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Contents 1 Introduction 2 Operator Interface and

1. Illustration 7 1 D1 D3 Single Capacitor Bank Assembly 380 480 500 Blue DC Link Capacitors 525 690 Black DC Link Capacitors Retaining nuts step 2 Retaining nuts step 4 Gate drive card step 3 CN 130 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 7 2 8 Soft Charge SC Resistors D2 D4 Units 1 Remove the upper capacitor bank assembly in accordance with procedure NB On D2 D4 units only the upper cap bank assembly is removed 2 MK4 connector on the soft charge card must be disconnected Disengage the soft charge card far enough to access the 4 see Illustration 7 3 in accordance with steps 1 3 in the soft charge card disassembly procedure 3 Note that the soft charge resistor is located under the bus bars and held in place by 2 retaining nuts Bus bars do not need to be removed Loosen the retaining nut 8 mm furthest to the right 4 Remove the 8 mm retaining nut furthest to the left 5 Lift the left side of the SC resistor and remove the resistor by sliding it to the left and out from under the bus bars Reinstall in reverse order of this procedure Tighten the 8 mm mounting nuts to 2 3 Nm 20 in Ibs Tighten 10 mm mounting nuts to
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4. w v Ti a n HA 77 ort RAE Tal m ls ECONOPACK MODULE 16871 130BX186 10 Illustration 3 7 Inverter section 52 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Frequency Converters 3 Internal Frequency Converter Operation 3 3 4 Brake Option For frequency converters equipped with the dynamic brake option a brake IGBT along with ter minals 81 R and 82 R is included for connecting an external brake resistor The function of the brake IGBT see Illustration 3 8 is to limit the voltage in the intermediate circuit whenever the maximum voltage limit is exceeded It does this by switching the externally mounted resistor across the DC bus to remove excess DC voltage present on the bus capacitors Excess DC bus voltage is generally a result of an overhauling load causing regenerative energy to be returned to the DC bus This occurs for example when the load frequency converters the motor causing the voltage to return to the DC bus circuit Placing the brake resistor externally has the advantages of selecting the resistor based on appli cation need dissipating the energy outside of the control panel and protecting the frequen
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20. Qo AUAM 2 97 _ Se Illustration 7 1 Fan Assembly 2 of 2 1 Inline Molex connector Step 5 2 Retaining nut Step 6 MG 90 L1 02 VLT is a registered Danfoss trademark 145 7 D Frame Sizes Disassembly and Assembly high Power Service Manual for VLT FC Series Instructions Frequency Converters 7 2 15 AC Input Terminals 1 Remove the input power cabling as required 2 Remove the R L1 S L2 T L3 terminals by removing the 3 retaining screws Reinstall in reverse order of this procedure Tighten the mounting nuts per specifications in the unit s instruction manual 130BX125 10 Illustration 7 1 AC Input Terminals no options shown 380 480 White label on fan transformer 525 690 Orange label on fan transformer AC input terminal AC input cable gland Step 1 Retaining screws Step 2 Retaining screw Step 2 HG 146 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 7 2 16 Modules D2 D4 Units 1 Remove the capacitor banks per instructions 2 Note the IGBT gate signal cables connected between gate drive card connectors MK100 temperature sensor MK102 U MK103 V and MK104 W and IGBTs These will need to be reconnected in the same locations during reassembly Units wit
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31. High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 10 Spare Parts List 10 Spare Parts List 10 1 Spare Parts List 10 1 1 General Notes General Notes All spare parts are suitable for conformal coated frequency converters and can be used in either coated or non conformal coated frequency converters Bus bars used in some units are aluminum Spare part bus bars are always plated copper Plated copper bus bars are useable for all units For the latest spare parts list visit the Danfoss website at www danfossdrives com MG 90 L1 02 VLT is a registered Danfoss trademark 177 High Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List 00 OStd OSbd c c 4 4 2 T T T T T T T T T T T T T T T T T T T 1 1 0 S enu UNE due _ l __ NE We ZOE 0 Wz Zo 00 0 e _ 0m _ _ _ ZOT lt 0544 O0cd O9Td CETd O0td SSEd STEd 0644 0044 09Td OObd SSEd STEd OScd 0044 09Td va ea JVA 00S 2VA 08 cot cot OTTd 06d coe 24 zoz 24 01 24 gt 2 2 24251 sued eJeds T 0T eger xueg de
32. 3 If mains voltage is present at the input of the frequency converter but not at MK106 of the power card conduct a static test of the soft charge fuses 6 2 1 MG 90 L1 02 VLT is a registered Danfoss trademark 119 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters 4 If voltage is present at MK106 check the voltage at the fan transformer read from con nector CN2 located near the transformer With a voltmeter read the AC voltage at CN2 pins 1 and 3 The voltage should correspond to the main mains voltage applied to the frequency converter 5 If voltage is not present ensure jumpers in place at power card connector 103 Otherwise connect an external source of power to terminal FK103 for fan supply voltage If the jumpers are in place or an auxiliary supply is connected and powered but no voltage is present at the fan transformer connector CN2 the power card is likely defective Replace the power card in accordance with the disassembly instructions in Section 7 or 8 Transformer output If the appropriate voltage is present at CN2 pins 1 and 3 next check the output of the transformer Prior to making this test ensure the fan transformer fuse is good 1 With a voltmeter measure mains voltage from CN2 terminal 1 to terminal 2 Voltage should equal 6696 of main AC supply voltage 48 for frequency converters 525 690 VAC applied to frequency converter or that of the auxilia
33. lt Eae 4 Gols Swi d 181 Tan L U Ts CBLIS lt SAPE RFI gt CBL24 Units E1 units 2 RFI cards No RFI relay 525 690V SOFTCHARGE BOARD PCAI Illustration 3 4 Rectifier circuit 48 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Frequency Converters 3 Internal Frequency Converter Operation 3 3 2 Intermediate Section Following the rectifier section voltage passes to the intermediate section see Illustration 3 5 This rectified voltage is smoothed by an LC filter circuit consisting of the DC bus inductor and the DC bus capacitor bank The DC bus inductor provides series impedance to changing current This aids the filtering process while reducing harmonic distortion to the input AC current waveform normally inherent in rectifier circuits The DC capacitor bank assembly consists of up to eight capacitors arranged in series parallel configuration Higher power units have two capacitor bank assemblies Also contained within the assembly is the bleeder balance circuitry This circuitry maintains equal voltage drops across each capacitor and provides a current path for discharging the capacitors once power has been removed from the frequency converter Also located in the intermedi
34. 5906 3 2055 25 5 105095 Juans gg ab Jed T 10595 quauuno ayy 5906 3 ZSEG 10595 Juans gg Jed T uej y 3nd3no 9UJeJ4 3 uey gg Jad pue YDS 1891 3 indino 1851 ag eds 4J 198 T y snq 3nd3no Buo 05 5 e1eds 198 T A aseud 10 4indino 1491 01 529 2 A 1030 gg 371 198 T M 10 N eseud 40 yndyjno 1491 01 s1 euuo2 M N 0N Heds 198 T y sng 3ndino Z 198 T uej y Huo 1891 s1 euuoo 3 1891 gg 205 198 T 1991 943 03 xueq y 529 2 25 1 gor Assy gg e1eds 1491 34 0 9 upiwpues sng dq 3 1991 Assy gg Aquwasse sng 1491 jeddn 5 1491 Assy gg Ajquasse sng 1491 Jamo puI 189I Assy gg Sleds 3 Assy gg aieds ayeig gg Ajqwasse 1891 pue xueq sj euuo2 1851 Assy gg
35. Frame Size P37k 30 37 40 50 37 45 D1 D3 P45k 37 45 50 60 45 55 01 03 P55k 45 55 60 75 55 75 D1 D3 P75k 55 75 75 100 75 90 01 03 P90k 75 90 100 125 90 110 D1 D3 P110 90 110 125 150 110 132 D1 D3 P132 110 132 150 200 132 160 D1 D3 P160 132 160 200 250 160 200 D2 D4 P200 160 200 250 300 200 250 D2 D4 P250 200 250 300 350 250 315 02 D4 P315 250 315 350 400 315 400 D2 D4 355 315 355 400 450 355 450 1 E2 400 315 400 400 500 400 500 1 E2 500 400 450 500 600 500 560 E1 E2 P560 450 500 600 650 560 630 E1 E2 Table 1 5 FC 302 AF 650 GP 525 690 VAC 1 6 Tools Required Operating Instructions for the FC Series Frequency Converter Metric socket set 7 19 mm Socket extensions 100 mm 150 mm 4 in and 6 in Torx driver set T10 T50 Torque wrench 0 675 19 Nm 6 170 in Ibs Needle nose pliers Magnetic sockets Ratchet Screwdrivers Standard and Philips Additional Tools Recommended for Testing Digital volt ohmmeter must be rated for 1200 VDC for 690 V units Analog voltmeter Oscilloscope Clamp on style ammeter Test cable p n 176F8439 Signal test board p n 176F8437 MG 90 L1 02 VLT is a registered Danfoss trademark 13 high Power Service Manual for VLT FC Series 1 Introduction Frequency Converters 1 7 General Torque Tightening Values For fastening hardware described in this manual the torqu
36. any 4ad 425 03 snq e3ejd 3ndui 539 3 T snid 425 ag eds 198 T 3ndui 425 03 snq 3ndui 5 nduj 425 eds sng 425 uoddns gg 425 pug apy Jad YS snq eyed 3ndui spauuod 11544 425 sieg sng Seg 90984971 96 lt 8 9 86 lt 8 9 4668 9 S098492T 098 9 20984921 09849 T 682849 1 V8 849 T 2828492 1 c6 849 T 06 84971 10984921 00984971 8 68 9 44 lt 8 9 94 849 19485941 665849 1 c8 849 1 T6 839ZT 6 58 9 865849 1 Z6S8492T 965849 1 882849 1 98 8497 T98 8397T 58 lt 8 9 668 9 182849 1 6ZE849ZT 5648 9 48 lt 8 9 b6E8AIZT 8 58 9 08 849 T JequinN eiq MG 90 L1 02 VLT is a registered Danfoss trademark 184 High Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List z 1 seg sng 3si sued eJeds g or eiqer 00 OStd 04 00 STEd SSEd SSEd STEd E do e v 6 E _ EE amp a 1 01001 0044 O9Td CETd 0 0544 00
37. For the D E and F Frame frequency converters the regulated voltage to the fans is monitored Troubleshooting Check fan resistance see section 6 2 9 or 6 2 10 Check soft charge fuses see section 6 2 1 or 6 2 3 WARNI NG 24 External fan fault The fan warning function is an extra protective function that checks if the fan is running mounted The fan warning can be disabled in par 14 53 Fan Monitor 0 Disabled For the D E and F Frame frequency converters the regulated voltage to the fans is monitored Troubleshooting Check fan resistance see section 6 2 9 or 6 2 10 Check soft charge fuses see section 6 2 1 or 6 2 3 WARNI NG 25 Brake resistor short circuit The brake resistor is monitored during operation If it short circuits the brake function is discon nected and the warning appears The frequency converter still works but without the brake function Turn off the frequency converter and replace the brake resistor see par 2 15 Brake Check WARNI NG ALARM 26 Brake resistor power limit The power transmitted to the brake resistor is calculated as a percentage as a mean value over the last 120 seconds on the basis of the resistance value of the brake resistor and the inter mediate circuit voltage The warning is active when the dissipated braking power is higher than 90 If 7rip 2 has been selected in par 2 13 Brake Power Monitoring the frequency converter cuts out and issues this alarm when the d
38. Series Frequency Converters MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 11 Block Diagrams 11 1 3 01 D3 525 690 VAC 130BX203 10 um EIE am m L Ed y 14 _ 1 2 MG 90 L1 02 VLT is a registered Danfoss trademark 205 11 Block Diagrams 206 High Power Service Manual for VLT9 Series Frequency Converters MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 11 Block Diagrams 11 1 4 02 04 525 690 VAC 130BX204 10 MG 90 L1 02 VLT is a registered Danfoss trademark 207 high Power Service Manual for VLT FC Series 11 Block Diagrams Frequency Converters 11 2 Block Diagrams for E Frames 11 2 1 1 2 380 500 VAC 130 202 10 2 2 d imm 20 2 gt Tite l SOFTCHARGE BOARD PCAN 208 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Ser
39. gg eeds 5 5 sjoqe 5 Meds 019849 1 0 8 9 9bS8492T 4 58 9 06 lt 8 9 TCv8439ZT 5 48 9 685849 1 84397T 885849 1 4 lt 8 9 458 977 8858 9 4 lt 8 9 8858 9 4 lt 8 9 4858 9 V0v849 T 662849 1 962849 1 84921 66 8492T S6 849 T 4858 9 SLE8AILT lt 8 9 489849 1 5 lt 8 9 V 8439 1 JequinN val val cal cal Tal Tal bal val val val cal cal cal cal cal cal Tal Tal Tal 40 wepe MG 90 L1 02 VLT is a registered Danfoss trademark 192 High Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List 0954 0 9d 0 9d 0064 0954 08 0954 08 m cem cm cem ES E E I eem cum cem T T c SS d STEd 06 O0cd OStd O0bd STEd 0444 OStd 00 STEd OSZd va ca OVA 069 SZS O9Td 0044 09 0044 O9Td coe 24 zoz 24 cot Os SJeq snq jeur epnpul 5 snq exeJq Jo 1991 9xXeJg OM aui SP UUOID 1991 9xe4q 03 snuiJ s12euuoo 1991 9xeJq 0 Snid 512euuo Jad T Josuas 3ua
40. 12 Remove the SCR diode module retaining screws on each module T30 and remove the SCR diode modules 130BX163 10 RAP m f ro gz LLLP Gy 222 a Illustration 7 1 D2 D4 SCR Diode Module 4 of 4 1 SCR diode module Step 12 2 SCR gate lead connectors Step 11 3 SCR diode module mounting screws Step 12 REASSEMBLY 1 To replace SCR diode modules follow the instructions included with the replacement module 2 Reassemble in reverse order Tighten the remaining T25 and 8 mm screws to 2 3 Nm 20 in Ibs and T30 to 4 Nm 35 in Ibs 3 Be sure to cross the tighten replacement unit with the spare part per instructions MG 90 L1 02 VLT is a registered Danfoss trademark 139 7 D Frame Sizes Disassembly and Assembly high Power Service Manual for VLT FC Series Instructions Frequency Converters 7 2 12 SCR Diode Module 01 D3 Units Remove the capacitor bank per instructions Remove the input terminal mounting plate per instructions Remove the retaining screw T25 from terminal 1 of each SCR diode module esc Remove the 8 mm retaining nut from the bus bar holding bracket and remove the bus bar one for each input phase CONTINUED ON NEXT PAGES 130BX165 10 Illustration 7 1 D1 D3 SCR Diode Module 1 of 3 Bus bar BB2 Step 4 Retaining screw access Step 3 Retaining nut Step 4 Bus bar SCR diode module 140 MG 90 L
41. 2 Hold ramp is activated via serial communication Freeze output request A freeze output command has been given but the motor will remain stopped until a Run permis sive signal is received via a digital input Freeze Ref Freeze Ref was chosen as a function for a digital input parameter group 5 1 The corresponding terminal is controlled The FC saves the actual reference Changing the reference is now only possible via terminal functions Speed up and Speed down Jog request A JOG command has been given but the motor will be stopped until a Run permissive signal is received via a digital input Jogging The motor is running with par 3 19 Jog Speed RPM 1 Jog was selected as function for a digital input parameter group 5 1 The correspond ing terminal e g Terminal 29 is active 32 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 7 42 Operator Interface and Frequency Converter Frequency Converters Control 2 Jog function is activated via the serial communication 3 Jog function was selected as a reaction for a monitoring function e g No signal The monitoring function is active Kinetic backup In par 14 10 Mains Failure a function was set as kinetic backup The Mains Voltage is below the value set in par 14 11 Ma ns Voltage at Mains Fault The FC is running the motor momentarily with kinetic energy from the inertia of the load Motor chec
42. 559 3 20 01 64205 lt 868 9 52180 eum T T T T T abieyo yos woy sseuJeu sng 64205 ejqe eds lt 66 8 9 92180 I I I I m mm m pJeoq 305 0 sseuJeu 3 LSY 5uoyos sjqe eds 968 9 ZA 9 mum e I 1 I pieog yos 01 Jamod sseuJeu LSY buxyos ejqe ejedS 6468 9 mm I I p4eoq 3jos Jamod 3ndul sseuJeu LSY 6423 05 ejqe ejeds p6g49 T 7199 mum mm mm T T T Em 0 1991 ajqed snuiy QL eds OZE849ZT 22180 EE is E I I SNUIW 1891 5 ejqe aiedS 9 8 9 22180 mm Em e T T T peura 0 1491 exeJq W014 ejqe ZA 5 ejqe ededS 692849 1 22182 os mem nm E Em I I jeuiuuJe snid 0 1891 ajqeo 9ujeJJ 5 eyeJg AQLI IEAS 099 8 9 22182 SSEd STEd 04044 00044 0974 ZETd 06 20224 JoquinN 00 4 SSEd STEd 0444 00044 0914 20234 5
43. 6 2 2 and 6 2 5 for D frame size units or 6 2 3 6 2 4 and 6 2 5 for E frame size units to ensure frequency converter is safe to start Disconnect the motor leads from the output terminals U V W of the frequency con verter Apply AC power to the frequency converter Give the frequency converter a run command and slowly increase the reference speed command to approximately 40 Hz Using an analog voltmeter or a DVM capable of measuring true RMS measure phase to phase output voltage on all three phases U to V U to W V to W All voltages must be balanced within 8 volts If unbalanced voltage is measured refer to Input Voltage Test 6 3 2 Stop the frequency converter and remove the input power Allow 40 minutes for DC capacitors to fully discharge for E frame size frequency converters or 20 minutes for D frame size frequency converters Reconnect the motor leads to the frequency converter output terminals U V W Reapply power and restart the frequency converter Adjust the motor speed to a nominal level Using a clamp on style ammeter measure the output current on each output phase All currents should be balanced If unbalanced current is measured refer to Current Sensor Test 6 3 14 MG 90 L1 02 VLT is a registered Danfoss trademark 75 Power Service Manual for VLT9 Series 5 Frequency Converter and Motor Applications Frequency Converters 76 MG 90 L1 02 VLT is a registered Danfoss
