in Chapter 5 of this manual Remove optio
401. the top and two screws are located at the bottom Install the left side panel Using a phillips or Torx amp screw driver install and tighten the four screws which hold the left side panel in place Two screws are located at the top and two screws are located at the bottom O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS UT Cnapter 4 rquipment Change Out December 1996 ATV66D33N4 and ATV66D46N4 Replacing the Auto This procedure explains how to replace the auto transformer for the following Transformer drive controllers Drive Controller No Auto Transformer No ATV66D33N4 ATV66D46N4 VY1 ADA604 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can
402. this procedure are e Aset of magnetized flat blade screw drivers e Aset of magnetized phillips screw drivers e Metric hex key set 2 to 14 mm Wire cutters With the drive controller door open 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Ifan I O Extension Module is installed remove the J22 J23 and J24 connectors then remove the module See User s Manual VDOC06T306_ for removal installation instructions 3 Using a flat blade screw driver carefully loosen and disconnect the P9 and P18 connector plugs at the top left of the control basket see Figure 121 on page 239 The P18 connector plug is landed at the J32 jack on the control basket and at the J18 jack on the power board NOTE On the power board the jacks are designated with a J whereas the corresponding connector plugs are designated with a P For example the P9 connector plug connects to the J9 jack on the power board and the J9 jack on the control basket 4 Using a flat blade screw driver carefully loosen and disconnect the J12 and J13 connectors located at the bottom of the control basket see Figure 121 on page 239 Do not remove the field wiring from the connectors 5 Using a flat blade screw driver loosen the two screws and disconnect the connector for the cable to the remote keypad display see Figure 123 on page 242 As needed use wire cutters to remove any tie wraps 6 Disconnect the connector
403. till present the red FAULT LED will be illuminated and a fault message will be displayed on the keypad display If this is the case make note of the fault displayed and proceed to Table 3 and Table 4 on page 17 The material referenced in the tables will guide maintenance personnel through troubleshooting procedures that are intended to expose the root cause of the problem The procedures may ultimately recommend specific repair strategy for the controller or system 1996 Square D All Rights Reserve MMMM 9 Cnapter 2 Investigating tne Problem Drive System Energized Bulletin No VDUCUOS U1 October 1997 Before performing any controller repairs record the controller set up and configuration programming by viewing the keypad menus and writing down parameter settings Once the controller diagnostic and set up information is recorded repair of the drive system should proceed Removal of power is required to perform repairs Review WORK PRACTICE PRECAUTIONS on page 3 prior to performing any repairs Always consult with the operating personnel responsible for the machinery and process prior to removing power to any equipment Use and obey all applicable lock out tag out procedures in force at the specific location The repair process should also include inspection of the drive controller and other system components for internal damage Such an inspection should include Perform PROCEDURE 4 CHECKING PERIPHERAL EQUIPMENT on p
404. ting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Aset of magnetized phillips screw drivers 1996 Square D All Rights Reserved 147 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D33N4 and ATV66D46N4 December 1996 With the drive controller door removed 1 Measure the bus voltage if not already performed as described in Chapter 5 of this manual 2 Remove the keypad display as described on page 146 3 Remove the options module if present See User s Manual VDOC06T306_ for removal installation instructions 4 Using a flat blade screw driver carefully loosen and disconnect the J9 and J32 connectors located at the top left of the control basket see Figure 80 on page 148 5 Using a flat blade screw driver carefully loosen and disconnect the J12 and J13 connectors located at the bottom of the control basket see Figure 80 on page 148 Mounting screw rd Mounting screw a Location of I O Extension Module if installed a Captive mounting ye Mounting screw screw J13 J12 Figure 80 Control Basket Connector Locations 6 Usingtwo small flatblade screw drivers carefully pull out on each side of the cable clasps may be either blue or white of J3 J4 and J5 to the release position see Figure 81 on page 149 Pull the ribbon c
405. tings menus 1 and 7 12 25 Cnapter 3 Correcting the Probiem Bulletin NO VVUCUbS U1 December 1996 Motor Accelerates Too Slowly Motor Accelerates Too Slowly continued 2 of 3 Motor accelerating under current limit or Possible motor torque limit cause Current limit setting Check menu 7 11 to be Motor torque limit setting performed menu 7 11 Current limit set too low Motor torque limit set too Result low Increase current limit setting Increase motor torque Solution limit setting Control parameters incorrectly set Check settings for IR compensation and voltage boost menu 1 Current limit already set to maximum value Motor torque limit already set to maximum limit Load cannot be Refer to VDOCO6S305_ accelerated at faster rate to choose correct settings See SC100 R5 95 for more information 26 s 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Motor Accelerates Too Slowly continued 3 of 3 Possible cause Check to be performed Result Solution O 1996 Square D All Rights Reserved Controller motor are incorrectly sized for expected load Peak current Peak torque Peak torque required exceeds motor capability at given speed Peak current required exceeds drive capability Apply controller and or motor which is correctly sized See SC100 R5 95 for more informati