44. DC output to DC bus and connect the positive meter lead to MK1 terminals R 5 and T in sequence Each reading should show a diode drop An incorrect reading here indicates the soft charge rectifier is shorted The rectifier is not serviced as a component Replace the entire soft charge card in accordance with the disassembly proce dures in Section 7 5 Reverse meter leads with the positive meter lead to the positive MK3 Connect the negative lead to MK1 terminals R S and T in sequence Each reading should show open 6 Connect the positive meter lead to the negative MK3 C Connect the negative meter lead to MK1 terminals R S and T in sequence Each reading should show a diode drop An incorrect reading here indicates the soft charge rectifier is shorted The rectifier is not serviced as a component Replace the entire soft charge card in accordance with the disassembly proce dures in Section 7 MG 90 L1 02 VLT is a registered Danfoss trademark 93 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters 94 7 Reverse the meter leads with the negative meter lead to the negative MK3 C Connect the positive meter lead to MK1 terminals R S T in sequence Each reading should show open If all tests indicate correctly while isolating between the SCR diode modules and the soft charge card the SCR diode modules are suspect Before re
45. Power Card Ambient D Frame Units E Frame Units Fan turn on to High Speed 8546 45 C Fan turn off from High Speed 30 40 C Fan turn on to High Speed 10 C lt 10 C Table 3 2 Power Card Ambient Temperature Sensor 3 Control card thermal sensor measured temperature The fan can be off or low speed based on this temperature 54 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Frequency Converters 3 Internal Frequency Converter Operation Control Card Ambient D Frame Units E Frame Units Fan turn on to Low Speed 5546 551E Fan turn off from Low Speed 45 C 45 C Table 3 3 Control Card Thermal Sensor 4 Output current value If the output current is greater than 60 of rated current the fan will turn on low speed 3 3 7 Load Sharing Units with the built in load sharing option contain terminals 89 DC and 88 DC Within the frequency converter these terminals connect to the DC bus in front of the DC link reactor and bus capacitors The use of the load sharing terminals can take on two different configurations In one method the terminals are used to tie the DC bus circuits of multiple frequency converters together This allows for the possibility of one frequency converter that is in a regenerative mode to share its excess bus voltage with another frequency converter that is in motoring mode When applied correctly this can reduce the need for ex
46. Reversing Set up select Isb Set up select msb Stop command from serial communication Quick stop DC brake NB External stop signals activated by means of control signals or a serial bus will over ride a start command via the LCP Off stops the connected motor The key can be selected as Enable 1 or Disable 0 via par 0 41 Off Key on LCP If no external stop function is selected and the Off key is inactive the motor can only be stopped by disconnecting the mains supply Auto On enables the frequency converter to be controlled via the control terminals and or serial commu nication When a start signal is applied on the control terminals and or the bus the frequency converter will start The key be selected as Enable 1 or Disable 0 via par 0 42 Auto Key on LCP NB An active HAND OFF AUTO signal via the digital inputs has higher priority than the control keys Hand On Auto Reset is used for resetting the frequency converter after an alarm trip It can be selected as nab e 1 or Disable 0 via par 0 43 Reset Key on LCP The parameter shortcut can be carried out by holding down the Main Menu key for 3 seconds The parameter shortcut allows direct access to any parameter 28 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 7 42 Operator Interface and Frequency Converter Frequency Conv
47. and the 17 mm connecting nuts T50 screw to 19 Nm 170 in lbs i o Cate 4 z Ow 2 um p 8 5 es T3 3 gt ral ELI 4 ea 12 95 est wp LEIN Le 59 2 REN oi 5 1 6 c 1 IGBT output bus bar BB49 4 Retaining nut Step 3 2 Fan housing 5 Molex connector Step 4 3 Retaining nut Step 5 6 Retaining nut Step 2 166 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 8 E Frame Sizes Disassembly and Assembly Frequency Converters 8 2 12 AC Input Motor Load Sharing or Regen Terminals 1 Remove the external wiring from the terminals as required 2 Remove the retaining nut 17 mm connecting the terminal bus bar to other bus bar assemblies 3 Remove the 2 retaining nuts 13 mm attaching the terminal bus bar to the terminal block insulation Slide the terminal bus bar out 4 If the terminal block is attached to the input terminal plate not shown remove the retaining screw T40 attaching the terminal block insulation otherwise go to step 5 5 If the terminal block is not attached to the input terminal plate remove the retaining nut 13 mm attaching the terminal block insulation Reinstall in reverse order of this procedure Tighten the 17 mm connecting nuts to
48. 10suas T 24 2 e1eds 105 95 1uaum 24 5 aseds JUaLIND 24 ajqeD eueds eue 78A 033005 5 e1eds 3 401 e qe Beds 24 9 22 eieds seiqe gt sped 848 9 89 lt 8 9 5968 9 CSE8S9ZT 78S8492T TSE8S9ZT V9 849 T 185849 1 052849 1 292849 1 085849 1 0 lt 88 9 9258492 192584921 952849 1 5 48 9 56849 1 VvS8397T 85 lt 8 9 0 58 9 849 1 58 9 88439 T 19849 1 145849 1 652849 1 lt 58 9 695849 1 895849 1 6 lt 8 9 lt 8 9 9859 9858492 1985849 1 9849 1 12182 ITAL 02182 61 81 1182 61 81 21180 61 81 1180 91182 97182 91182 91180 91182 bT 18 vT185 21182 21180 21182 1182 6182 6182 8182 8182 8182 8182 8182 8182 6182 6182 65182 6182 2182 182 1182 zupe aueds 181 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Frequency Converters 1511 Sued S OT eiqer MG 90 L1 02 VLT is a registered Danfoss trademark I I 1 em mm mum pem mem asnj pie gt awel 3 24 ededs 19849 T 92180 I I I I Eum emm 01 305
49. 15 49 SW ID Control Card par 15 50 SW ID Power Card par 15 60 Option Mounted par 15 61 Option SW Version for each option slot MG 90 L1 02 VLT is a registered Danfoss trademark 67 high Power Service Manual for VLT FC Series 4 Troubleshooting Frequency Converters ALARM 16 Short circuit There is short circuiting in the motor or on the motor terminals Turn off the frequency converter and remove the short circuit See section 1 9 for trip levels WARNI NG ALARM 17 Control word time out There is no communication to the frequency converter The warning will only be active when par 8 04 Contro Word Timeout Function is NOT set to OFF If par 8 04 Contro Word Timeout Function is set to Stop and Trip a warning appears and the frequency converter ramps down until it trips while giving an alarm Troubleshooting Check connections on the serial communication cable Increasepar 8 03 Control Word Timeout Time Check the operation of the communication equipment Verify a proper installation based on EMC requirements See section 5 WARNI NG 22 Hoist mechanical brake The report value will show what kind it is 0 The torque reference was not reached before time out 1 There was no brake feedback before the time out WARNING 23 I nternal fan fault The fan warning function is an extra protective function that checks if the fan is running mounted The fan warning can be disabled in par 14 53 Fan Monitor 0 Disabled
50. 485849 1 V0v849 T 66 8492T 962849 1 V0v849 T 66 8492T S6 8H9JV l 9562849 1 4858 9 S 84397T V 849 T 4858 9 5 lt 8 9 V 839 T JequunN syed val bal cal cal cal Tal Tal val val bal val cal cal cal cal cal Tal Tal Tal 4o3eufiiseg 183 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List OSbd SSEd 00 STEd SSEd SSEd 0S d STEd ela SERERE T T 1 Qo qo C cue Fr ft 1 T T DS Zz a Tt ft e el s t 50 _ amp _ amp 0044 09 06d 0544 0044 O9Td OTTd OScd 0044 O9Td CETd 005 2VA 08 08E 605 34 206 24 601 2d sueg sng 5351 sued 01 Sjeq snq euru sjeq snq JO 1991 ow y SP UUOID 1891 0 snuiJ S1 euuo snulp ayeig gg e1eds 1991 0 5 SP UUOID snig e1eds Jad T 105 5 y
51. Check the connections on all the analog input terminals Control card terminals 53 and 54 for signals terminal 55 common MCB 101 terminals 11 and 12 for signals terminal 10 common MCB 109 terminals 1 3 5 for signals terminals 2 4 6 common Make sure that the frequency converter programming and switch settings match the analog signal type Perform the Input Terminal Signal Test in Section 6 3 16 WARNI NG ALARM 3 No motor No motor has been connected to the output of the frequency converter This warning or alarm will only appear if programmed by the user in par 1 80 Function at Stop Troubleshooting Check the connection between the frequency converter and the motor WARNI NG ALARM 4 Mains phase loss A phase is missing on the supply side or the mains voltage imbalance is too high This message also appears for a fault in the input rectifier on the frequency converter Options are programmed at par 14 12 Function at Mains Imbalance Troubleshooting Check the supply voltage and supply currents to the frequency converter See Section 5 1 2 for troubleshooting details WARNI NG 5 DC link voltage high The intermediate circuit voltage DC is higher than the high voltage warning limit The limit is dependent on the frequency converter voltage rating The frequency converter is still active See ratings table in Section 1 9 for the voltage limits WARNI NG 6 DC link voltage low The intermediate circuit voltage DC is lower
52. EMI Frequency Converter Motor AC Line Motor cable Stray capacitance AC Line High frequency currents can be coupled into the mains supplying the frequency converter when the mains conductors are located close to the motor cables 130BX140 12 Illustration 5 4 Alternate Signal Conductor Currents 84 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series 7 44 Frequency Converters 5 Frequency Converter and Motor Applications 5 2 7 Preventive Measures EMI related problems are more effectively alleviated during the design and installation phases rather than after the system is in service Many of the steps listed here can be implemented at a relatively low cost when compared to the cost for identifying and fixing the problem later in the field Earthing The frequency converter and motor should be solidly earthed to the equipment frame A good high frequency connection is necessary to allow the high frequency currents to return back to the frequency converter rather than to travel thorough the power network The earth connection will be ineffective if it has high impedance to high frequency currents therefore it should be as short and direct as practical Flat braided cable has lower high frequency impedance than round cable Simply mounting the frequency converter or motor onto a painted surface will not create an ef fective earth connection In addition running a separate earth c
53. Illustration 6 4 Illustration 6 5 Illustration 6 6 Illustration 6 7 Illustration 6 8 Illustration 6 9 Illustration 6 10 Illustration 6 11 Illustration 6 12 Illustration 6 13 Illustration 6 14 Illustration 6 15 Illustration 6 16 Illustration 6 17 Illustration 6 18 Exploded view D3 Frame size D1 frame is similar Exploded view D4 frame size D2 frame is similar Exploded view E2 frame size E1 frame is similar Control Terminals Control Terminals Electrical Diagram Control Card Logic Logic Section Typical Power Section Rectifier circuit Intermediate section Output Voltage and Current Waveforms Inverter section Brake option Frequency Converter Functionality Diagram Earth Currents Signal Conductor Currents Alternate Signal Conductor Currents Proper EMC Installation Signal Test Board SCR Shorting Plug Two Pin Three Pin Power Card and Mounting Plate Soft Charge Card Fuses Soft Charge Card Connectors Soft Charge Card Fuse Location Soft Charge Card Connectors Fan Transformer and Fuse Location Fan and DC Bus Fuse Locations Drive Power Terminals Normal AC Input Voltage Waveform AC Input Current Waveform with Diode Bridge Input Current Waveform with Phase Loss SCR Gate Signal Gate Drive Card Test Connectors 15 16 17 36 40 43 44 46 48 50 51 52 53 83 83 84 84 86 88 89 89 89 90 91 94 95 97 102 104 105 110 110 111 112 115 Gate Signal Waveform
54. Illustration 8 1 IGBT Modules 1 of 4 1 Retaining nuts Step 7 3 IGBT board 2 Wire retaining nut on bus bar BB41 Step 3 4 Wire retaining nuts for output bus bars BB42 Steps 5 amp 6 168 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 7 44 8 E Frame Sizes Disassembly and Assembly Frequency Converters Instructions 8 Ifthe unit is not equipped with the load sharing option proceed to step 9 If the unit is equipped with load sharing the load share minus bus bar must be removed as follows 8a Remove the 2 retaining nuts 13 mm connecting the load share bus bar to the SCR output bus bar 8b Remove the retaining nut 17 mm connecting the load share bus bar to the load share terminal on the opposite end of the bus bar not shown 8c Remove the load share bus bar 9 Remove both positive and negative SCR output bus bars by removing the 6 con nection screws T50 There are 3 screws per bus bar 10 Remove the three SCR and diode input bus bars by removing the 6 connection screws T50 There are 2 screws per bus bar CONTINUED NEXT PAGE c 5 poe E ce o th o lt i ce E 5 1 9 9 oe 3 4 gt 9 A a0 9 2 c A 6 DB o Illustration 8 1 IGBT Modules 2 of 4 1 Load sharing option retainin
55. Mains Phase Warning 5 sec delay DC Bus Ripple VAC 50 50 50 50 50 Mains Phase Alarm 25 sec delay DC Bus Ripple VAC 50 50 50 50 50 MG 90 L1 02 VLT is a registered Danfoss trademark Mains supply 3 x 380 480 500 V High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 1 Introduction Model number FC102 202 P315 355 400 450 02 250 P315 P355 P400 Normal overload current ratings 110 Output current Nominal A 380 440 V 600 658 745 800 MAX 60 sec A 380 440 V 660 724 820 880 Nominal A 441 500 V 540 590 678 730 MAX 60 sec A 441 500 V 594 649 746 803 Output Nominal kVA 400 V 416 456 516 554 Nominal kVA 460 V 430 470 540 592 Nominal KVA 500 V 468 511 587 632 Typical shaft output kW 400 V 315 355 400 450 HP 460 V 450 500 550 600 600 kW 500 V 355 400 500 530 High overload torque 16096 Output current Nominal A 380 440 V 480 600 658 695 MAX 60 sec A 380 440 V 720 900 987 1043 Nominal A 441 500 V 443 540 590 678 MAX 60 sec A 441 500 V 665 810 885 1017 Output Nominal kVA 400 V 333 416 456 482 Nominal kVA 460 V 353 430 470 540 Nominal kVA 500 V 384 468 511 587 Typical shaft output kW 400 V 250 315 355 400 HP 460 V 350 450 500 550 kW 500 V 315 355 400 500 Power loss Normal overload W 6790 7701 8879 9670 Power loss High overload W 5165 6960 7691 8636 Limits and Ranges Ove
56. Remove the intermediate IGBT bus bars 9 Remove 4 nuts 10 mm two on either side connecting the rectifier DC bus bars to the main DC bus bars These are located to either side of the SCR diode modules CONTINUED NEXT PAGE Illustration 7 1 D2 D4 SCR Diode Module 2 of 4 1 Retaining screws Step 9 7 IGBT output retaining screws Step 7 2 Retaining nut Step 8 8 Retaining screws Step 9 3 IGBT module 9 Intermediate IGBT output bus bar BB30 Step 8 4 Main DC bus bar BB25 Step 9 10 Bus bar BB31 5 Bus bar BB27 11 Bus bar BB30 6 Bus bar BB26 MG 90 L1 02 VLT is a registered Danfoss trademark 137 7 D Frame Sizes Disassembly and Assembly Power Service Manual for VLT FC Series Instructions Frequency Converters NB Note which gate leads are attached to which module to ensure that the leads are reconnected to the correct modules upon reassembly 10 Remove the rectifier DC bus bars by removing the 3 screws T25 connecting each rec tifier DC bus bar to standoffs on the SCR diode modules 130BX185 10 Bus bar BB27 Bus bar BB28 Retaining screws Step 10 Rectifier DC bus bars BB23 or BB24 per drive power rating Step 10 138 MG 90 L1 02 VLT is registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 11 Remove the SCR gate lead connectors from the modules
57. Remove the control assembly support bracket Reinstall in reverse order of this procedure Tighten the mounting screws to 4 Nm 35 in Ibs 154 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 8 E Frame Sizes Disassembly and Assembly Frequency Converters Instructions 8 2 3 Power Card Remove the control assembly support bracket in accordance with procedure Unplug power card connectors 100 MK102 105 MK106 107 and MK109 If customer connections are present unplug connectors 102 FK103 and MK112 Remove the 7 mounting screws T25 Torx from the power card Remove the power card from the plastic standoff at the top right of the power card Ow OT Remove the current scaling card from the power card by pushing in the retaining clips on the standoffs KEEP THIS SCALING CARD FOR FUTURE REINSTALLATION OF ANY REPLACEMENT POWER CARD The scaling card controls signals operating with this spe cific frequency converter The scaling card is not part of the replacement power card Reinstall in reverse order of this procedure When installing the power card ensure that the in sulator sheet is installed behind the power card Tighten the mounting screws to 2 3 Nm 20 in Ibs 130BX172 10 Illustration 8 1 Power Card and Mounting Plate 380 480 500V Yellow tape on the main SMPS 525 690V White tape on the main SMPS transformer in the upper ri
58. check for faulty reference signals Motor speed unstable Possible incorrect parameter settings faulty current feedback circuit loss of motor output phase Check the settings of all motor parameters including all motor compensation settings Slip Com pensation Load Compensation etc For Closed Loop operation check PID settings Perform Input Terminal Signal Test 6 3 16 to check for faulty reference signals Perform the Output Imbalance of Supply Voltage Test 6 3 10 to check for loss of motor phase Motor runs rough Possible over magnetization incorrect motor settings or an IGBT misfiring Note Motor may also stall when loaded or the frequency converter may trip occasionally on Alarm 13 Check setting of all motor parameters Perform the Output Imbalance of Supply Voltage Test 6 3 10 If output voltage is unbalanced perform the Gate Drive Signal Test 6 3 11 Motor draws high current but cannot start Possible open winding in motor or open phase in connection to motor Perform the Output Imbalance of Supply Voltage Test 6 3 10 to ensure the frequency converter is providing correct output see Motor Runs Rough above Run an AMA to check the motor for open windings and unbalanced resistance Inspect all motor wiring connections Motor will not brake Possible fault in the brake circuit Possible incorrect setting in the brake parameters The ramp down time too short Note May be accompanied by an alarm or warnin
59. uey 5v doj 100q 00dI ue4 dol 2d 24 eJeds Y ue4 10001 eJeds 9UJ amp J4 3 Wy 3u9A 4000 9 5 784 uey 40001 Assy suey 41 deop aweiy ueg qv aieds ANT AOSZT jeqqnus 1891 dyd Hed SES849ZT CV 839 T 9 S8492T 0 8 9 0 8 9 922849 1 6 S8492T 8 9 8 9 659849 1 CEESAOZT 8 9 0 8497T 6 lt lt 8 9 1 CES8AOZT vES8s9ZT TUL vnd snd c Tnd bd TO Ts 0T 6 8 9 J4o3eubi 197 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List I I I I I I I I I I I I T T T T T T T T I I I I I I I I I I I I I I I vs Tc vs Tc vs Tc vs Tc vs Tc I I I I I I I I I I I I I I I pSdI 6541 5 I I I I I X06d 5 524 SGd 524 SGd Grd JVA 069 SZS abieyd Yos 2 yos 0 Jamod 3ndui
60. 0 24 which can be accessed via QUICK MENU Q3 Function Setups Q3 1 General Settings Q3 13 Display Settings Each value measurement readout parameter selected in par 0 20 Display Line 1 1 5 0 24 Display Line 3 Large has its own scale and number of digits after a possible decimal point Larger numeric values are displayed with few digits after the decimal point Ex Current readout 5 25 A 15 2 A 105 A 24 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 42 Operator Interface and Frequency Converter Frequency Converters Control Status display 1 This readout state is standard after start up initialisation 6 Use INFO to obtain information about the B value measurement linked to the displayed operating variables 1 1 1 2 1 3 2 and 3 See the operating variables shown in the dis play in this illustration 1 1 1 2 and 1 3 are shown in small size 2 and 3 are shown in me dium size Status display 11 See the operating variables 1 1 1 2 1 3 and 2 shown in the display in this illustration In the example Speed Motor current Motor power and Frequency are selected as varia bles in the first and second lines 1 1 1 2 and 1 3 are shown in small size 2 is shown in large size 130 062 10 C2 o Status display 111 This state displays the event and action of the Smart Logic Control The Bottom section always shows
61. 19 Nm 170 165 and the 13 mm or T40 Torx screw to 9 5 Nm 85 in Ibs 130BX106 10 Illustration 8 1 Terminal Blocks 1 Retaining nuts Step 3 3 Terminal block insulation Step 4 or 5 2 Retaining nut Step 2 MG 90 L1 02 VLT is a registered Danfoss trademark Instructions 167 8 E Frame Sizes Disassembly and Assembly ish Power Service Manual for VLT FC Series Instructions Frequency Converters 8 2 13 Modules Remove both DC capacitor banks accordance with the procedure Remove the Input Terminal Plate in accordance with procedure Remove the wire retaining nut 10 mm from each of the 3 SCR input bus bars oe Note colour coding for each of the 3 wires attached to the retaining studs Ensure that the correct wire is attached to the applicable stud upon reassembly Remove the wiring from the studs 5 Remove the wire retaining nut 8 mm from the SCR output bus bars One from the DC bus bar and one from the DC bus bar 6 Note colour coding for each wire attached to the retaining studs Ensure that the correct wire is attached to the applicable stud upon reassembly Remove the wiring from the studs 7 Remove the 4 retaining nuts 13 mm on the side of the bus bars 2 on each bus bar CONTINUED NEXT PAGE 130BX130 10 58
62. 2 11 Soft charge fuses DC inductor L1 Fan transformer TR1 IGBT module 2 3 SCR and Diode SCR1 SCR2 SCR3 and D1 D2 D3 Fan inductor not on all units Soft charge resistor assy R1 IGBT output bus bar Fan assembly F1 C1 Output motor terminals TB2 Current sensor L2 L3 L4 Main AC power input terminals TB1 Input terminal mounting plate assembly AC input bus bar Soft charge card PCA12 Lower capacitor bank assembly CBANK1 PCA10 MG 90 L1 02 VLT is a registered Danfoss trademark 17 1 Introduction 1 9 Ratings Tables 18 high Power Service Manual for VLT FC Series Frequency Converters DC Voltage Levels 380 480 and 380 500 units 525 690 units Inrush Circuit Enabled 370 VDC 548 VDC Inrush Circuit Disabled 395 VDC 600 VDC Inverter Undervoltage Disable 402 VDC 553 VDC Undervoltage Warning 423 VDC 585 VDC Inverter Undervoltage Re Enable warning re 442 VDC 602 VDC set Overvoltage Warning without brake 817 VDC 1084 VDC Dynamic Brake Turn On 810 VDC 1099 VDC Inverter Overvoltage Re Enable warning re 821 VDC 1099 VDC set Overvoltage Warning with brake 828 VDC 1109 VDC Overvoltage Trip 855 VDC 1130 VDC Mains supply 3 x 380 480 500 V Model number FC102 202 110 132 P160 P200 P250 FC302 P90K P110 P132 P160 P200 Normal overload current ratings 110 Output current Nominal A 380 440 V 212 260 315 395 480 60 sec A 38
63. 2 6849 1 5958 9 958 9 8 9 0 lt 8 9 6 8439 T 822849 1 45 2849 1 6098 9 849 1 8492 922849 1 lt 648 9 165849 1 922849 1 849 1 deds TMS TMS TMS TMS S1 TUL TUL TUL vec snd MG 90 L1 02 VLT is a registered Danfoss trademark 180 High Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List 1511 sued eJeds 0 eiqer vs Tc 0 00 OStd 04 vs Tc 0041 SS d STEd 0929 00 4 SSEd STEd OObd SSEd STEd bSdI 00 0S d bSdI 09Td 0044 00 va ca bSdI 09Td 09Td DIVA 005 2VA 064 coe 24 zoz DA 601 24 1891 0 psed e3eb 1991 o3 pe sseuJeu 1891 03 psed 55 03 1991 uon euuoo Jed T 1991 03 QA Jad 1891 p423
64. 24 Ajquiasse 103sisa1 YOS pue YS T 19 Jed 1851 T 4J Jed 1891 T yueg de aseds peg aouejeg yueg 3expeiq 305 Aouenbaj4 p1eog p129 UO SJ e3suT pied 5 payeod pied Buljeos p4e5 pa3eoo psed pied Buie s pIe paeo 5 pa3eoo psed pied Buie s epnpui psed pied 5 pJe pied Buljeos pied 5 pa3eoo pJe pied 25 psed pied 5 PLOI pJe pied Buljeos pJe paeo 5
65. 33 Inrush fault X X 34 Fieldbus communication fault X X 36 Mains failure X X 38 Internal fault X X 39 Heatsink sensor X X 40 Overload of Digital Output Terminal 27 X 41 Overload of Digital Output Terminal 29 X 42 Overload of Digital Output on X30 6 or Overload of Digital X Output on X30 7 46 Power card supply X X 47 24 V supply low X X X 48 1 8 V supply low X X 49 Speed limit X 50 AMA calibration failed X 5 AMA check Unom and Inom X 52 AMA low Inom X 53 AMA motor too big X 54 AMA motor too small X 55 AMA parameter out of range X 56 AMA interrupted by user X 57 AMA time out X 58 AMA internal fault X X 59 Current limit X 60 External interlock X 61 Encoder loss X X 62 Output frequency at maximum limit X X 63 Mechanical brake low X 64 Voltage limit X 65 Control board overtemperature X X X 66 Heatsink temperature low X 67 Option configuration has changed X 68 Safe stop activated X xp 69 Power card temperature X X 70 Illegal FC configuration X 71 1 safe stop X X 72 Dangerous failure X X X 73 Safe stop auto restart X 79 Illegal PS config X X 80 Drive initialised to default value X 81 CSIV corrupt X 82 CSIV parameter error X 90 Encoder loss X X 9t Analog input 54 wrong settings X 92 No flow X X 93 Dry pump X X 94 End of curve X X 95 Broken belt X X 96 Start delayed X 97 Stop delayed X 98 Clock fault X 100 199 See Operating Instructions for MCO 305 200 Fire mode X 201 Fire mode was
66. 380 500 P160 P160 P132 3 1 380 500 P200 P200 P160 2 6 380 500 P250 P250 P200 5 1 380 500 P315 P315 P250 4 2 380 500 P355 P355 P315 2 6 380 500 P400 P400 P355 2 6 380 500 P450 P450 P400 2 3 525 690 P45K P45K P37K 5 9 525 690 P55K P55K P45K 5 9 525 690 P75K P75K P55K 5 9 525 690 P90K P90K P75K 5 9 525 690 P110 P110 P90K 5 9 525 690 P132 P132 P110 5 9 525 690 P160 P160 P132 4 5 525 690 P200 P200 P160 3 1 525 690 P250 P250 P200 3 1 525 690 P315 P315 P250 2 6 525 690 P400 P400 P315 5 1 525 690 P450 P450 P355 4 5 525 690 P500 P500 P400 4 5 525 690 P560 P560 P500 3 8 525 690 P630 P630 P560 2 6 Table 6 2 Scaling Card Resistance Values 6 3 15 Fan Tests The fan control circuit is made up of the fan transformer and the control circuitry located on the power card along with control signals for ON OFF and speed control from the control card Since the fans do not necessarily run at all times see the description for cooling fan operation under sequence of operation in Section 3 3 5 Supply voltage Supply voltage for the fans is from the soft charge card to power card connector 106 First verify the supply voltage is present as follows 1 Use a voltmeter to measure the AC phase to phase voltage at R S and T of power card connector MK106 It should equal main supply voltage applied to frequency converter 2 If voltage is not present ensure proper mains voltage is applied to frequency converter Conduct Input Voltage test 6 3 2
67. 4 Nm 35 in Ibs 130BX77 10 Illustration 7 1 02 04 Soft Charge Resistor 380 480 500 Clear wire leads 525 690V Black wire leads Bus bars BB27 do not remove Soft charge resistor Retaining nut loosen Step 3 MG 90 L1 02 VLT is a registered Danfoss trademark 131 7 D Frame Sizes Disassembly and Assembly high Power Service Manual for VLT FC Series Instructions Frequency Converters 7 2 9 Soft Charge SC Resistors D1 D3 Units 1 Remove the capacitor bank per instructions 2 Remove the input terminal mounting plate per instructions 3 Note the colour coding for each of three wires attached to terminal 1 for each SCR diode module Ensure that the correct wire is attached to the applicable stud during reassembly Remove the wiring from the studs Remove the retaining screw T25 from terminal 1 of each of 3 SCR diode modules and remove the bus bar CONTINUED ON NEXT PAGE 05 gt L7 7 No 130BX87 10 Illustration 7 1 D2 D4 Soft Charge Resistor 1 of 3 380 480 500V Clear wire leads 525 690 Black wire leads 1 Soft charge resistor 2 Bus bar BB2 Step 3 3 Retaining screw Step 3 132 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 4 Rem
68. 5 2 5 Sources of EMI Modern frequency converters see Illustration 5 1 utilise Insulated Gate Bipolar Transistors IGBTs to provide an efficient and cost effective means to create the Pulse Width Modulated PWM output waveform necessary for accurate motor control These devices rapidly switch the fixed DC bus voltage creating a variable frequency variable voltage PWM waveform This high rate of voltage change dV dt is the primary source of the frequency converter generated EMI The high rate of voltage change caused by the IGBT switching creates high frequency EMI 82 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 5 Frequency Converter and Motor Applications Rectifier DC Bus Inverter 130BX137 10 Filter reactor IGBT Filter capacitor Sine wave PWM waveform Illustration 5 1 Frequency Converter Functionality Diagram 5 2 6 EMI Propagation Frequency converter generated EMI is both conducted to the mains and radiated to nearby con ductors See Illustrations 5 2 and 5 3 Motor cable 130BX138 11 Stray capacitance Ground Potential 1 Potential 2 Potential 3 Illustration 5 2 Earth Currents Stray capacitance between the motor conductors equipment earth and other nearby conductors results in induced high frequency currents High earth circuit impedance at hi
69. 74 5 rectifier module ALARM 244 Heatsink temperature This alarm is only for F Frame frequency converters It is equivalent to Alarm 29 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or F4 drive 2 right inverter module in F1 or F3 drive 3 right inverter module in F2 or drive 5 rectifier module ALARM 245 Heatsink sensor This alarm is only for F Frame frequency converters It is equivalent to Alarm 39 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or F4 drive 2 right inverter module in F1 or F3 drive 3 right inverter module in F2 or F4 drive 5 rectifier module ALARM 246 Power card supply This alarm is only for F Frame frequency converters It is equivalent to Alarm 46 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or F4 drive 2 right inverter module in F1 or F3 drive 3 right inverter module in F2 or F4 drive 5 rectifier module ALARM 247 Power card temperature This alarm is only for F Frame frequency converters It is equivalent to Alarm 69 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in
70. A minimum 100 mm 4 in extension is required 3 Remove the 4 retaining nuts 10 mm from the cap bank cover plate and remove the cover plate 4 Note that the weight of the cap bank is approximately 9 kg 20 Ibs Remove the bank by pulling it free from the mounting studs Reinstall in reverse order of this procedure Tighten the mounting screws to 4 Nm 35 in lbs 130BX73 10 Illustration 7 1 D2 D4 Upper and Lower Capacitor Bank Assemblies 380 480 500 Blue DC Link Capacitors 525 690V Black DC Link Capacitors 1 Upper cap bank assy retaining nuts step 2 4 Lower cover plate retaining nut step 3 2 Upper cover plate Gate drive card 3 Upper cover plate retaining nut step 3 6 Lower cap bank assy retaining nuts step 1 MG 90 L1 02 VLT is a registered Danfoss trademark 129 7 D Frame Sizes Disassembly and Assembly high Power Service Manual for VLT FC Series Instructions Frequency Converters Lower capacitor bank D2 D4 units 1 Capacitor bank connection to DC bus bars can be seen recessed in the gap between upper and lower cap banks Remove the 2 cap bank retaining nuts 10 mm furthest to the right from the DC bus bars A minimum 100 mm 4 in extension is required 2 Note that the IGBT gate drive card can remain attached to the cap bank cover plate Disconnect M
71. Biseq MG 90 L1 02 VLT is a registered Danfoss trademark 188 High Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List suey pue sJoj ede sjo3sises s1oynpuoolules 451 sued eJeds TT 0T 21921 0954 0 9d 0 9d v 9 16 0041 0041 vSdI v 9 16 v S Tc 9 16 T 0064 00 0954 0064 0954 006 bS TZ 56 72 vs Tc 041 0041 004 0041 bSdl 54 pSdI bS TZ 96 72 vS TZ bS TZ bS TZ 96 72 9 12 s e 6 9 9 9 cup o E E E z Z Zz g o al SS d 6164 OSZd 0024 OSbd 00 4 5764 0524 05 4 00 4 STEd 0524 IVA 069 526 v s Tc 0041 v s Tc v 09Td 0044 00 vs Tc vs Tc 0041 0041 vSdI vs Tc vs Tc vs Tc vs Tc COE DA O9Td 20604 097 20134 4ad ue ue 40001 pSdI TZdI 198 uey Ajuo ue4 dol 0041 GA Ajuo ue uey 401 0041 OT S 1000 Qn Jad quan sJeue1sej uoddns sapnjouy yy 3u9A 10001 Jed suauaysey uioddns 5 16 uej sepnpug 1000 Se qe uey
72. D3 D1 D3 D1 D3 Current Sensors Fan Assembly 1 of 2 Fan Assembly 2 of 2 AC Input Terminals no options shown D2 D4 D2 D4 D2 D4 D1 D3 D1 D3 Control Card Access Power Card and Mounting Plate Soft Charge Card Gate Drive Card Upper and Lower Capacitor Bank Assemblies 116 124 125 127 128 129 130 131 132 133 134 135 136 137 139 140 141 142 143 144 145 146 147 148 149 150 151 154 155 156 157 159 Input Terminal Mounting Plate Assy shown with RFI and mains fuse options Soft Charge Resistor SCR and Diode Modules 1 of 3 SCR and Diode Modules 2 of 3 SCR and Diode Modules 3 of 3 Current Sensors MG 90 L1 02 VLT is a registered Danfoss trademark 160 161 162 163 164 165 Danfoss Power Service Manual for VLT FC Series Contents Frequency Converters Illustration 8 1 Fan Assembly 166 Illustration 8 1 Terminal Blocks 167 Illustration 8 1 IGBT Modules 1 of 4 168 Illustration 8 1 IGBT Modules 2 of 4 169 Illustration 8 1 IGBT Modules 3 of 4 170 Illustration 8 1 IGBT Modules 4 of 4 171 Illustration 9 1 SCR Shorting Plug 173 Illustration 9 2 Two pin 173 Illustration 9 3 Three pin 173 Illustration 9 4 Signal Test Board 174 8 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters Contents Table Table 1 1 Table 1 2 Table 1 3 Table 1 4 Table 1 5 Table 1 6 Table 1 7 T
73. D4 P250 250 350 D2 D4 P315 315 450 E1 E2 P355 355 500 E1 E2 P400 400 550 E1 E2 P450 450 600 E1 E2 Table 1 1 FC 102 and FC 202 380 480 VAC 380 500 VAC Power Model FC 302 High Normal Overload 2400 VAC HP 460 VAC kw 500 VAC Frame Size P90K 90 110 125 150 110 132 D1 D3 P110 110 132 150 200 132 160 D1 D3 P132 132 160 200 250 160 200 D2 D4 P160 160 200 250 300 200 250 D2 D4 P200 200 250 300 350 250 315 D2 D4 P250 250 315 350 450 315 355 E1 E2 P315 315 355 450 500 355 400 E1 E2 P355 355 400 500 550 400 500 E1 E2 P400 400 450 550 600 500 530 E1 E2 Table 1 2 FC 302 380 500 VAC MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 1 Introduction 525 690 VAC Power Model FC 102 and FC 202 VLT AQUA Drive kW 550 VAC HP 8575 kW 2690 Frame Size P45K 37 50 45 D1 D3 P55K 45 60 55 D1 D3 P75K 55 75 75 D1 D3 75 100 90 D1 D3 P110 90 125 110 D1 D3 P132 110 150 132 D1 D3 P160 132 200 160 D1 D3 P200 160 250 200 D2 D4 P250 200 300 250 D2 D4 P315 250 350 315 D2 D4 P400 315 400 400 D2 D4 P450 355 450 450 E1 E2 P500 400 500 500 E1 E2 P560 450 600 560 E1 E2 P630 500 650 630 E1 E2 Table 1 3 FC 102 and FC 202 525 690 VAC 525 690 VAC Power Model FC 302 High Normal Overload kW 8550 HP 0575 kW 9690
74. DC Brake Cut In Speed RPM a Stop com mand e g Stop inverse is active 2 DC Brake inverse is selected as a function for a digital input parameter group 5 1 The corresponding terminal is not active 3 The DC Brake is activated via serial communication DC Voltage UO In par 1 01 Motor Control Principle U f and in par 1 80 Function at Stop DC Voltage UO is selected A Stop command e g Stop inverse is activated The voltage selected according to the par 1 55 U f Characteristic U 0 UF Characteristic U V is applied to the motor Feedback high In par 4 57 Warning Feedback High an upper feedback limit is set The sum of all active feed backs is above the feedback limit Feedback low In par 4 56 Warning Feedback Low a lower feedback limit is set The sum of all active feedbacks is below the feedback limit Flying start In par 1 73 Flying Start the Flying start function is activated The FC is testing if the connected motor is running with a speed that is in the adjusted speed range The process was started by connecting a digital input parameter group 5 1 programmed as Coast inverse or by connecting to mains Freeze output The remote reference is active and the momentarily given speed is saved 1 Freeze output was selected as a function for a digital input Group 5 1 The corre sponding terminal is active Speed control is only possible via the terminal functions Speed up and Speed down