406. tion statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Set of magnetized flat blade screw drivers Torque wrench set to 15 Ib in 1 7 Nem e Flat blade screw drivers for torque wrench With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Using a flat blade screw driver loosen the six terminal screws on the circuit protector Remove the two wires and two jumpers from terminals see Figure 145 on page 297 Save the jumpers for later use 3 Using a flat blade screw driver loosen the two end clamp mounting screws Slide the end clamp and circuit protector off of the mounting rail 4 Slidethe new circuit protector onto the mounting rail with the START button facing outwards see Figure 145 on page 297 5 Slide the end clamp onto the mounting rail Using a flat blade screw driver tighten the two end clamp mounting screws 6 Install one of the saved jumpers between terminals 1L1 and 3L2 of the circuit protector Install the second saved jumper between terminals 4T2 and 6T3 of the circuit protector Using a torque wrench and flat blade screw driver socket tighten the terminal screws to 15 Ib in 1 7 Nem 7 Install the CKB 5L wire into the 5L3 terminal of the circuit protector Install the CKB 2T into the 2T1 terminal of the circuit protecto
407. tions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of Torx screw drivers e 4 Needle nose pliers e Control basket procedure tool list page 192 With the drive controller door removed 1 Remove the control basket as described in the procedure on page 191 2 Using a phillips or Torx screw driver loosen and remove the four screws located along the left edge of the controller top and bottom panels in order to remove the left side panel 3 Remove the left side panel see Figure 104 on page 197 198 s 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D54N4 to D79N4 4 Using a phillips screw driver loosen and remove the four screws which hold the top IP20 protection cover in place see Figure 104 on page 197 Remove the top IP20 protection cover This allows access to the gate dr
408. to C19N4 drive controllers The current sensor kit contains one current sensor This procedure explains how to remove the current sensor assembly from the following drive controllers Drive Controller No Current Sensor No ATV66C10N4 VY1 A66106 ATV66C13N4 VY1 A66106 ATV66C15N4 VY1 A66107 ATV66C19N4 VY1 A66107 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter set to 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WO
409. to load effects cause s condition an undesired Direction of rotation Phase rotation sequence Check operation selected by keypad selected menu 7 11 to be Operation of rotation Direction of rotation Controller output power performed prevention devices commanded in terminal wiring ratchets stops check mode valves holding brakes etc Condition is not Improper direction of Phase rotation sequence desired rotation selected or selected is incorrect Result Rotation prevention commanded Controller output phase devices not operating wiring is incorrect Rotation prevention Correct keypad selection Correct the direction of devices may be necessary or terminal command rotation using Rotation for holding motor Norm menu 7 11 Solution Correct operation of devices For 8839 controllers follow procedure in 50006 523 01 Figure 12 Motor Turns in Wrong Direction 24 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Drive Will Not Follow Speed Command Specific Drive Function Does Not Work as Expected Not at All Cnapter 3 Correcting the Problem Drive Will Not Follow Speed Command Check the analog input level in the I O Map menu 2 for presence of input If input is present refer to the following sections e Poor Speed Stability page 20 e Motor Accelerates Too Slowly page 25 e Motor Decelerates Too Slowly
410. to place Install the bottom cover Using a phillips screw driver tighten the three screws holding the bottom cover in place Install the IP20 protection cover see Figure 49 on page 92 Install the top cover Using a phillips screw driver tighten the two screws holding the top cover in place Connect J1 at the bottom of the power board see Figure 49 on page 92 Using a torque wrench and a flat blade screwdriver socket install and tighten the field wiring on the termination points on connector J2 See Receiving and Installation manual VDOC065304_ for torque specification Install the control basket as described in the procedure on page 90 1996 Square D All Rights Reserved 97 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66U41N4 to ATV66U72N4 December 1996 98 gt _ _ _ 0 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 ATV66U90N4 and D12N4 Cnapter 4 Equipment Cnange Out ATV66U90N4 and ATV66D12N4 This section contains spare part information and change out procedures for drive controllers e ATV66U90N4 e ATV66D12N4 Table 9 lists the spare parts Refer to the pages indicated in the table for spare part change out procedures Table 9 Spare Parts for Drive Controllers ATV66U90N4 and D12N4 Description For Drive Catalog Number For Change Out Cont