75. Equipment Frequency Converters To install the cable first make sure the frequency converter is powered down and the DC bus is fully discharged 1 For D frame size units follow the procedure in Section 7 for soft charge card removal and disengage the soft charge card far enough to disconnect the cable plugged into the 2 Forall frame sizes disconnect the cable from the MK3 connector on the soft charge card and connect one end of the test cable into the MK3 For D frame size units reinstall the soft charge card For all frame sizes disconnect connectors MK100 and MK105 on the power card For all frame sizes connect the free end of the test cable into MK105 For all frame sizes connect the SCR gate shorting plug into the cable that was removed from MK100 When reapplying main input power to the frequency converter the soft charge rectifier provides DC power to the power card Testing with the use of the gate signal board and the signal test board can now be carried out without the presence of DC bus voltage 9 1 2 Signal Test Board p n 176F8437 The signal test board provides access to a va riety of signals that can be helpful in trouble shooting the frequency converter The signal test board is plugged into power card connector MK104 Points on the signal test board can be monitored with or without the DC bus disabled In some cases the fre quency converter will need the DC bus ena bled and oper
76. F2 or F4 drive 2 right inverter module in F1 or F3 drive 3 right inverter module in F2 or F4 drive 5 rectifier module ALARM 248 Illegal power section configuration This alarm is only for F frame frequency converters It is equivalent to Alarm 79 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or F4 drive 2 right inverter module in F1 or F3 drive 3 right inverter module in F2 or F4 drive 5 rectifier module ALARM 250 New spare part The power or switch mode power supply has been exchanged The frequency converter type code must be restored in the EEPROM Select the correct type code in par 14 23 7ypecode Setting according to the label on the unit Remember to select Save to EEPROM to complete MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss 4 Troubleshooting Frequency Converters ALARM 251 New type code The frequency converter has a new type code 4 7 After Repair Tests Following any repair to a frequency converter or testing of a frequency converter suspected of being faulty the following procedure must be followed to ensure that all circuitry in the frequency converter is functioning properly before putting the unit into operation 10 Perform visual inspection procedures as described in Table 3 1 Perform static test procedures 6 2 1
77. FC Series 1 Introduction Frequency Converters 16 130BX166 10 Illustration 1 2 Exploded view D4 frame size D2 frame is similar 1 Control card PCA1 15 IGBT module IGBT1 2 2 Control input terminals 16 SCR Diode module SCR1 2 3 3 Local Control Panel LCP 17 IGBT output bus bar 4 Control card C option 18 Output motor terminals TB2 5 Mounting bracket 19 Current sensor L2 L3 L4 6 Power card mounting plate 20 Fan assembly F1 C1 CBL11 7 21 Main AC power input terminals TB1 8 Upper capacitor bank cover plate 22 AC input bus bar 9 Upper capacitor bank assembly CBANK2 10 23 Input terminal mounting plate assembly 10 Soft charge fuses 24 Fan transformer TR1 11 Soft charge card PCA11 25 Fan fuse FU4 12 DC inductor L1 26 Lower capacitor bank assembly CBANK1 PCA9 13 Soft charge resistor assy R1 CBL26 27 Lower capacitor bank cover plate 14 IGBT snubber capacitors C2 C3 C4 C5 C6 7 28 IGBT gate drive card 5 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Frequency Converters 19 18 Dont 1 Introduction 130BX168 10 Illustration 1 3 Exploded view E2 frame size E1 frame is similar Control card PCA1 Control input terminals Local Control Panel LCP Control card C option Mounting bracket Power card mounting plate Power card PCA3 IGBT gate drive card PCA5 Upper capacitor bank assembly
78. HA eporp eds 3 ZL VO t YDS eds 7717082 VA 25 eds 771 v09T 425 eds 33 i 1991 exeig ejeds 3771 VOSt WA 1891 24 Heds 2771 V00 WA 1991 24 Heds ZL VOS 39 1891 24 Heds 1 v00 1891 24 S4032npuooiues oweN 8 9 8 9 659849 1 2 684921 8 9 0 849 T 6 8849 1 84858494T 6 lt lt 8 9 1 859849 1 48 9 c 8839 T 48 9 97849 1 48 9 SEV84397T 8 9 0 lt 58 9 6458 9 912849 1 929849 1 lt 98 9 98 9 TE98494T JequinN 4 v T9414 T T4 T0414 Z DINVED C DINVSD Z DINVEO OT 6 8 Z 94571248 09 Ta 2 0 1405 2 0 1405 2 0 1405 51851 2 11891 E 1 991 7 TLEDI 211851 wep 189 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List I I I I I I I I I I T 0 0 0 0 0 I I I I I I I I 6 I I I T m 0 I I I I I I I I I I I I T ydq
79. Illustration 8 1 Upper and Lower Capacitor Bank Assemblies 1 Upper capacitor bank assy Lower capacitor bank assy 2 Upper cap bank assy electrical connection nuts Step 6 Gate drive card 2 3 Lower cap bank assy electrical connection nuts Step 7 Upper cap bank assy retaining nut Step 4 2 4 Lower cap bank assy retaining nut Step 3 Soft charge card 380 480 500 Blue DC Link Capacitors 525 690V Black DC Link Capacitors 380 480 500V Blue MOV and 8 PTCs 525 690 Red MOV and 6 PTCs MG 90 L1 02 VLT is a registered Danfoss trademark 159 8 E Frame Sizes Disassembly and Assembly sn Power Service Manual for VLT FC Series Instructions Frequency Converters 8 2 7 Input Terminal Mounting Plate Assy Option 160 The frequency converter has component options that can be mounted on the input mounting plate This results in differing unit configurations These options include input terminal blocks input disconnect RFI filter input fuses and an additional cooling fan These options may need to be removed from the mounting plate assembly to reduce the weight of the assembly for ease of removal 1 Disconnect the input power wiring from terminals L1 L2 L3 and earth connector 2 Remove the upper most bus bar retaining nut 17 mm from each of three terminals 3 If a disconnect not shown is mounted remove the disconnect from the terminal plate assembly to reduce the weight of the
80. Power EEPROM data version mismatch Cannot read Digital Signal Processor soft ware version Option SW in slot A is too old Option SW in slot B is too old Option SW in slot CO is too old Option SW in slot C1 is too old Option SW in slot A is not supported not al lowed Option SW in slot B is not supported not al lowed Option SW in slot is not supported not allowed Option SW in slot C1 is not supported not allowed Option A did not respond when calculating Platform Version Option B did not respond when calculating Platform Version Option did not respond when calculating Platform Version Option C1 did not respond when calculating Platform Version An exception in the Application Orientated Control is registered Debug information written in LCP ALARM 39 Heatsink sensor No feedback from the heatsink temperature sensor 1792 2049 2064 20 72 2080 20 88 2096 21 04 2304 2305 2314 2315 2316 2324 2325 2326 2327 2330 2561 2562 2816 2817 2818 2819 2820 2821 2822 2836 3072 51 22 5123 5124 5125 5126 5376 62 31 DSP watchdog is active Debugging of pow er part data Motor Orientated Control data not transferred correctly Power data restarted H081x option in slot x has restarted H082x option in slot x has issued a power up wait H083x option in slot x has issued a legal power up wait Could not read any data from power EE PROM Missing SW vers
81. Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List 00 OStd OStd STEd OScd 0 SSEd STEd 00 4 SSEd STEd 00 0Scd O9Td 06 0044 09 4 0044 O9Td OVA 005 086 2 08 086 cOE 24 zoz 24 cot 24 pjeoq A uanbaJJ ubiu 104 AouanbaJ 10 3expeiq 09 3sl sped ejeds 60 pued apis 0041 pued epis EC 0041 pub 4H pug eieds pub 4H pug e1eds 09 ejqe lt oweN 80 8 9 9827849 1 4 lt 8 9 6 8 9 06 8 9 0 8 9 Syed eia MG 90 L1 02 is a registered Danfoss trademark 186 High Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List 0954 0 9d 0 9d 00564 00 0954 0054 0954 0054 m NE _ zu 0 ZOT SS d STEd 0644 0024 055 OStd 00 STEd OSZd 056 OStd 00 4 STEd OScd JVA 069 SZS 09
82. Test Equipment SCR s for fan volt age control In sync with line freq MG 90 L1 02 VLT is a registered Danfoss trademark am 4076 2msDv 7 trigger pulses at 3Khz Pin Sche Function Description Reading Using a Digital Voltmeter No matic Acro nym 1 IU1 Current sensed amo rata E 937 165 of CT current U phase not con i rating AC waveform output frequen ditioned ZI x Cy of the frequency converter EN Approx 400 mv RMS 100 load 2 IVi Current sensed 937 VACpeak 165 of CT current V phase not con i rating AC waveform 9 output frequen ditioned 3 Toy P Cy of the frequency converter LUNET Approx 400 RMS 100 load 3 Current sensed zmo mot 937 165 of CT current W phase not i rating AC waveform output frequen ditioned so a cy of the frequency converter Sa LUNETA 2 Approx 400 RMS 100 load 4 COM Logic common This common is
83. Warning Degrees C 0 0 0 0 0 Power Card Ambient Overtemperature Degrees C 60 60 60 60 60 Power Card Ambient Overtemperature Degrees 20 20 20 20 20 Mains Phase Warning 5 sec delay DC Bus Ripple VAC 70 70 70 70 70 Mains Phase Alarm 25 sec delay DC Bus Ripple VAC 70 70 70 70 70 MG 90 L1 02 VLT is a registered Danfoss trademark 21 1 Introduction 22 high Power Service Manual for VLT FC Series Frequency Converters Mains supply 525 690 V Model number FC102 202 P450 P500 P560 P630 FC302 P355 P400 P500 P560 Normal overload current ratings 11096 Output current Nominal A 525 550 V 470 523 596 630 60 sec A 525 550 V 517 575 656 693 551 690 450 500 570 630 60 sec A 551 690 V 495 550 627 693 Output Nominal kVA 550 V 448 498 568 600 Nominal kVA 575 V 448 498 568 627 Nominal kVA 690 V 538 598 681 753 Typical shaft output kW 550 V 355 400 450 500 HP 575 V 450 500 600 650 kW 690 V 450 500 560 630 High overload torque 160 Output current Nominal A 525 550 V 395 429 523 59 60 sec A 525 550 V 593 644 785 894 551 690 380 410 500 570 60 sec A 551 690 V 570 615 750 855 Output Nominal kVA 550 V 376 409 498 568 575 376 408 498 568 Nominal kVA 690 V 454 490 598 681 Typical shaft output kW 550 V 315 315 400 450 HP 575
84. current waveform that nearly replicates a true AC sine wave This waveform as generated by the Danfoss VVCplus PWM principle at the control card provides optimal performance and minimal losses in the motor Hall effect current sensors monitor the output current and deliver proportional signals to the power card where they are buffered and delivered to the control card These current signals are used by the control card logic to determine proper waveform compensations based on load conditions They further serve to detect overcurrent conditions including earth faults and phase to phase shorts on the output During normal operation the power card and control card are monitoring various functions within the frequency converter The current sensors provide current feedback information The DC bus voltage and mains voltage are monitored as well as the voltage delivered to the motor A thermal sensor mounted inside one of IGBT modules provides heatsink temperature feedback 130BX136 10 Illustration 3 6 Output Voltage and Current Waveforms MG 90 L1 02 VLT is a registered Danfoss trademark 51 ish Power Service Manual for VLT FC Series 3 Internal Frequency Converter Operation Frequency Converters
85. experienced and AMA has not been performed it should be done AMA can only be performed on single motor applications within the programming range of the frequency converter Consult the Operating Instructions for more on this function Parameters 1 30 and 1 35 as stated should be set by the AMA function values supplied by the motor manufacturer or left at the factory default values Never adjust these parameters to random values even though it may seem to improve operation Such adjustments can result in unpredict able operation under changing conditions MG 90 L1 02 VLT is a registered Danfoss trademark 77 ish Power Service Manual for VLT FC Series 5 Frequency Converter and Motor Applications Frequency Converters par 4 17 Torque Limit Generator Mode sets the limit for frequency converter torque The factory setting is 160 for FC 302 series and 110 for FC 102 202 series and will vary with motor power setting For example a frequency converter programmed to operate a smaller rated motor will yield a higher torque limit value than the same frequency converter programmed to operate a larger size motor It is important that this value not be set too low for the requirements of the application In some cases it may be desirable to have a torque limit set at a lesser value This offers protection for the application in that the frequency converter will limit the torque It may however require higher torque at initial start up U
86. for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 7 2 10 Input Terminal Mounting Plate Assembly 1 Disconnect the input power wiring from L1 L2 L3 and earth connection 2 Remove the upper most bus bar retaining nuts 13 mm from the AC power input bus bars L1 L2 and L3 3 Disconnect the fan autotransformer cable at the in line connector 4 Remove the 4 or 5 10 mm retaining nuts varies with size from the mounting plate The input terminal mounting plate weighs approximately 7 27 kg 15 60 165 de pending on the mounted options 5 Remove the entire assembly from the mounting studs Reinstall in reverse order of this procedure Tighten the 10 mm mounting nuts to 4 Nm 35 in Ibs and the 13 mm nuts to 9 5 Nm 85 in Ib 130BX81 10 Illustration 7 1 Input Terminal Mounting Plate Assembly no options shown 380 480 500V White label on fan transform 525 690 Orange label on fan transformer er Input power connector Step 1 Bus bar retaining nuts shown removed Step 2 Transformer connector Step 3 Retaining nuts Step 4 MG 90 L1 02 VLT is a registered Danfoss trademark 135 7 D Frame Sizes Disassembly and Assembly high Power Service Manual for VLT FC Series Instructions Frequency Converters 7 2 11 SCR Diode Module D2 D4 Units Remove the lower DC capacitor ban
87. from Gate Drive Card IGBT Gate Signal measured on the Gate Drive Card 5 volts per division vertical scale 50 microseconds per division time scale Unit running at 30 Hz MG 90 L1 02 VLT is a registered Danfoss trademark 115 High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters Contents Illustration 6 19 Gate Signal Waveform from Signal Test Board IGBT Gate Signal measured with the Signal Test Board 2 volts per division vertical scale 50 microseconds per division time scale Unit running at 30 Hertz Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 7 1 Illustration 8 1 Illustration 8 1 Illustration 8 1 Illustration 8 1 Illustration 8 1 Illustration 8 1 Illustration 8 1 Illustration 8 1 Illustration 8 1 Illustration 8 1 Illustration 8 1 Control Card Access Power Card and Mounting Plate Soft Charge Card Assy Gate Drive Card D2 D4 D1 D3 D2 D4 D2 D4 D1 D3 D1 D3 Input Terminal Mounting Plate Assembly no options shown D2 D4 D2 D4 D2 D4 D1
88. high the frequency converter switches the resistor across the DC bus and dissipates the unwanted energy into the external resistor bank mounted outside of the frequency converter This will actually increase the rate of deceleration Less often is the case that the overvoltage condition is caused by the load while it is running at speed In this case the dynamic brake option can be used or the overvoltage control circuit It works with the load in this way As stated earlier regeneration occurs when the speed of the load is greater than the commanded speed Should the load become regenerative while the frequency converter is running at a steady state speed the overvoltage circuit will increase the frequency to match the speed of the load The same restriction on the amount of influence applies The 78 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series 7 44 Frequency Converters 5 Frequency Converter and Motor Applications frequency converter will add about 1096 to the base speed before a trip occurs Otherwise the speed could continue to rise to potentially unsafe levels 5 1 2 Mains Phase Loss Trips The frequency converter actually monitors phase loss by monitoring the amount of ripple voltage on the DC bus Ripple voltage on the DC bus is a product of a phase loss The main concern is that ripple voltage causes overheating in the DC bus capacitors and the DC coil Left unchecked the lifetime o
89. in parameter 4 53 or low limit set in parameter 4 52 In Process Control Closed Loop par 1 00 Configuration Mode this warning is displayed MG 90 L1 02 VLT is a registered Danfoss trademark 69 4 Troubleshooting WARNI NG ALARM 36 Mains failure This warning alarm is only active if the supply voltage to the frequency converter is lost and par 14 10 Mains Failure is NOT set to OFF Check the fuses to the frequency converter ALARM 38 I nternal fault It may be necessary to contact your Danfoss supplier Some typical alarm messages High Power Service Manual for VLT9 FC Series Frequency Converters 0 256 25 512 513 514 515 516 517 518 519 783 1024 1 279 1281 1282 1283 1284 1299 1300 1301 1302 1315 1316 1317 1318 1379 1380 1381 1382 1536 Serial port cannot initialised Serious hardware failure Power EEPROM data is defect or too old Control board EEPROM data is defect or too old Communication time out reading EEPROM data Communication time out reading EEPROM data Application Orientated Control cannot rec ognise the EEPROM data Cannot write to the EEPROM because a write command is on progress Write command is under time out Failure in the EEPROM Missing or invalid Barcode data in EEPROM Parameter value outside of min max limits A CAN telegram that must be sent couldn t be sent Digital Signal Processor flash time out Power micro software version mismatch