411. transformer 1 Mount the control power transformer on the back on the transformer contactor assembly see Figure 143 on page 289 Orient the transformer such that the X1 X2 and X3 transformer terminals are facing the top of the transformer contactor assembly 2 Using a drive socket install and tighten the four transformer mounting nuts and washers 1996 Square D All Rights Reserved 289 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 3 Make the transformer connections as shown in Table 16 Using a flat blade screw driver install and tighten the connection screws Table 16 Transformer Connections ATV66C10N4 to C19N4 Wire Designation Transformer Connection Point UTE od o WE 3 T1 X2 X2 T1 X3 X3 T1 H1 H1 T1 H2 H2 NOTE Before performing step 4 make the following preparations Cut off two 3 4 inch pieces of electrical tape Place these pieces of tape where they will be easily accessible when installing the transformer contactor assembly 4 Position the transformer contactor assembly over the four mounting holes While supporting the transformer contactor assembly with one hand install the two bottom transformer contactor assembly mounting screws see Figure 142 on page 288 with other hand Use a drive socket with a 12 extension to tighten the two
412. troller door removed 1 Remove the control basket as described in the procedure on page 147 Using a phillips or Torx screw driver loosen and remove the four screws which hold the left side panel Two screws are located at the top and two screws are located at the bottom Remove the left side panel see Figure 83 on page 153 3 Usinga phillips screw driver loosen and remove the four screws which hold the top IP20 protection cover in place Remove the top IP20 protection cover see Figure 83 on page 153 4 Using a flat blade screw driver loosen the ground terminal screw on the J2 terminal block assembly for the ground wires from the U T1 V T2 and W 13 cables see Figure 82 on page 151 Pull the ground wires out of the way 5 Using a hex key wrench loosen the terminal screw for V T2 at the drive controller side of the terminal block Pull the cable out of the way This allows for access to the mounting screws to the current sensors 6 Using a hex key wrench loosen the terminal screw for U T1 or W T3 at the drive controller side of the terminal block The terminal screw to be loosened will depend on which current sensor is to be replaced 7 Pull the U T1 or W T3 cable back through the current sensor and out of the way 8 Using needle nose pliers carefully disconnect the wire at the bottom of the current sensor to be replaced 9 Using a hex key wrench loosen and remove the two mounting screws for the current sensor to be
413. tructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter setto 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure 282 _ _ _ _ _ ___ 0 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 The tools needed for this procedure are A set of magnetized flat blade screw drivers 1 4 drive metric socket set 5 5 to 14 mm Torque wrench set to 323 lb in 36 5 Nem Metric hex key set 2 to 14 mm Metric hex key sockets for torque wrench 2 to 14 mm Metric drive sockets for torque wrench With the controller door open or removed
414. ts Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D16N4 and ATV66D23N4 NOTE The yellow keys in both the plugs and sockets are designed to prevent incorrect insertion of both J12 and J13 7 Install the field wiring on the new connectors for J1 J12 and J13 Using a flat blade screw driver tighten the terminal screws for the field wiring installed 8 Reinstall options module if previously present See User s Manual VDOC06T306_ for removal installation instructions 00 Figure 63 Location of J1 J2 J12 and J13 Connectors Removing the Gate Driver This procedure explains how to remove the gate driver board from the following Board drive controllers Drive Controller No Gate Driver Board No ATV66D16N4 VX5 A66103 ATV66D23N4 VX5 A66104 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved c 117 Cnapter 4 Equipment Cnange Out ATV66D16N4 and ATV66D23N4 118 Bulletin NO VDUC
415. tsink 254 c 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Installing the IGBT Module Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Gate Driver Board typical of 6 IGBT Module typical of 6 Figure 129 IGBT Module Locations There are six IGBT modules in the ATV66C10N4 to C19N4 drive controllers The power pole kit contains two IGBT modules This procedure explains how to install an individual IGBT module in the following drive controllers Drive Controller No Power Pole Kit No ATV66C10N4 VZ3 IM1300M1206 ATV66C13N4 VZ3 IM1400M1206 ATV66C15N4 VZ3 IM1400M1206 ATV66C19N4 VZ3 IM1500M1206 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage 1996 Square D All Rights Reserved 255 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to C19N4 December 1996 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed f