90. incorrect reading of a gate signal indicates either the power card is defective or the signal has been lost prior to arriving at the power card There is no test to verify the signals directly out of the control card The power card would be suspect if a single gate signal is incorrect The control card would be suspect if all six signals are incorrect Replace the corresponding card in accordance with the disassembly procedures in Section 7 or 8 6 3 12 IGBT Switching Test Using the test cable 176F8439 while the frequency converter is powered and the DC bus is disa bled a simple test can be made to determine if the IGBTs are actually turning on Before proceeding verify that the DC bus is in fact disabled 1 Disconnect the cable from connector MK105 on the power card With a voltmeter meas ure between white lead of the cable disconnected from MK105 and output terminals U V and W in sequence Switch between AC and DC scales Voltage should read nearly zero 2 Measure between the black lead of the same cable and the output terminals U V and W in sequence Voltage should read nearly zero With the DC bus disabled proceed using a DVM set on a diode scale 1 With the frequency converter in stop mode connect the positive meter lead to the black lead of MK105 cable disconnected from the power card 2 In sequence connect the negative meter lead to the frequency converter output ter minals U V and W The meter should i
91. infinity due to capacitance within the frequency converter being charged by the meter Incorrect reading With the Part I test connection the SCR modules are blocking current flow A short indicates a shorted SCR module Main rectifier circuit test E frames part 11 1 Reverse meter leads by connecting the negative meter lead to the positive DC bus connector MK105 A on the power card 2 Connect the positive meter lead to L1 L2 and in sequence Each reading should show open Incorrect reading With the Part II test connection the SCR modules are blocking current flow A short indicates a shorted SCR module Main rectifier circuit test E frames part 111 1 the positive meter lead to the negative DC bus connector MK105 B on the power card 2 Connect the negative meter lead to terminals L1 L2 and L3 in sequence Each reading should show a diode drop Incorrect reading With the Part III test connection the diodes in the main rectifier diode modules are forward biased The meter reads the diode drops If a short circuit or an open circuit exists the diode module is damaged Main rectifier circuit test E frames part IV 1 Reverse meter leads by connecting the negative meter lead to the negative DC bus connector MK105 B on the power card 2 Connect the positive meter lead to L1 L2 and in sequence Each reading should show infinity Each reading should show i
92. nut 8 mm from the SCR output bus bars 8842 One from the DC bus bar and one from the DC bus bar 6 colour coding for each wire attached to the retaining studs Ensure that the correct wire is attached to the applicable stud upon reassembly Remove the wiring from the studs 7 Remove the 4 retaining nuts 13 mm on the side of the bus bars 2 on each bus bar ou o 130BX105 10 1 Retaining nuts Step 7 4 Diode module 2 Wire retaining nut on bus bar BB41 Step 3 5 Wire retaining nuts for output bus bars BB42 Steps 5 amp 6 3 SCR module 162 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 7 44 8 E Frame Sizes Disassembly and Assembly Frequency Converters Instructions 8 Ifthe unit is not equipped with the load sharing option proceed to step 9 If the unit is equipped with load sharing the load share minus bus bar must be removed as follows 8a Remove the 2 retaining nuts 13 mm connecting the load share bus bar to the SCR output bus bar 8b Remove the retaining nut 17 mm connecting the load share bus bar to the load share terminal on the opposite end of the bus bar not shown 8c Remove the load share bus bar 9 Remove both positive and negative SCR output bus bars by removing the 6 con nection screws T50 There are 3 s
93. provides the unit with 24 VDC 18 VDC 18 VDC and 5 VDC operating voltage The logic and interface circuitry is powered by the SMPS The SMPS is supplied by the DC bus voltage The frequency converters can be purchased with an optional secondary SMPS which is powered from a customer supplied 24 VDC source This secondary SMPS provides power to the logic circuitry with main input disconnected It can keep units with communication options live on a network when the frequency converter is not powered from the mains Circuitry for controlling the speed of the cooling fans is also provided on the power card The gate frequency converter signals from the control card to the output transistors IGBTs are isolated and buffered on the gate drive card In units that have the dynamic brake option the driver circuits for the brake transistors are also located on this card MG 90 L1 02 VLT is a registered Danfoss trademark 45 Power Service Manual for VLT9 FC Series 3 Internal Frequency Converter Operation Frequency Converters 3 2 3 Power Section The high voltage power section consists of AC input terminals AC and DC bus bars fusing har nessing AC output and optional components The power section see Illustration 3 3 also contains circuitry for the soft charge and SCR diode modules in the rectifier the DC bus filter circuitry containing the DC coils often referred to as the intermediate or DC bus circuit and the output IGBT
94. quency converter and wait at least 20 minutes to let the frequency converter capacitors fully discharge Only a competent technician should carry out service ELECTROSTATIC DISCHARGE ESD Many electronic components within the frequency converter are sensitive to static electricity Vol tages so low that they cannot be felt seen or heard can reduce the life affect performance or completely destroy sensitive electronic components Use proper electrostatic discharge ESD procedures to prevent damage to sensitive components when servicing the frequency converter NB Frame size is used throughout this manual where ever procedures or components differ between frequency converters based upon the unit s physical size Refer to the tables in the Introduction Section to determine frame size definitions See Sec tion 8 for E frame sizes disassembly and assembly instructions 7 2 Instructions 7 2 1 Control Card and Control Card Mounting Plate 1 Open the front panel door or remove the front cover depending on the unit type 2 Illustration 7 1 Unplug the LCP ribbon cable not shown from the control card or remove LCP depending on unit type LCP can be removed by hand 3 Remove the LCP cradle LCP cradle can be removed by hand 4 Remove any customer control wiring from the control card terminal blocks 5 Remove the 4 screws T20 Torx securing the control card mounting plate to the control asse
95. replacement module 2 Reinstall the module and mounting screws Tighten the remaining T25 and 8 mm screws to 2 3 Nm 20 in Ibs and T30 and 10 mm to 4 Nm 35 in lbs 3 Reassemble the remaining parts in reverse order of their removal 142 MG 90 L1 02 VLT is a registered Danfoss trademark Frequency Converters High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 7 2 13 Current Sensor 1 Remove the motor cabling as required 2 Remove the input terminal mounting plate assembly per instructions 3 Remove terminals U V and W by removing the 3 mounting screws The terminal slides out from under the current sensor 4 Disconnect the current sensor cable from the current sensor Note which cables attach to which sensor for reassembly Remove the 2 8 mm retaining nuts from the stud on the chassis base plate and remove the sensor Reinstall in reverse order of this procedure Tighten the 8 mm mounting nuts to 2 3 Nm 20 in Ibs 130BX124 11 Illustration 7 1 Current Sensors 1 Terminal 4 Current sensor mounting screws 2 2 Current sensor 5 Terminal mounting screws 2 3 Terminal mounting screw 6 Output motor cable connection screws 2 MG 90 L1 02 VLT is a registered Danfoss trademark 143 7 D Frame Sizes Disassembly and Assembly high Power Service Manual for VLT FC Series Instructions Frequency Converters 7 2 14 He
96. running its load If suspect readings are recorded then the motor leads may have to be disconnected to further isolate the problem 1 Using a voltmeter measure AC output voltage at frequency converter motor terminals 96 U 97 V and 98 W Measure phase to phase checking U to V then U to W and then V to W All three readings should be within 8 VAC of each other The actual value of the voltage depends on the speed at which the frequency converter is running The volts hertz ratio is relatively linear except in VT mode so at 60Hz the voltage should be approximately equal to the mains voltage applied At 30 Hz it is about half of that and so on for any other speed selected The exact voltage reading is less important than balance between phases 2 Next monitor three output phases at frequency converter motor terminals 96 U 97 V and 98 W with the clamp on the ammeter An analog device is preferred To achieve an accurate reading run the frequency converter above 40Hz as this is normally the frequency limitation of such meters The output current should be balanced from phase to phase and no phase should be more than 2 to 3 different from another If the above tests are successful the frequency converter is operating normally 3 If a greater imbalance exists than described above disconnect the motor leads and repeat the voltage balance test Since the current will follow the voltage it is necessary to differentiate betwe
97. terminal plate as follows 3a Loosen the connection nut 17 mm between the fuse and disconnect 3b Remove the 4 mounting screws T40 from the disconnect Note that the weight of the disconnect can be up to 16 kg 35 165 Slide dis connect down to clear fuses and remove 4 If a cooling fan is mounted disconnect the fan cable If an RFI filter is mounted disconnect the RFI cable 6 Note that the weight of the terminal plate without the disconnect can be up to 20 kg 44 Ibs To remove the terminal plate remove the 8 retaining nuts 10 mm from the ter minal plate and lift the entire assembly from the mounting studs Reinstall in reverse order of this procedure Tighten the 10 mm mounting nuts to 4 Nm 35 in Ibs 17 mm connection nuts to 19 Nm 170 in lbs and T40 mounting screws to 9 5 Nm 85 in Ibs HESS z 4y eee Ny 130BX97 10 Illustration 8 1 Input Terminal Mounting Plate Assy shown with RFI and mains fuse options 1 Input terminals Step 1 5 Retaining nut Step 2 2 Connection nut Step 3a 6 Cooling fan Step 4 3 Fuse 7 Input terminal mounting plate 4 RFI filter assembly MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 8 E Frame Sizes Disassembly and Assembly Frequency Converters Instructions 8 2 8 Soft Charge Resistor 1 Remove the input terminal plate assembly in accordance with procedure 2 Disconnect t
98. the state lt of the frequency converter Status mode Middle section lt Display contrast adjustment Bottom section lt Press status 4 for darker display Press status and Y for brighter display 1 130BP074 10 MG 90 L1 02 VLT is a registered Danfoss trademark 25 2 Operator Interface and Frequency Converter High Power Service Manual for VLT FC Series Control Frequency Converters Indicator lights LEDs If certain threshold values are exceeded the alarm and or warning LED lights up A status and alarm text appears on the control panel The On indicator lamp is activated when the frequency converter receives power from mains volt age a DC bus terminal or an external 24 V supply At the same time the back light is on Green LED On Control section is working Yellow LED Warn Indicates a warn ing Flashing Red LED Alarm Indicates an alarm 130 044 10 LCP keys Menu keys The menu keys are divided into functions The keys below the display and indicator lamps are used for parameter set up including choice of display indication during normal operation 130BP045 10 Status indicates the status of the frequency converter and or the motor Three different readouts can be chosen by pressing the Status key 5 line readouts 4 line readouts or Smart Logic Control Use Status for selecting the mode of display or for changing bac
99. those diodes If an open reading were present it would indicate the upper diodes in the soft charge rectifier are open It could also indicate that one or more of the soft charge fuses are open It could further indicate that the soft charge resistor is open To isolate between the three possibilities perform the Soft Charge Fuse Test and Soft Charge Rectifier Test A short circuit reading indicates either one or more of the upper soft charge rectifier diodes are shorted or the SCRs are shorted in the SCR diode module To isolate between SCRs or the soft charge rectifier perform the Soft Charge Rectifier Test Main rectifier circuit test part 111 1 Connect the positive meter lead to the negative DC bus connector MK105 B on the power card 2 Connect the negative meter lead to terminals L1 L2 and L3 in sequence Each reading should show a diode drop Incorrect reading With the Part III test connection the diodes in the SCR diode modules are forward biased as well as the lower diodes in the soft charge rectifier The meter reads the diode drops If a short circuit exists it would be possible that either the diodes in the SCR diode modules or the lower diodes the soft charge rectifier are shorted To isolate between SCRs or the soft charge rectifier perform the Soft Charge Rectifier Test Although an open reading is possible it is unlikely since that indicates that both the diodes in the SCR diode modules and the lowe
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102. 0 440 V 233 286 347 434 528 Nominal A 441 500 V 190 240 302 361 443 60 441 500 209 264 332 397 487 Output Nominal kVA 400 V 147 180 218 274 333 Nominal kVA 460 V 151 191 241 288 353 Nominal kVA 500 V 165 208 262 313 384 Typical shaft output kW 400 V 110 132 160 200 250 HP 460 V 150 200 250 300 350 kW 500 V 132 160 200 250 315 High overload torque 16096 Output current Nominal A 380 440 V 177 212 260 315 395 60 sec A 380 440 266 318 390 473 593 Nominal A 441 500 V 160 190 240 302 361 MAX 60 sec A 441 500 V 240 285 360 453 542 Output Nominal kVA 400 V 123 147 180 218 274 Nominal kVA 460 V 177 151 191 241 288 Nominal kVA 500 V 139 165 208 262 313 Typical shaft output kW 400 V 90 110 132 160 200 HP 460 V 125 150 200 250 300 kW 500 V 110 132 160 200 250 Power loss Normal overload W 3234 3782 4213 5117 5893 Power loss High overload W 2641 2995 3425 3910 4625 Limits and Ranges Overcurrent Warning VLT ARMS Out 329 394 484 586 735 Overcurrent Alarm 1 5 sec delay VLT ARMS Out 322 394 484 586 735 Earth Ground Fault Alarm VLT ARMS Out 80 95 120 151 180 Short Circuit Alarm VLT ARMS Out 420 502 616 747 936 Heatsink Overtemperature Degrees C 85 90 105 105 115 Heatsink Undertemperature Warning Degrees 0 0 0 0 0 Power Card Ambient Overtemperature Degrees C 60 60 60 60 60 Power Card Ambient Undertemperature Degrees C 20 20 20 20 20
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104. 03 MK104 MK106 and if the unit has a brake option MK105 and for 380 500 V units with an RFI filter MK101 2 Remove the gate drive card by removing the 6 mounting screws T25 Torx from the standoffs Reinstall in reverse order of this procedure Tighten the mounting screws to 2 3 Nm 20 in Ibs SV cw Ou E Qus 5 E Que ay E Qus E E en rm rm en 130BX160 10 7 wr E 00 000 00 000 ers 4 Illustration 7 1 Gate Drive Card MK100 temperature sensor MK101 RFI filter MK106 MK105 brake option MK102 U MK103 V MK104 W 128 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 7 2 7 Capacitor Bank s Some D2 D4 size units have 2 capacitor bank assemblies mounted one above the other Separate disassembly instructions are given for upper and lower capacitor banks For units with one capacitor bank assembly only disassemble in accordance with instructions for Single capacitor bank D1 D3 units Upper capacitor bank D2 D4 units 1 Remove the control assembly support bracket in accordance with instructions 2 Capacitor bank connection to DC bus bars can be seen recessed the gap between upper and lower cap banks Remove the 2 nuts 10 mm furthest from the DC bus bars
105. 08 DC Undervoltage Test 109 Input Imbalance of Supply Voltage Test 109 Input Waveform Test 110 Input SCR Test 111 Output Imbalance of Supply Voltage Test 113 IGBT Gate Drive Signals Test 114 IGBT Switching Test 116 Brake IGBT Test 117 Current Sensors Test 118 Fan Tests 119 Input Terminal Signal Tests 121 Initial Start Up or After Repair Drive Tests 122 7 D Frame Sizes Disassembly and Assembly I nstructions 123 Electrostatic Discharge ESD 123 Instructions 123 Control Card and Control Card Mounting Plate 123 Control Assembly Support Bracket 124 Power Card 125 Power Card Mounting Plate 126 Soft Charge Card 126 Gate Drive Card 128 Capacitor Bank s 129 Soft Charge SC Resistors D2 D4 Units 131 Soft Charge SC Resistors D1 D3 Units 132 Input Terminal Mounting Plate Assembly 135 MG 90 L1 02 VLT is a registered Danfoss trademark 3 Contents high Power Service Manual for VLT FC Series Frequency Converters SCR Diode Module D2 D4 Units SCR Diode Module D1 D3 Units Current Sensor Heatsink Fan Assembly AC Input Terminals IGBT Modules D2 D4 Units IGBT Modules D1 D3 Units 8 E Frame Sizes Disassembly and Assembly I nstructions Electrostatic Discharge ESD Instructions Control Card and Control Card Mounting Plate Control Assembly Support Bracket Power Card Soft Charge Card Gate Drive Card Capacitor Banks Input Terminal Mounting Plate Assy Option Soft Charge Resistor SCR and Diode Modules Current Senso