416. u 7 11 Regeneration torque limit setting menu 7 11 Motor current during deceleration Current limit set too low Regeneration torque limit set too low If motor current and torque are less than the setting of the controller current and torque limits then controller is not capable of producing sufficient deceleration torque Increase current limit setting Increase regeneration torque limit setting Add Dynamic Braking Resistor Kit so that controller can produce deceleration torque Current limit already set to maximum value Regeneration torque limit already set to maximum value If motor current and torque are less than the setting of the controller current and torque limits then controller is not capable of producing sufficient deceleration torque Add a Dynamic Braking Resistor Kit so that controller can produce deceleration torque Load cannot be decelerated at a faster rate 39 Cnapter 3 Correcting tne Probiem Bulletin NO VDUCUOS UT Motor Turns in Wrong Direction December 1996 Motor Turns in Wrong Figure 12 illustrates the troubleshooting procedure when the motor is turning in Direction the wrong direction MOTOR TURNING TURNS IN WRONG DIRECTION Operating Condition Motor may be Wrong direction of Motor phasing incorrect windmilling turbining due rotation selected Possible
417. uce Add a DB option Controller may require resistance for DB resistors Refer to VDOCO6S201_ DB Option Solution Refer to VDOCO6N908 to determine required Refer to SC100 R5 95 for more information resistance of DB option for more information Refer to SC100 R5 95 for Refer to SC100 R5 95 more information for more information 33 1996 Square D All Rights Reserved Cnapter 3 Correcting tne Problem Cannot Stop Motor Bulletin NO VDUCUOS U1 December 1996 Cannot Stop Motor continued 3 of 3 Tachometer encoder velocity feedback incorrectly set on speed regulated drive system Tachometer with unidirectional output used on speed regulated drive system Possible cause Presence and correct directional sense of tachometer encoder signal Scaling of speed feedback signal Check to be performed Bidirectional characteristic of tachometer encoder velocity feedback device Feedback signal absent wrong directional sense Result incorrectly scaled Repair or replace the tachometer encoder device Correct directional sense of velocity feedback device Refer to VD0C06S306 Replace unidirectional velocity feedback device with bidirectional velocity feedback device Solution O 1996 Square D All Rights Reserved Motor deceleration under current limit or regeneration torque limit Current limit setting men
418. ue limits then controller is not capable of producing sufficient deceleration torque Add a Dynamic Braking Resistor Kit so that controller can produce deceleration torque Load cannot be decelerated at a faster rate 31 Cnapter 3 Correcting tne Problem Bulletin NO VDUCUOS U1 Cannot Start Motor December 1996 Cannot Start Motor Figure 10 illustrates the troubleshooting procedure when the motor cannot be started no controller faults present CANNOT START Operating Condition MOTOR No power present at controller Motor not connected to controller Start command signals not present corrupted Possible Controller not set to cause proper command mode Line side disconnect Check logic input map Motor disconnect Check Line side switching menu 2 for presence Load side switching to be devices of run command devices performed Line side overcurrent Check keypad Load side conductors protective device configuration menu 5 e Line side wiring Line side devices are Run command not Load side devices are open present open Result Bad line side wiring Incorrect command mode Damaged load side selected wiring Correct line side Check wiring and Correct load side power power protection devices external control circuitry device sequencing or Solution sequencing or operation Select proper command operations
419. ue wrench set to 35 4 Ib in 4 0 Nem Flat blade screw driver sockets for torque wrench e Metric drive sockets for torque wrench With the drive controller door open or removed 1 Measure the bus voltage if not already performed as described in chapter 5 of this manual 2 Using a flat blade screw driver remove the screws which connect the R11 A and R8 A wires to the resistors see Figure 145 on page 297 3 Using a drive socket loosen and remove the five resistor mounting plate screws Lift the bottom of the resistor plate upwards to expose the precharge contactor see Figure 145 on page 297 Secure resistor plate with wire ties or some other restraining device O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66C10N4 to C19N4 Using a flat blade screw driver remove the AUX 51 AUX 61 jumper remove the AUX 71 AUX 81 jumper remove the AUX 62 AUX 72 jumper remove AUX 52 and AUX 82 control wires from the auxiliary contact block Save the three jumpers for later use see Figure 146 on page 300 Using a flat blade screw driver lift and hold the auxiliary contact block release lever at the top of the auxiliary contact block While holding the release lever up slide the auxiliary contact block upwards and remove from the contactor assembly Slide the new auxiliary contact block into place on the contactor assembly Make sure that the release lever for the contac