106. 1 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters Main rectifier circuit test part 1 1 Connect the positive meter lead to the positive DC bus connector MK105 A on the power card 2 Connect the negative meter lead to terminals L1 L2 and L3 in sequence Each reading should show infinity The meter will start at a low value and slowly climb towards infinity due to capacitance within the frequency converter being charged by the meter Incorrect reading With the Part I test connection the SCRs in the SCR diode modules are reverse biased so they are blocking current flow If a short circuit exists it would be possible that either the SCRs or the diodes in the soft charge rectifier are shorted To isolate between SCRs or the soft charge rectifier perform the Soft Charge Rectifier Test Main rectifier circuit test part 11 i Reverse meter leads by connecting the negative meter lead to the positive DC bus connector MK105 A on the power card 2 Connect the positive meter lead to L1 L2 and in sequence Each reading should show a diode drop Incorrect reading With the Part II test connection even though the SCRs in the SCR diode modules are forward biased by the meter current will not flow through the SCRs without providing a signal to their gates The upper diodes in the soft charge rectifier are forward biased so the meter reads the voltage drop across
107. 1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 5 Remove the six retaining screws T25 from the SCR diode modules terminals 2 and 3 in each module 6 Remove the 4 10 mm retaining nuts from the DC inductor input bus bars and the 4 retaining nuts not shown from the side mounted bus bars Side mounted bus bars are only present on units with load sharing Remove the DC input bus assembly S Nes SN gt lt 130BX93 10 Illustration 7 1 D1 D3 SCR Diode Module 2 of 3 Bus bar BB4 Retaining nuts Step 6 DC input bus assembly BB3 Step 6 Retaining screws Step 5 SCR diode module MG 90 L1 02 VLT is a registered Danfoss trademark 141 7 D Frame Sizes Disassembly and Assembly high Power Service Manual for VLT FC Series Instructions 7 Note which gate leads attach to which module for reassembly Remove the SCR diode gate lead connectors from the modules not shown 8 Iftheunit is equipped with a brake option remove the two bus bars attaching the brake IGBT module to the IGBT bus assy Remove the SCR diode mounting screws 130BX92 10 Illustration 7 1 D1 D3 SCR Diode Module 3 of 3 1 SCR diode module 2 Mounting screws Step 8 REASSEMBLY 1 To replace SCR diode modules follow the instructions included with the
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113. Apply AC power to the frequency converter 5 Give the frequency converter a run command and slowly increase the reference speed command to approximately 40 Hz 6 Using an analog voltmeter or a DVM capable of measuring true RMS measure phase to phase output voltage on all three phases U to V U to W V to W voltages must be balanced within 8 volts If unbalanced voltage is measured refer to Input Voltage Test 6 3 2 7 Stop the frequency converter and remove the input power Allow 40 minutes for DC capacitors to fully discharge for E frame size frequency converters or 20 minutes for D frame size frequency converters 8 Reconnect the motor leads to the frequency converter output terminals U V W Reapply power and restart the frequency converter Adjust the motor speed to a nominal level 10 Using a clamp on style ammeter measure the output current on each output phase currents should be balanced If unbalanced current is measured refer to Current Sensor Test 6 3 14 122 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 7 D Frame Sizes Disassembly and Assembly In structions 7 1 Electrostatic Discharge ESD Frequency converters contain dangerous voltages when connected to mains voltage No disassembly should be attempted with power applied Remove power to the fre
114. C102 202 45 1 Introduction P55K P75K 110 FC302 P37K 45 P55K P75K P90K Normal overload current ratings 110 Output current Nominal A 525 550 V 56 76 90 113 137 MAX 60 sec A 525 550 V 62 84 99 124 151 Nominal A 551 690 V 54 73 86 108 131 MAX 60 sec A 551 690 V 59 80 95 119 144 Output Nominal kVA 550 V 53 72 86 108 131 Nominal kVA 575 V 54 73 86 108 130 Nominal kVA 690 V 65 87 103 129 157 Typical shaft output kW 550 V 37 45 55 75 90 575 50 60 75 100 125 kW 690 V 45 bb 75 90 110 High overload torque 160 Output current Nominal A 525 550 V 48 56 76 90 113 MAX 60 sec A 525 550 V 77 90 122 135 170 Nominal A 551 690 V 46 54 73 86 108 MAX 60 sec A 551 690 V 74 86 117 129 162 Output Nominal kVA 550 V 46 53 72 86 108 Nominal kVA 575 V 46 54 73 86 108 Nominal kVA 690 V 55 65 87 103 129 Typical shaft output kW 550 V 30 87 45 55 75 HP 575 V 40 50 60 75 100 kW 690 V 37 45 55 75 90 Power loss Normal overload W 1458 1717 1913 2262 2662 Power loss High overload W 1355 1459 1721 1913 2264 Limits and Ranges Overcurrent Warning VLT ARMS Out 256 256 256 256 256 Overcurrent Alarm 1 5 sec delay VLT ARMS Out 256 256 256 256 256 Earth Ground Fault Alarm VLT ARMS Out 23 27 37 43 54 Short Circuit Alarm VLT ARMS Out 925 925 4325 4325 Heatsink Overtemperature Degrees C 85 85 85 85 85 Heatsink Undertemperature
115. CP cradle can be removed by hand 4 Remove any customer control wiring from the control card terminal blocks 5 Remove the 4 screws T20 Torx securing the control card mounting plate to the control assembly support bracket 6 Unplug the ribbon cable from the back of the control card Reinstall in reverse order of this procedure The red conductor on the ribbon cable between the control card and the power card should be on the bottom of the connector Tighten the control card mounting plate screws to 1 Nm 8 in Ib MG 90 L1 02 VLT is a registered Danfoss trademark 153 8 E Frame Sizes Disassembly and Assembly Danfoss Power Service Manual for VLT FC Series Instructions Frequency Converters 130BX183 11 Illustration 8 1 Control Card Access 380 480 500V Yellow tape on the main SMPS 525 690V White tape on the main SMPS transformer in the upper right corner transformer in the upper right corner 1 Local control panel LCP Step 2 8 Power card PCA3 2 LCP cradle Step 3 9 102 ring lug connection 3 C option if installed 10 DC bus fuse 4 Mounting screws Step 5 11 Control card mounting plate 5 Control assembly support bracket 12 Control card terminal block 6 Attaching hardware 13 Control card under LCP 7 Power card mounting plate 8 2 2 Control Assembly Support Bracket 1 Remove the control card mounting plate in accordance with procedure 2 Remove the 6 mounting nuts 10 mm see Illustration 8 1 3
116. CR shorting plug ensures that the SCRs do not fire There are two cable types the D frame frequency converters use the 2 pin cable and the E frame fre quency converters use the 3 pin cable see the illustrations below The D frame cable connects to the wire harness above the power card by the SMPS fuse to the power card connector 105 The E frame connects between the soft charge connector MK3 and the power card connector MK105 130BX64 10 Illustration 6 2 SCR Shorting Plug WHITE m Illustration 6 3 Two Pin D frame Test Cable 130BX197 10 130 199 10 Illustration 6 4 Three Pin E frame Test Cable MG 90 L1 02 VLT is a registered Danfoss trademark 89 ish Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters 6 2 Static Test Procedures All tests should be made with a meter capable of testing diodes Use a digital volt ohmmeter VOM set on the diode scale or an analog ohmmeter set on Rx100 scale Before making any checks disconnect all input motor and brake resistor connections Illustration 6 3 Power Card PCA Connector Identification is provided as a reference for finding the appropriate connectors described in the test procedures in this section Some connectors are op tional and not on all frequency converter configurations NB For best troubleshooting results it is recommended that static test procedures de scr
117. Digital I O Mode and par 5 01 Terminal 27 Mode WARNI NG 41 Overload of Digital Output Terminal 29 Check the load connected to terminal 29 or remove the short circuit connection Check par 5 00 Digital I O Mode and par 5 02 Terminal 29 Mode 70 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 4 Troubleshooting WARNING 42 Overload of Digital Output on X30 6 or Overload of Digital Output on X30 7 For X30 6 check the load connected to X30 6 or remove the short circuit connection Check par 5 32 Term X30 6 Digi Out MCB 101 For X30 7 check the load connected to X30 7 or remove the short circuit connection Check par 5 33 Term X30 7 Digi Out MCB 101 ALARM 46 Power card supply The supply on the power card is out of range There are three power supplies generated by the switch mode power supply SMPS on the power card 24 V 5V 18V When powered with 24 VDC with the MCB 107 option only the 24 V and 5 V supplies are monitored When powered with three phase mains voltage all three supplied are monitored WARNING 47 24 V supply low The 24 VDC is measured on the control card The external 24 VDC backup power supply may be overloaded otherwise contact your Danfoss supplier WARNING 48 1 8 V supply low The 1 8 Volt DC supply used on the control card is outside of allowable limits The power supply is measured on the control card WARNIN
118. G 49 Speed limit The speed is not within the specified range in par 4 11 Motor Speed Low Limit RPM and par 4 13 Motor Speed High Limit RPM ALARM 50 AMA calibration failed Contact your Danfoss supplier ALARM 51 AMA check Unom and I nom The setting of motor voltage motor current and motor power is presumably wrong Check the settings ALARM 52 low I nom The motor current is too low Check the settings ALARM 53 AMA motor too big The motor is too big for the AMA to be carried out ALARM 54 AMA motor too small The motor is too big for the AMA to be carried out ALARM 55 AMA parameter out of range The parameter values found from the motor are outside acceptable range ALARM 56 AMA interrupted by user The AMA has been interrupted by the user ALARM 57 AMA time out Try to start the AMA again a number of times until the AMA is carried out Please note that repeated runs may heat the motor to a level where the resistances Rs and Rr are increased In most cases however this is not critical ALARM 58 AMA internal fault Contact your Danfoss supplier WARNI NG 59 Current limit The current is higher than the value in par 4 18 Current Limit WARNI 60 External interlock External interlock has been activated To resume normal operation apply 24 VDC to the terminal programmed for external interlock and reset the frequency converter via serial communication digital I O or by pressing the reset butt
119. High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters Contents Contents 1 Introduction 11 Purpose 11 VLT FC Product Overview 11 For Your Safety 11 Electrostatic Discharge ESD 12 Frame Size Definitions 12 Tools Required 13 General Torque Tightening Values 13 Exploded Views 15 Ratings Tables 18 2 Operator I nterface and Frequency Converter Control 23 Introduction 23 User Interface 23 Numeric Local Control Panel NLCP 29 Tips and Tricks 29 Status Messages 30 Service Functions 35 Frequency Converter Inputs and Outputs 36 Input signals 37 Output signals 37 Control Terminals 38 Control Terminal Functions 39 Earthing Screened Cables 41 3 Internal Frequency Converter Operation 43 General 43 Description of Operation 43 Logic Section 44 Logic to Power Interface 45 Power Section 46 Sequence of Operation 47 Rectifier Section 47 Intermediate Section 49 Inverter Section 51 Brake Option 53 Cooling Fans 54 Fan Speed Control 54 Load Sharing 55 MG 90 L1 02 VLT is a registered Danfoss trademark 1 Contents Power Service Manual for VLT9 FC Series Frequency Converters Specific Card Connections 4 Troubleshooting Troubleshooting Tips Exterior Fault Troubleshooting Fault Symptom Troubleshooting Visual Inspection Fault Symptoms No Display Intermittent Display Motor Will not Run Incorrect Motor Operation Warning Alarm Messages Warning Alarm Code List After Repair Tests 5 Frequency Conve
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121. K100 MK102 MK103 MK104 and MK106 from the gate drive card Also remove the MK105 for units with a brake and MK101 for units with an RFI filter 3 Remove the 4 retaining nuts 10 mm from the cap bank cover plate and remove the plate 4 Note that the weight of the cap bank is approximately 9 kg 20 165 Remove the cap bank by pulling it free from the mounting studs Reinstall in reverse order of this procedure Tighten the mounting screws to 4 Nm 35 in Ibs Single capacitor bank D1 D3 units 1 Remove the control assembly support bracket in accordance with instructions 2 Remove the 2 capacitor bank retaining nuts 10 mm from the DC bus bars A minimum 100 mm 4 in extension is required 7 3 Note that the IGBT gate drive card can remain attached to the cap bank cover plate Disconnect MK100 MK102 MK103 MK104 and MK106 from the gate drive card Also remove the MK105 for units with a brake and MK101 for units with an RFI filter 4 Remove the 4 retaining nuts 10 mm from the cap bank cover plate and remove the plate 5 Note that the weight of the cap bank is approximately 9 kg 20 165 Remove the cap bank by pulling it free from the mounting studs Reinstall in reverse order of this procedure Tighten the mounting screws to 4 Nm 35 in Ibs 130BX72 10 i
122. MG 90 L1 02 VLT is a registered Danfoss trademark 8 E Frame Sizes Disassembly and Assembly High Power Service Manual for VLT9 FC Series 7 44 Frequency Converters Instructions 15 Remove the 18 retaining screws T30 on the IGBT input terminals Note snubber ca pacitors come off when screws are removed There are 6 screws for each IGBT module 16 Remove the 2 retaining nuts 8 mm connecting each IGBT cap bus bar assembly to the IGBT Ind bus bar assembly and remove the IGBT cap bus bar assembly There are three IGBT cap bus bar assemblies 17 Remove the retaining nut 8 mm from the high frequency board 18 Remove the 2 retaining screws T25 from the high frequency board 19 Disconnect the wire assembly from the high frequency board and remove the board 20 Ifthe unit has Brake IGBTs remove the 4 retaining screws T30 connecting the IGBT Ind bus bar assembly to the Brake IGBT Note that there are 2 screws per Brake IGBT module 21 Remove the 4 retaining nuts 13 mm connecting the IGBT Ind bus bar assembly to two DC bus bars from the inductor Remove the IGBT Ind bus bar assembly 22 Remove the 8 retaining screws T25 mounting each IGBT module 3 2 4 1 5 6 7 8 9 5555 i TH 10 2 TE E el 11 if oe 130BX131 10 Illustration 8 1 IGBT Modules 4 of 4 1 Snubber capaci
123. P450 P400 4 3 1 4 yes 525 690 P400 P400 P355 20 8 12 21 no 525 690 P500 P500 P400 20 8 12 21 no 525 690 P560 P560 P500 74 3 6 3 2 4 yes 525 690 P630 P630 P560 74 3 6 3 2 4 yes Table 6 1 Fan transformer resistance Incorrect reading An incorrect reading would indicate a defective fan transformer Replace the fan transformer When finished reconnect the MK107 MG 90 L1 02 VLT is a registered Danfoss trademark 103 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters Ohm test of fans 1 Measure between terminals 3 and 5 of power card connector 107 It should read approximately value D in Table 6 1 Incorrect reading For fans without an inductor replace the fan For frequency converters with a fan and inductor isolate the fault between the fan and the inductor as fol lows 1 Disconnect CN3 and measure the resistance between pins 1 2 on the fan side of the connector Reading should be approx 4 ohms If incorrect replace fan 1b Disconnect CN4 and CN5 Measure the resistance across the inductor Reading should be less than 1 ohm If incorrect replace the inductor 2 Measure between terminals 11 and 13 of power card connector MK107 For units with one top mounted fan a reading of 400 ohms is expected For units with two door moun ted fans a reading of 200 ohms is expected Incorrect reading For units with one top mounted fan replace the fan For units with two d
124. Power Service Manual for VLT Series Control Frequency Converters Display lines a Status line Status messages dis 1308801519 playing icons and graphics b Line 1 2 Operator data lines dis Status playing data and variables defined TEEM 304A chosen by the user pressing the 1 43 5 Status key up to one extra line can be added Run OK Status line Status messages dis playing text pter Quick Main Alarm 2 Status Mei Log The display is divided into three sections Top section a shows the status when in status mode or up to two variables when not in status mode and in the case of Alarm Warning The number of the Active Set up selected as the Active Set up in par 0 10 Active Set up is shown When programming in another Set up than the Active Set up the number of the Set up being programmed appears to the right in brackets The Middle section b shows up to 5 variables with related unit regardless of status In case of alarm warning the warning is shown instead of the variables It is possible to toggle between three status readout displays by pressing the Status key Operating variables with different formatting are shown in each status screen see below Several values or measurements can be linked to each of the displayed operating variables The values measurements to be displayed can be defined via par 0 20 0 21 0 22 0 23 and
125. Screened Cables It is recommended that screened control cables be connected with cable clamps at both ends to the metal cabinet of the frequency converter Table 2 3 shows earth cabling for optimal results PLC etc Correct earthing Control cables and cables for serial communication must be fit 2 z vey ted with cable clamps at both ends to ensure the best possible electrical connection PE PLC ete Incorrect earthing Do not use twisted cable ends pigtails since these increase screen impedance at high frequencies PLC ste Earth potential protection When the earth potential between the frequency 9 converter and the PLC or other interface device is different electrical noise may occur that can disturb the entire system This can be resolved by fitting an equal izing cable next to the control cable Minimum cable cross section is 8 AWG Lmin 16mm Equalizing cable 50 60 Hz earth loops When using very long control cables 50 60 Hz earth loops may occur that can disturb the entire system This can be resolved by connecting one end of the screen with a 100 nF capacitor and keeping the lead short PLC etc VIT Serial communication control cables Low frequency noise currents between e frequency converters can be eliminated by connecting one end of the screened E pes ca