420. ult motor builder for correct base speed requirements of load and motor Reduce ambient temperature Figure 7 Excessive Motor Temperature O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Excessive Motor Tem perature continued 2 of 3 Cnapter 3 Correcting tne Propiem Excessive Motor Temperature Motor ventilation system Motor driven at speed is clogged or damaged which is outside of its Possible The motor blower is Speed range cause inoperative Control law parameters are incorrectly set V Hz E boost IR Comp etc Check speed range of Check drive to be Check speed range of performed motor on motor nameplate or data sheets Driven motor speed is outside of motor speed Result range Verify that motor Apply motor with ventilation system is open correct speed range Solution Verify that motor blower is operating properly Refer to VD0C06S305 to choose correct settings 1996 Square D All Rights Reserved 23 Cnapter 3 Correcting tne Probiem Excessive Motor Temperature Excessive Motor Temperature continued 3 of 3 24 Possible cause Check to be performed Result Solution Motor currents voltages are unbalanced or unstable Controller tuning Motor Controller
421. uments and insulated tools approved for job Disconnect all power before servicing drive controller WAIT ONE MINUTE until DC bus capacitors discharge then measure DC bus capacity or voltage between the PA and terminals to verify that DC voltage is less than 45 VDC refer to PROCEDURE 1 BUS VOLTAGE MEASUREMENT in Chapter 5 DC bus LED is not accurate indication of absence of DC bus voltage DO NOT short across DC bus capacitors or touch unshielded components or terminal strip screw connections with voltage present Install all covers and close drive controller door before applying power or starting and stopping drive controller Observe and follow all applicable lock out and tag out procedures for specific installation Failure to follow these instructions will cause shock or burn resulting in death or serious injury ALTIVAR is a trademark of Telemecanique S A or its successor in interest Schneider Electric S A Thermalcote is a registered trademark of Thermalloy Inc Thermstrate is a trademark of Power Devices Inc Torx is a registered trademark of Textron Inc O 1996 Square D All Rights Reserved This document may not be copied in whole or in part or transferred to any other media without the written permission of Square D Electrical equipment should be serviced only by qualified electrical maintenance personnel No responsibility is assumed by Square D for any consequences arising out of the use of this material
422. ut eek a e Ribbon Cable Ribbon Cable Circuit Board Circuit Board l Blue Cable Clasp Release Position Release Position White Cable Clasps Blue Cable Clasps Figure 102 Cable Connector Secure and Release Positions Installing the Control Basket This procedure explains how to install the control basket in the following drive controllers Drive Controller No Control Kit No ATV66D54N4 ATV66D64N4 VX4 A66CK1 ATV66D79N4 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Aset of magnetized phillips screw drivers Torque wrench set to 8 9 Ib in 1 0 Nem e Aset of phillips screw driver sockets for torque wrench For the control basket to be installed 1 Placethecontrol basket in the controller Using a torque wrench and a phillips screw driver socket tighten the one captive screw and install and tighten the three othe
423. ve Controller No ATV66D16N4 ATV66D23N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm e Set of open end wrenches 5 5 to 19 mm e Power board procedure tool list page 122 e Gate drive board procedure tool list page 118 e Control basket procedure tool list page 113 126 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out
424. ve any wiring Loosen the precharge assembly by using a drive socket to remove the five precharge resistor plate mounting screws see Figure 139 on page 283 Do not remove any of the wiring from the precharge assembly Using a hex key wrench loosen and remove the two bolts which hold the RB and RB cables to the rectifier bus bars Install the new capacitor assembly NOTE If the bottom capacitor assembly has been replaced it will be necessary to reinstall the circuit protector the precharge resistor plate and the RB and RB cables see Figure 139 on page 283 First place the RB cable over its mounting location on the RB bus bar Using a torque wrench with a hex key socket install and tighten the mounting screw to a torque of 74 3 lb in 8 4 Nem Next place the RB cable over its mounting location on the RB bus bar Using a torque wrench with a hex key socket install and tighten the mounting screw to a torque of 74 3 Ib in 8 4 Nem Align the precharge resistor plate over the five mounting holes Using a torque wrench with a drive socket install and tighten the five mounting screw to 35 4 Ib in 4 0 Nem Reinstall the circuit protector following the procedure on page 305 Using a torque wrench with a drive socket install the two capacitor assembly screws and tighten to 35 4 Ib in 4 0 Nem Install the two capacitor jumpers and three capacitor jumper screws see Figure 139 on page 283 Using a torque wrench and a he
425. ve the diode bridge from the following drive controllers Drive Controller No ATV66D16N4 ATV66D23N4 Diode Bridge No VZ3 DM6075M1601 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are Filter board procedure tool list page 132 e Power board procedure tool list page 122 Gate driver procedure tool list page 118 e Control basket procedure tool list page 113 With the drive controller door removed 1 Remove