126. Service Manual for VLT9 FC Frequency Converters 3 Internal Frequency Converter Operation 3 3 3 Inverter Section In the inverter section see Illustration 3 7 gate signals are delivered from the control card through the power card and gate frequency converter card to the gates of the IGBTs The series connection of each set of IGBTs is delivered to the output first passing through the current sen Sors Once a run command and speed reference are present the IGBTs begin switching to create the output waveform as shown in Illustration 3 6 Looking at the phase to phase voltage waveform with an oscilloscope it can be seen that the Pulse Width Modulation PWM principal creates a series of pulses which vary in width Basically the pulses are narrower as zero crossing is ap proached and wider the farther from zero crossing The width is controlled by the pulse duration of applied DC voltage Although the voltage waveform is a consistent amplitude the inductance within the motor windings will serve to average the voltage delivered and so as the pulse width of the waveform varies the average voltage seen by the motor varies as well This then equates to the resultant current waveform which takes on the sine wave shape that we expect to see in an AC system The frequency of the waveform is then determined by the rate at which the pulses occur By employing a sophisticated control scheme the frequency converter is capable of deliv ering a
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129. Test equipment de scribed in this section is available from Danfoss Using the test cable allows powering the frequency converter without having to charge DC bus capacitors Main input power is required and all devices and power supplies connected to mains are energised at rated voltage Use extreme caution when conducting tests on a powered frequency converter Contact with powered components could result in electrical shock and personal injury 9 1 1 Test Cables and SCR Shorting Plug Kit p n 176F8439 This tool provides the ability to power up the Switch Mode Power Supplies SMPS and ac tivate all the control functions of the frequen cy converter without having the DC bus capacitors charged It provides protection for troubleshooting gate drive signals and other important control signals within the frequency 130BX64 10 Illustration 9 1 SCR Shorting Plug converter 2 ce B LEM XM a The test kit includes the shorting plug and Illustration 9 2 Two pin D frame Test Cable connector cables The cable is connected be tween the soft charge card and the power card The SCR shorting plug shorts the gates 7 fr 3 of the SCRs to ensure they do not fire and add i B a charge to the DC bus Illustration 9 3 Three pin E frame Test Cable MG 90 L1 02 VLT is a registered Danfoss trademark 173 high Power Service Manual for VLT FC Series 9 Special Test
130. Test sections are independent for D frame and E frame fre quency converters Replace any defective component and retest the frequency converter with the new component before applying power to the frequency converter as described in Jnitia Start Up or After Repair Drive Tests MG 90 L1 02 VLT is a registered Danfoss trademark 87 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters 6 1 1 Tools Required for Testing Digital volt ohm meter capable of reading real RMS Analog volt meter Oscilloscope Clamp on style ammeter Signal test board p n 176F8437 Test cable p n 176F8439 6 1 2 Signal Test Board The signal test board can be used to test circuitry within the frequency converter and provides easy access to test points The test board plugs into connector MK104 on the power card Its use is described the procedures where called out See S gna Test Board Section 9 Special Test Equipment for detailed pin descriptions o ea o m Illustration 6 1 Signal Test Board 88 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 1 3 Test Cables The test cables bypass the main DC bus capacitors and supply DC voltage to the power card from the soft charge card This provides voltage for testing the power card without the frequency con verter circuitry being powered The S
131. UUN 0041 UO 5y 10 sseuJeu SUUN pue TZdI UO 10 SseuJeu SUUN 0041 suej 5y 10 sseuJeu a JaulJOJSUeJ y Ped Jamod sseuJeu a JeuuoJsued 0 y sseuJeu a 5105 5 JUS1IND 03 Jamod sseuJeu 5105 5 03 ped J MOd WO sseuJeu 5105 5 1ua Jno 03 Jamod sseuJeu 5105 5 03 ped J MOd sseuJeu pied JeMod 0 pJe uoqqu 421 uoqqu dI pJe jo 3u0o2 0 421 e qe uoqqu Sjueuiuio 9UJeJJ 3 ue4 asny 54 AQV aueds 3 sng 64205 sjqe sng 5u 3jos sjqe 4 3 LSY 5uxyos sjqe e1eds 9Ue LSY bu yos LSY 5u yos Leds 5 48 Mog sjqe dS sjqe ejeds 5 sjqe aueds 5 5 3 1891 sjqe 4 1851 91 95 1991 1991 ejqe
132. V 400 400 500 600 kW 690 V 355 400 500 560 Power loss Normal overload W 6449 7249 8727 9673 Power loss High overload W 5383 5818 7671 8715 Limits and Ranges Overcurrent Warning VLT AR SQut 824 824 989 1168 Overcurrent Alarm 1 5 sec delay VLT ARMSOut 824 824 989 1168 Earth Ground Fault Alarm ARMSOut 190 205 250 285 Short Circuit Alarm ARMSOut 1046 1046 1255 1490 Heatsink Overtemperature Degrees C 85 85 85 85 Heatsink Undertemperature Warning Degrees C 0 0 0 0 Power Card Ambient Overtemperature Degrees C 68 68 68 68 Power Card Ambient Undertemperature Degrees 20 20 20 20 Mains Phase Warning 5 sec delay DC Bus Ripple VAC 70 70 70 70 Mains Phase Alarm 25 sec delay DC Bus Ripple VAC 70 70 70 70 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 7 42 Operator Interface and Frequency Converter Frequency Converters Control 2 Operator Interface and Frequency Converter Control 2 1 Introduction Frequency converters are designed with self diagnostic circuitry to isolate fault conditions and activate display messages which greatly simplify troubleshooting and service The operating status of the frequency converter is displayed in real time Virtually every command given to the fre quency converter results in some indication on the local control panel LCP display Fault logs are maintained within the frequency converter for fault history The frequen
133. a line start In its basic form the frequency converter can be divided into four main sections rectifier inter mediate circuit inverter and control see Illustration 3 1 RECTIFIER INTERMEDIATE INVERTER SCR DIODES CIRCUIT SECTION IGBTs k Da L1 4 T1 L2 T2 L3 T3 p ZO 5 Power Section SOFT CHARGE CIRCUITRY Logic to Power Interface Control Logic 130BX135 10 Illustration 3 1 Control Card Logic To provide an overview the main frequency converter components will be grouped into three categories consisting of the control logic section logic to power interface and power section In the sequence of operation description these three sections will be covered in greater detail while describing how power and control signals move throughout the frequency converter MG 90 L1 02 VLT is a registered Danfoss trademark 43 Power Service Manual for VLT9 FC Series 3 Internal Frequency Converter Operation Frequency Converters 3 2 1 Logic Section The control card contains most of the logic section see Illustration 3 2 The primary logic element of the control card is a microprocessor which supervises and controls all functions of frequency converter operation In addition separate PROMs contain the parameters to provide the u
134. able Drive interior EMC considerations Environmental conditions Earthing Input power wiring Motor Output to motor wiring Programming Proper clearance Vibration via the local control panel display on the drive The frequency converter interior must be free of dirt metal chips moisture and corrosion Check for burnt or damaged power components or carbon deposits resulting from cata strophic component failure Check for cracks or breaks in the housings of power semicon ductors or pieces of broken component housings loose inside the unit Check for proper installation with regard to electromagnetic capability Refer to the fre quency converter operating instructions and Section 5 of this manual for further details Under specific conditions these units can be operated within a maximum ambient of 50 C 122 F Humidity levels must be less than 95 noncondensing Check for harmful airborne contaminates such as sulphur based compounds The frequency converter requires a dedicated earth wire from its chassis to the building earth It is also suggested that the motor be earthed to the frequency converter chassis as well The use of a conduit or mounting the frequency converter onto a metal surface is not considered a suitable earth Check for good earth connections that are tight and free of oxidation Check for loose connections Check for proper fusing Check for blown fuses Check the nameplate ratings of the motor En
135. able 2 1 Table 2 2 Table 2 3 Table 3 1 Table 3 2 Table 3 3 Table 4 1 Table 4 2 Table 4 3 Table 6 1 Table 6 2 Table FC 102 and FC 202 380 480 VAC FC 302 380 500 VAC FC 102 and FC 202 525 690 VAC AF 600 FP 525 600 VAC FC 302 AF 650 GP 525 690 VAC 650 GP 525 690 VAC Torque Values Table Tips and tricks Control Terminals and Associated Parameter Earthing Screened Cables IGBT Thermal Sensor Power Card Ambient Temperature Sensor Control Card Thermal Sensor Visual Inspection Warning alarm code list Alarm warning code list Fan transformer resistance Scaling Card Resistance Values 6 3 Scaling Card Resistance AF 600 FP only up to 600 V Table 10 1 Spare Parts List PCA3 PCA4 5 PCA8 and 11 Table 10 2 Spare Parts List Semiconductors Resistors Capacitors and Fans Table 10 3 Spare Parts List Fuses Inductors amp Current Sensors and Disconnects Table 10 4 Spare Parts List Cables Table 10 5 Spare Parts List Cables Table 10 6 Spare parts list Terminals Labels Insulators Table 10 7 Spare parts lists Bus Bars tabel 1 Table 10 8 Spare parts list Bus Bars table 2 Table 10 9 Spare parts list Enclosure Table 10 10 Spare Parts List PCA3 11 Table 10 11 Spare Parts List Semiconductors Resistors Capacitors and Fans Table 10 12 Spare Parts List Fuses Inductors amp Current Sensors and Disconnects Table 10 13 Spare Parts List Cables Table 10 14 Spare Parts List terminals Labels Insu
136. abled T fans force the fans on high OVDC fans on high 17 FAN ON Pulse train to gate E 5VDC fans off 175 9 Special Test Equipment high Power Service Manual for VLT FC Series Frequency Converters 176 Pin Sche Function Description Reading Using a Digital Voltmeter No matic Acro nym 18 HI_LOW Control signal Signal to switch fan speeds between high 5VDC fans on high from Power Card and low Otherwise OVDC 19 SCR DI Control signal for Indicates SCR front end is enabled or dis 0 6 to 0 8 VDC SCRs enabled S SCR front end abled OVDC SCR disabled 20 INV DI Control signal Disables IGBT gate voltages 5VDC inverter disabled S from Power Card OVDC inverter enabled 21 Not used 22 UINVEX Bus Voltage scaled Signal proportional to UDC OV switch must be off down 1 VDC 450 VDC T4 T5 1 VDC 610 VDC T7 23 VDD 24 VDC power Yellow LED indicates voltage is present 24 VDC regulated supply supply 23 to 25 VDC 24 VCC 5 0 VDC regula The green LED indicates voltage 15 5 0 VDC regulated supply 4 75
137. active X 202 Fire mode limits exceeded X 243 Brake IGBT X X 244 Heatsink temperature X X X 245 Heatsink sensor X X 246 Power card supply X X 247 Power card temperature X X 248 Illegal PS config X X 250 New spare part X 251 New type code X X Table 4 3 Alarm warning code list X Programmable dependent on parameter setting 1 Cannot be auto reset via parameter selection 64 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 4 Troubleshooting LED indication Warning yellow Alarm flashing red Trip locked yellow and red WARNING 1 10 volts low The control card voltage is below 10 V from terminal 50 Remove some of the load from terminal 50 as the 10 V supply is overloaded Max 15 mA or minimum 590 Q This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer Troubleshooting Remove the wiring from terminal 50 If the warning clears the problem is with the customer wiring If the warning does not clear replace the control card WARNI NG ALARM 2 Live zero error This warning or alarm will only appear if programmed by the user in par 6 01 Live Zero Timeout Function The signal on one of the analog inputs is less than 50 of the minimum value pro grammed for that input This condition can be caused by broken wiring or faulty device sending the signal Troubleshooting
138. an Run AMA in par 1 29 Automatic Motor Adaptation AMA WARNI NG ALARM 11 Motor thermistor overtemp The thermistor or the thermistor connection is disconnected Select whether the frequency con verter gives a warning or an alarm when the counter reaches 100 in par 1 90 Motor Thermal Protection Troubleshooting Check if motor is overheating Check if the motor is mechanically overloaded 66 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 4 Troubleshooting Check that the thermistor is connected correctly between terminal 53 or 54 analog volt age input and terminal 50 10 V supply or between terminal 18 or 19 digital input PNP only and terminal 50 If a KTY sensor is used check for correct connection between terminal 54 and 55 If using a thermal switch or thermistor check the programming of par 1 93 7hermistor Resource matches sensor wiring If using a KTY sensor check the programming of parameters 1 95 1 96 and 1 97 match sensor wiring WARNI NG ALARM 12 Torque limit The torque is higher than the value in par 4 16 7orque Limit Motor Mode in motor operation or the torque is higher than the value in par 4 17 7orque Limit Generator Mode in regenerative operation par 14 25 77 Delay at Torque Limit can be used to change this from a warning only condition to a warning followed by an alarm See section 5 1 for troubles
139. are not disabled 9 Run the frequency converter with a zero speed reference Note the output current read ing in the display The display should indicate approximately 1 to 2 amps If the current is greater than 1 to 2 amps and a current producing parameter is not active the test will need to be made again with the motor leads disconnected 4 Remove power from the frequency converter Monitor the DC bus voltage at power card connector MK105 A and B to ensure the bus is fully discharged Remove the output motor leads from terminals U V and W Apply power to the frequency converter Run the frequency converter with a zero speed reference Note the output current read ing in the display The display should indicate less than 1 amp If an incorrect reading was obtained from the above tests further tests of the current feedback signals are required using the signal test board Testing current feedback with the signal test board 8 Remove power to frequency converter Make sure the DC bus is fully discharged 9 Install the signal test board into power card connector MK104 10 Using a DVM measure the resistance between terminals 1 and 4 2 and 4 and 3 and 4 of the signal test board Resistance should be the same for all three readings Table 6 2 shows approximate resistance readings based on frequency converter power and voltage rating Note that values listed are values at the current scaling card When measuring with a signa
140. at Terminals R S and T of power card connector MK106 2 Measurements should correspond with measurements called out in the Input Voltage Test 6 3 2 An incorrect reading at MK106 with a correct input voltage may indicate a problem in the soft charge card or the connecting cable If the above tests reveal no abnormalities it is further possible that the inrush signal has not been enabled by the control card Using the signal test card verify the inrush signal is present and the SCR disable signal is at the correct voltage level as follows 3 Insert the signal test board into power card connector MK104 4 Check the SCR disable signal 5 Using a voltmeter connect the negative meter lead to terminal 4 common of the test board 6 Connect the positive meter lead to terminal 19 of the signal board MG 90 L1 02 VLT is a registered Danfoss trademark 111 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters A reading of 0 VDC indicates the SCRs have been disabled A reading of 0 6 to 0 8 VDC indicates the SCRs are active and should be gated With a reading of 0 VDC and proper mains applied to the frequency converter it would be likely that the input at power card terminal FK102 has caused the SCRs to be disabled Given the con nection at FK102 has been verified the control card would be suspect Check the inrush signal as follows 7 Connect the positive meter lead to term
141. ate section is the high frequency HF filter card It contains a high frequency filter circuit to reduce naturally occurring currents in the HF range to prevent interfer ence with other sensitive equipment in the area The circuit as with other RFI filter circuitry can be sensitive to unbalanced phase to earth voltages in the three phase AC input line This can occasionally result in nuisance overvoltage alarms For this reason the high frequency filter card on 380 500 V range frequency converters contains a set of relay contacts in the earth connection of the filter capacitors The relay is tied into the RFI HF switch which can be switched on or off in par 14 50 RAT Filter This disconnects the earth references to all filters should unbalanced phase to earth voltages create nuisance overvoltage conditions For 525 690 V frequency converters there are no relay contacts that disconnect the earthing MG 90 L1 02 VLT is a registered Danfoss trademark 49 ish Power Service Manual for VLT FC Series 3 Internal Frequency Converter Operation Frequency Converters LI DC INDUCTOR DC CAP BANK 130BX188 10 HF SWITCH No RFI relay on 525 690V units Illustration 3 5 Intermediate section 50 MG 90 L1 02 VLT is a registered Danfoss trademark High Power