426. ver in place Install the J1 terminal block see Figure 104 on page 197 Install the right side panel Using a phillips or Torx screw driver install and tighten the 4 screws which hold the right side panel in place Install the gate driver board as described in the procedure on page 200 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Removing the Diode Block Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 There are three diode blocks on this size of drive controller This procedure explains how to remove the diode block from the following drive controllers Drive Controller No Diode Block No ATV66D54N4 ATV66D64N4 VZ3 DM2160M1606 ATV66D79N4 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handlin
427. ver procedure tool list page 120 e Control basket procedure tool list page 115 For the diode bridge to be installed 1 Clean the portion of the heatsink which will make contact with the diode bridge 2 Evenly coat the bottom of the diode bridge with a thin coat of thermal grease 3 Install the diode bridge with the PA and terminals rotated toward the right side of the drive controller Using a torque wrench with a hex key socket install and tighten the two screws to 17 7 lb in 2 Nem 4 Install the filter board as described in the procedure on page 134 O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Replacing the Precharge Resistor Cnapter 4 Equipment Cnange vut ATV66D16N4 and ATV66D23N4 This procedure explains how to replace the precharge resistor for the following drive controllers Drive Controller No ATV66D16N4 ATV66D23N4 Precharge Resistor No VZ3 RO33W009 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE SEPARATE POWER Separate power may be present on power board connectors Verify that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury A
428. w Location of I O Extension Module if installed 1 Captive mounting 2 dd Mounting screw screw J13 J12 Figure 101 Control Basket Connector Locations 4 Using a flat blade screw driver carefully loosen and disconnect the J9 and J32 connectors located at the top left of the control basket see Figure 101 on page 192 5 Using a flat blade screw driver carefully loosen and disconnect the J12 and J13 connectors located at the bottom of the control basket 6 Using two small flat blade screw drivers carefully pull out on each side of the cable clasps of J3 J4 and J5 to the release position see Figure 102 on page 193 Pull the ribbon cables from the sockets sing a phillips screw driver loosen the four corner screws on the control basket see Figure 101 on page 192 N C 8 Remove the control basket from the drive controller 192 A929ai_23 _e ei 1996 Square D All Rights Reserved Bulletin NO VDUCUOS UI December 1996 Cnapter 4 Equipment Cnange Out ATV66D54N4 to D79N4 NOTE Be sure the ribbon cables have been released before pulling to avoid damage to the cables There are two versions of the cable clasps blue and white White Cable Clasp Ribbon Cable i Ribbon Cable li Circuit Board Ls Circuit Board X hor oe a Blue Cable Clasp Secure Position Secure Position White Cable Clasp Pull Out Pull O
429. w braking IGBT module 2 Evenly coat the bottom of the new braking IGBT module with a thin coating of thermal grease 3 Install the new braking IGBT module Using a torque wrench with a hex key socket install and tighten the four mounting screws to 26 5 Ib in 3 Nem Torque screws in the sequence shown D u p d O9 9 a 4 Position the bus bar and align the mounting holes 5 Position the C cable over the bus bar terminal and the C cable over the bus bar terminal see Figure 108 on page 206 Using a torque wrench with hex key attachment install and tighten the two screws which hold the C and C cables to the bus bar to 17 7 lb in 2 Nem O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66D54N4 to D79N4 NOTE To ensure that the power board is mounted level make sure that each mounting pin has two washers mounted under it and that the red end of the pins are facing up Also the three pins with the stripe s are to be used for connecting the U V and W cables to the IGBT modules 6 Position the U cable over the mounting hole in the top IGBT Position the V cable over the mounting hole in the middle IGBT and the W cable over the mounting hole on the bottom IGBT 7 Using a torque wrench with hex key attachment install the 12 hex head screws with the balancing resistors which connect the bus bar to
430. w drivers Torque wrench set to 8 9 Ib in 1 0 Nem e Aset of phillips screw driver sockets for torque wrench For the control basket to be installed 1 Thread the three ribbon cables through the cable guides on the back of the control basket see Figure 47 on page 89 2 Place the control basket in the controller and slide it up until the two bottom mounting holes are aligned with the holes in the controller Ensure the two ears at the top of the control basket are behind the tabs on the drive controller see Figure 47 on page 89 3 Insert the bottom screw that is not captive and using a torque wrench with a phillips screw drive socket tighten both screws to a torque of 8 9 Ib in 1 0 Nem NOTE The captive mounting screw provides the grounding connection for the control basket and shield connection on J13 Ensure this screw is properly threaded and torqued 4 Snap the four connectors J9 J12 J13 and J32 into place see Figure 47 on page 89 NOTE The yellow keys in both the plugs and sockets are designed to prevent incorrect insertion of J12 and J13 5 Make sure all three cable connectors are pulled out on connectors J3 J4 and J5 see Figure 48 on page 89 390 z AAA 01996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66U41N4 to ATV66U72N4 6 Carefully insert the three ribbon cables into the cable connectors at the J3 seven connector cable J4 six c
431. wer section of the drive controller a stressed or overheated IGBT power block or a problem with the gate driver itself its power supply or its connections to the IGBT power block A display of SHORT CIRCUIT indicates that the output current sensors have detected an output overcurrent problem If peak output current as measured by the output current sensors exceeds 2 828 times the continuous output 400V CT current rating of the drive controller see Table 1 1 in the VDOC06S304_ manual a LIC or warning pulse is generated example continuous output 400V CT current rating for ATV66D79N4 is 115 5 amps More than 100 LIC pulses within 255 msecs will trigger the SHORT CIRCUIT fault For the ATV66C10N4 through ATV66C19N4 5 LIC pulses within 255 msecs will trigger the SHORT CIRCUIT fault 1996 Square D All Rights Reserved 61 Cnapter 3 Correcting tne Problem Short Circuit 62 Fault Displayed Short circuit between phases Possible cause Keypad display shows Check short circuit to be performed Result Check the wiring and the motor Solution 1 ATV66D16N4 ATV66D23N4 ATV66D79N4 ATV66D33N4 ATV66C10N4 ATV66D46N4 ATV66C13N4 ATV66D54N4 ATV66C15N4 Figure 29 Short Circuit ATV66D64N4 ATV66C19N4 Bulletin NO VDUCUOS U1 December 1996 SHORT CIRCUIT Insufficient moto
432. wing drive controllers Drive Controller No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Fan and Capacitor No VZ3 V666 Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e 4 Needle nose pliers e Aset of magnetized flat blade screw drivers e 1 4 metric drive socket set 5 5 to 14 mm For the main fan and capacitor assembly to be installed 1 Install the new main fan capacitor in the fan capacitor assembly Using a drive socket install and tighten the mounting washers and nut 2 Slide the fan capacitor assembly and the filter board assembly onto their mounting screws in the drive controller Using a drive socket install and tighten the mounting washers and nuts see Figure 118 on page 234 3 Using needle nose pliers connect the C34 A and C34 B connectors on the left side of the fan capacitor assembly see Figure 118 on page 234 4 Insert the blue main fan capacitor wire into the left side of terminal 2 of TB1 Insert the brown main fan capacitor wire into the left side of terminal 3 of TB1 Ensure that all wires that were previously installed in terminals 2 and 3 with the two fan wires are reinserted Using a flat blade screw driver tighten the two terminals see Figure 118 on page 234 5 Install the new main fan into the bottom of the drive contr
433. wing faults are displayed during a line supply power break e The line undervoltage fault if the motor is driven e The input phase loss fault if the motor is not driven The voltage values can be displayed on the keypad display Undervoltage is a self clearing fault If the cause of the fault is corrected i e the DC bus voltage is restored to the proper level internal logic will clear the fault and unlatch the drive controller The drive controller will then be ready to start O 1996 Square D All Rights Reserve 43 Cnapter 3 Correcting tne Probiem Bulletin NO VDUCU6S UT Undervoltage December 1996 Figure 15 illustrates the troubleshooting procedure when the undervoltage fault is present UNDERVOLTAGE Fault Displayed Line supply too low Possible cause Refer to chapter 3 Check section Drive Controller to be Internal Measurements performed Check and measure the voltage at terminals L1 L2 L3 and at terminals PA and No or insufficient voltage Powered Operating Powered Operating supply to L1 L2 L3 of up Up Result controller 450V 400V 450V 400V or or 575V 525V 575V 525V Refer to Checking For ATV66C10N4 to Refer to chapter 4 to Peripheral Equipment C19N4 check power change the Solution In Chapter gt fures Power board For ATV66C10N4 to C19N4 check for tripped GV2 th
434. wiring method or source output Refer to VDO0C06S304_ Repair or replace signal Source Refer to VD0C06S305 to select correct settings Refer to SC100 R5 95 Figure 6 Poor Speed Stability A AAAAAA 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Poor Speed Stability continued 2 of 2 Possible cause Check to be performed Result Solution Cnapter 3 Correcting the Probiem Drive controller motor are incorrectly sized for the expected load Load fluctuations Poor Speed Stability Load torque fluctuates with machinery speed or as machinery is loaded Controller in current torque limit when speed stability is poor Contact machine builder Verify that steady state and transient torque requirements with speed are within capabilities of controller and motor Peak torque required exceeds motor capability at given speed Peak current required exceeds drive capability at given speed Apply a larger controller motor Existing motor and controller may be incorrectly dimensioned for the application See SC100 R5 95 for more information O 1996 Square D All Rights Reserved 21 Cnapter 3 Correcting the Probiem Excessive Motor Temperature Excessive Motor Temperature 22 Bulletin NO VVUCUbS U1 December 1996 Figure 7 illustrates the troubleshooting procedure when excessive motor tempera ture i
435. wo connectors to the new thermal switch 7 Install the GD4 gate driver board as described in the procedure on page 252 Replacing the Filter Board This procedure explains how to replace the filter board assembly for the following Assembly drive controllers Drive Controller No ATV66C10N4 ATV66C13N4 ATV66C15N4 ATV66C19N4 Filter Board Assembly VX4 A66106 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS VOLTAGE MEASUREMENT in chapter 5 Failure to follow these instructions will cause shock or burn resulting in death or serious injury A DANGER HAZARDOUS VOLTAGE STORED ENERGY If controller is damaged voltage may be present on metal can capacitors and snubber board capacitors see Figure 127 on page 249 Always check for presence of voltage using voltmeter setto 1000 VDC scale If voltage is present allow voltmeter to discharge capacitor stored charge Refer to PROCEDURE 2 DISCHARGING STORED ENERGY IN CAPACITORS in chapter 5 for further information Failure to follow these instructions will cause shock or burn resulting in death or serious injury Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure 280 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 December 1996 Cnapter 4 Equipment Cnange Out ATV66C
436. wrench with a hex key socket install and tighten the two screws to 26 5 Ib in 3 Nem 4 Place the diode block bus work over the diode block mounting holes 5 Usinga torque wrench with a hex key socket install and tighten the four screws which hold the diode bridge bus work to the outside diode blocks to 26 5 lb in 3 Nem 6 Using a torque wrench and drive socket install and tighten the lower mounting posts on the center diode block which attach the block to the bus work and the filter board to 17 7 Ib in 2 Nem 7 Using a torque wrench and drive socket install and tighten the mounting post and incoming line cable for the diode block that was replaced to 17 7 Ib in 2 Nem 8 Install the filter board as described in the procedure on page 173 1996 Square D All Rights Reserved CL 177 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66D33N4 and ATV66D46N4 December 1996 NOTE Use the wiring termination chart in Figure 95 on page 178 to place the wires when performing steps 5 through 7 Figure 95 Diode Block Wiring Terminations Replacing the Current There are two current sensors in this size of drive controller This procedure Sensor explains how to replace a current sensor for the following drive controllers Drive Controller No Current Sensor No ATV66D33N4 ATV66D46N4 VY1 A66104 A DANGER HAZARDOUS VOLTAGE Remove all power before performing this procedure Follow PROCEDURE 1 BUS
437. x key socket tighten the screws to 40 7 Ib in 4 6 Nem Install the capacitor bus bar See Figure 141 on page 286 for the correct orientation The side with the captive mounting nut is the back side The upper right corner of the capacitor bus bar must be mounted under the bus connector lip see Figure 139 on page 283 Install the bus mounting bolt Using a torque wrench and hex key socket tighten the bolt to 74 3 Ib in 8 4 Nem O 1996 Square D All Rights Reserved Bulletin NO VDUCUOS U1 Cnapter 4 Equipment Cnange Out December 1996 ATV66C10N4 to C19N4 Bus capacitor fuse Capacitor assembly D 4 Capacitor assembly screws 2 I Capacitor assembly lt Capacitor assembly screws 2 Circuit protector mounting screws Capacitor assembly Capacitor assembly screws 2 Precharge assembly Figure 140 Capacitor Assembly Mounting Diagram Side View 1996 Square D All Rights Reserved 285 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS U1 ATV66C10N4 to
438. y that all power has been removed from J1 J12 and J13 connectors If I O Extension Module is installed verify that all power is removed from J22 J23 and J24 connectors Failure to follow these instructions will cause shock or burn resulting in death or serious injury A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Aset of magnetized flat blade screw drivers e Aset of magnetized phillips screw drivers 1996 Square D All Rights Reserved 101 Cnapter 4 Equipment Cnange Out Bulletin NO VDUCUOS UT ATV66U90N4 and ATV66D12N4 December 1996 With the drive controller door open 1 Measure the bus voltage if not already performed as described in Chapter 5 of this manual 2 Remove the keypad display as described on page 100 3 Remove options module if present See User s Manual VDOC06T306_ for r
439. y that all power has been removed from J1 connector Failure to follow these instructions will cause shock or burn resulting in death or serious injury 1996 Square D All Rights Reserved 141 Cnapter 4 rquipment Change Out Bulletin NO VDUCUbS UI ATV66D16N4 and ATV66D23N4 142 December 1996 A CAUTION STATIC SENSITIVE COMPONENTS Many drive controller components may be damaged by static electricity Follow the electrostatic precautions listed in Static Sensitive Components on page 4 of this manual when handling controller circuit boards or testing components Failure to follow this instruction can result in equipment damage Read WORK PRACTICE PRECAUTIONS on page 3 and the precaution statement on the inside cover of this manual before performing any maintenance or troubleshooting procedure The tools needed for this procedure are e Metric hex key set 2 to 14 mm e Power board procedure tool list page 122 Gate driver board procedure tool list page 118 e Control basket procedure tool list page 113 With drive controller door removed 1 Remove the power board as described in the procedure on page 121 2 Identify and tag all field wiring for future re assembly 3 Disconnect the field wiring of the J2 connector at the bottom of the controller see Figure 63 on page 117 4

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