142. ating a load to verify some test signals o gt lt m The following is a description of the signals Test Board available on the signal test board Section 6 of this manual describes when these tests would be called for and what the signal should be at that given test point 9 1 3 Signal Test Board Pin Outs Description and Voltage Levels The tables on the following pages list the pins located on the signal test board For each pin its function description and voltage levels are provided Details on performing tests using the test fixture are provided in Section 6 of this manual Other than power supply measurements most of the signals being measured are made up of waveforms Although in some cases a digital voltmeter can be used to verify the presence of such signals it cannot be relied upon to verify that the waveform is correct An oscilloscope is the instrument prefered However when similar signals are being measured at multiple points a digital voltmeter can be used with some degree of confidence By comparing several signals to each other such as gate drive signals and obtaining similar readings it can be concluded each of the waveforms match one another and are therefore correct Values are provided for using a digital voltmeter for testing as well 174 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 9 Special
143. atsink Fan Assembly 1 Remove the input terminal mounting plate assembly per instructions 2 Remove the 3 IGBT output bus bars see Illustration 7 19 by removing the 6 retaining nuts 8 mm one from each end of the IGBT output bus bars Remove the bus bars NB Omit steps 3 and 4 for D2 D4 units 3 Use a 100 mm 4 in minimum extension and remove terminal 1 from the SCR diode module 4 Note the colour coding for each of the three wires attached to the retaining studs Ensure that the correct wire is attached to the applicable stud during reassembly Remove the AC power lead to the intermediate SCR input bus bar by removing the nut 8 mm and remove the bus bar CONTINUED ON NEXT PAGE o x a Illustration 7 1 Fan Assembly 1 of 2 Terminal Step 3 Intermediate SCR input bus bar Step 3 Retaining nut Step 4 Retaining nut Step 2 IGBT output bus bar Step 2 Retaining nut Step 2 144 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 5 Disconnect the in line Molex connector 6 Remove the fan assy by removing the 6 8 mm retaining nuts from the stud Note that the fan assembly weighs approximately 8 kg 18 Ibs Reinstall in reverse order of this procedure Tighten mounting nuts to 2 3 Nm 20 in Ibs 130BX89 10
144. be zero When the sensor becomes defective the output voltage level varies by more than the 15mv al lowed The defective current sensor in that phase indicates current flow when there is none This results in the sum of the three output currents being a value other than zero an indication of leakage current flowing If the deviation from zero current amplitude approaches a specific level the frequency converter assumes an earth fault and issues an alarm The simplest method of determining whether a current sensor is defective is to disconnect the motor from the frequency converter then observe the current in the display of the frequency converter With the motor disconnected the current should of course be zero A frequency con verter with a defective current sensor will indicate some current flow Because the current sensors for the higher horsepower frequency converters have less resolution an indication of a fraction of an amp on a frequency converter is tolerable However that value should be considerably less than one amp Therefore if the display shows more than one amp of current there is a defective current sensor To determine which current sensor is defective measure the voltage offset at zero current of each current sensor See the current sensor test procedure MG 90 L1 02 VLT is a registered Danfoss trademark 81 ish Power Service Manual for VLT FC Series 5 Frequency Converter and Motor Applications Frequen
145. ble to frequency converter terminal 61 This terminal connects to earth through internal RC link It is recommended to use twisted pair cables to reduce the PE differential mode interference between conductors 17574165 11 Table 2 3 Earthing Screened Cables MG 90 L1 02 VLT is a registered Danfoss trademark 41 Power Service Manual for VLT9 Series 3 Internal Frequency Converter Operation Frequency Converters 42 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Frequency Converters 3 Internal Frequency Converter Operation 3 Internal Frequency Converter Operation 3 1 General This section is intended to provide an operational overview of the frequency converter s main assemblies and circuitry With this information a repair technician should have a better under standing of the frequency converter s operation and aid in the troubleshooting process 3 2 Description of Operation A frequency converter is an electronic controller that supplies a regulated amount of AC power to a three phase induction motor in order to control the speed of the motor By supplying variable frequency and voltage to the motor the frequency converter controls the motor speed or main tains a constant speed as the load on the motor changes The frequency converter can also stop and start a motor without the mechanical stress associated with
146. cally result in a corresponding current imbalance 2 Apply power to the frequency converter and place it in run 3 Using a clamp on amp meter analog preferred read the current on each of three input lines at L1 R L2 S and L3 T Typically the current should not vary from phase to phase by more than 596 Should a greater current variation exist it would indicate a possible problem with the mains supply to the frequency converter or a problem within the frequency converter itself One way to determine if the mains supply is at fault is to swap two of the incoming phases This assumes that two phases read one current while the third deviates by more than 5 If all three phases are different from one another swap the phase with the highest current with the phase with the lowest current 4 Remove power to frequency converter 5 the phase that appears to be incorrect with one of other two phases 6 Reapply power to the frequency converter and place it in run 7 Repeat the current measurements If the imbalance of supply voltage moves with swapping the leads then the mains supply is sus pect Otherwise it may indicate a problem with the gating of the SCR This may be due to a defective SCR or in the gate signals from the power card to the module including the possibility of the wire harness from the power card to the SCR gates Further tests on the proper gating of the SCRs require an oscilloscope equipped with current probes P
147. cation cables as to other signal cables Using twisted pair cables and routing them away from power conductors is encouraged While screened cable provides additional EMI protection the screen capacitance may reduce the maximum allowable cable length at high data rates MG 90 L1 02 VLT is a registered Danfoss trademark 85 ish Power Service Manual for VLT FC Series 5 Frequency Converter and Motor Applications Frequency Converters 5 2 8 Proper Installation 86 Shown in the illustration below is a correct installation with EMC considerations in mind Although most installations will not follow all the recommended practices the closer an installation resembles this example the better immunity the network will have against EMI Should EMI problems arise in an installation refer to this example Attempt to replicate this installation recommendation as closely as possible to alleviate such problems PLC etc Panel Es jo B 8 9 20000 ggg OLEN 000 10505 0000 EI 2 711 900 Output con factor etc mr xA Earthing rail Cable insula esa tion stripped ui Min 16mm2 Equalizing cable cable entries in one sid
148. charge circuit card also provides snubbing for the SCRs It is important to pay close attention to the polarity of the meter leads to ensure identification of a faulty component should an incorrect reading appear Prior to performing the test it is necessary to ensure the soft charge fuses 1 F2 and located on the soft charge card are good Illustration 6 4 shows the soft charge card and the location of the fuses It is for reference only It is not necessary to remove the card to perform the tests Soft charge fuse test Use a digital ohmmeter to test continuity on rectifier fuses F1 F2 and F3 at connector MK106 on the power card NB If the unit has fused disconnect option make test connections 11 12 and L3 to the output drive side of the disconnect Do not unplug the connector 1 Measure fuse F1 from the mains input 11 R to MK106 pin 10 the power card 2 Measure fuse F2 from the mains input L2 S to MK106 pin 8 on the power card 3 Measure fuse F3 from the mains input L3 T to MK106 pin 6 on the power card A measurement of 0 ohms indicates good continuity Replace any open fuse infinite resistance To replace a soft charge fuse follow the soft charge disassembly instructions in Section 7 F1 F2 F3 130BX65 12 Illustration 6 6 Soft Charge Card Fuses 380 480 500 Blue amp 8 PTCs 525 690V Red MOV amp 6 PTCs MG 90 L1 02 VLT is a registered Danfoss trademark 9
149. connecting the cable at MK3 return to the Main Rectifier tests and repeat those tests Put the power card temporarily back in place to retest the main rectifier Replace any defective assemblies in accordance with the disassembly proce dures in Section 7 130BX71 10 Illustration 6 7 Soft Charge Card Connectors 380 480 500V Blue MOV amp 8 PTCs 525 690V Red MOV amp 6 PTCs 1 MK1 3 MK4 2 MK2 4 MK3 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 2 3 Soft Charge and Rectifier Circuits Test E frame Size For E frame size frequency converters the rectifier and soft charge circuits are tested separately The soft charge circuit is made up of the soft charge rectifier fuses and the soft charge resistor The rectifier circuit is made up of the SCR and diode modules The soft charge resistor limits the inrush current when power is applied to the frequency converter The soft charge circuit card also provides snubbing for the SCRs It is important to pay close attention to the polarity of the meter leads to ensure identification of a faulty component should an incorrect reading appear Prior to performing the test it is necessary to ensure the soft charge fuses F1 F2 and F3 located on the soft charge card are good An open fuse could indicate a problem in the soft charge circuit Continue test procedures Illustration 6 6
150. crews per bus bar 10 Remove the three SCR and diode input bus bars by removing the 6 connection screws T50 There are 2 screws per bus bar CONTINUED NEXT PAGE EN 5 2 n 1 d 3 4 C 5 6 Illustration 8 1 SCR and Diode Modules 2 of 3 1 Load sharing option retaining stud Step 8 4 Positive output bus bar connecting screw Step 9 2 SCR and diode input bus bar BB41 Step 10 5 Negative output bus bar BB42 Step 9 3 Positive output bus bar BB42 Step 9 6 Negative output bus bar connecting screw Step 9 MG 90 L1 02 VLT is a registered Danfoss trademark 163 8 E Frame Sizes Disassembly and Assembly sn Power Service Manual for VLT FC Series Instructions Frequency Converters 11 Note which gate lead connects to which SCR module Ensure that the correct wire is attached to the applicable SCR upon reassembly Remove the wiring from each SCR module The connector is keyed for proper reinstallation DO NOT force the connection 12 Remove the SCR or diode module by removing the 4 retaining screws T25 from each module 130BX107 10 Illustration 8 1 SCR and Diode Modules 3 of 3 1 SCR module SCR2 5 Diode module D1 2 Retaining screw Step 12 6 Diode module D2 3 SCR module SCR1 7 Diode module D3 4 SCR gate lead connection Step 11 8 SCR module SCR3 REASSEMBLY Equipment Damage Do not rever
151. critical status e g an overcurrent overvoltage To avoid tripping the frequency converter alarm protection mode is activated which includes reducing the switching frequency to 4 kHz If possible protection mode ends after approximately 10 s Activation of protection mode can be restricted by adjusting the par 14 26 Trip Delay at Inverter Fault QStop The motor is stopped using a quick stop ramp par 3 81 Quick Stop Ramp Time 1 Quick stop inverse was chosen as a function for a digital input parameter group 5 1 The corresponding terminal e g Terminal 27 is not active 2 Quick stop function was activated via serial communication Ramping The motor is accelerating decelerating using the active Ramp Up Down The reference a limit value or a standstill is not yet reached Ref high In par 4 55 Warning Reference High a reference high limit is set The sum of all active references is above the reference limit Ref low In par 4 55 Warning Reference High a reference low limit is set The sum of all active references is below the reference limit Run on ref MG 90 L1 02 VLT is a registered Danfoss trademark 33 2 Operator Interface and Frequency Converter 2 High Power Service Manual for VLT Series Control Frequency Converters The FC is running in the reference range The feedback value matches the set reference value Run request FC 100 200 only A start command has been given but the motor
152. cy converter from overheating if the brake resistor is overloaded The Brake IGBT gate signal originates on the control card and is delivered to the brake IGBT via the power card and gate frequency converter card Additionally the power and control cards monitor the brake IGBT and brake resistor connection for short circuits and overloads CBL23 gar onare wla RESISTOR BRAKE IGBT BRK R MK105 a 82 R BRAKE GATE RES CARD 183 PCAI3 EM GATE COL 1308X132 10 Illustration 3 8 Brake option MG 90 L1 02 VLT is a registered Danfoss trademark 53 Power Service Manual for VLT9 FC Series 3 Internal Frequency Converter Operation Frequency Converters 3 3 5 Cooling Fans All frequency converters in this size range are equipped with cooling fans to provide airflow along the heatsink Units in NEMA 1 IP21 and NEMA 12 IP54 enclosures have a fan mounted in the enclosure door to provide additional airflow to the unit Chassis 00 enclosures have a fan or fans mounted to the top of the unit for additional cooling Some frequency converters in this size range have a small 24 VDC fan mounted on the input plate This fan is only mounted on E frame size units equipped with both an RFI filter and mains fuses The fan provides air flo
153. cy Converters 5 2 3 Signal and Power Wiring Considerations for Frequency Con verter Electromagnetic Compatibility The following is an overview of general signal and power wiring considerations when addressing the Electromagnetic Compatibility EMC concerns for typical commercial and industrial equip ment Only certain high frequency phenomena RF emissions RF immunity are discussed Low frequency phenomena harmonics mains voltage imbalance notching are not covered Special installations or compliance to the European CE EMC directives will require strict adherence to relevant standards and are not discussed here 5 2 4 Effect of EMI While Electromagnetic Interference EMI related disturbances to frequency converter operation are uncommon the following detrimental EMI effects may be seen Motor speed fluctuations Serial communication transmission errors Drive CPU exception faults Unexplained frequency converter trips A disturbance resulting from other nearby equipment is more common Generally other industrial control equipment has a high level of EMI immunity However non industrial commercial and consumer equipment is often susceptible to lower levels of EMI Detrimental effects to these sys tems may include the following Pressure flow temperature signal transmitter signal distortion or aberrant behaviour Radio and TV interference Telephone interference Computer network data loss Digital control system faults
154. cy converter or connected equipment Power is removed from the motor A trip lock can only be reset after the condition is cleared by cycling power Once the problem has been rectified only the alarm con tinues flashing until the frequency converter is reset An X marked in the table below means that action occurs A warning precedes an alarm No Description Warning Alarm Trip Alarm Trip Lock 1 10 volts low X 2 Live zero error X X 3 No motor X 4 Mains phase loss X X X 5 DC link voltage high X 6 DC link voltage low X 7 DC overvoltage X X 8 DC undervoltage X X 9 Inverter overloaded X X 10 Motor overtemperature X X 11 Motor thermistor overtemperature X X 12 Torque limit X X 13 Overcurrent X X X 14 Earth ground fault X X X 15 Hardware mismatch X X 16 Short circuit X X 17 Control word time out X X 22 Hoist mechanical brake X 23 Internal fan fault X 24 External fan fault X 25 Brake resistor short circuit X Table 4 2 Warning alarm code list MG 90 L1 02 VLT is a registered Danfoss trademark 63 high Power Service Manual for VLT FC Series 4 Troubleshooting Frequency Converters No Description Warning Alarm Trip Alarm Trip Lock 26 Brake resistor power limit X X 27 Brake chopper fault X X 28 Brake check failed X X 29 Heatsink temp X X X 30 Motor phase U missing X X X 31 Motor phase V missing X X X 32 Motor phase W missing X X X
155. cy converter monitors supply and output voltages along with the operational condition of the motor and load When the frequency converter issues a warning or alarm it cannot be assumed that the fault lies within the frequency converter itself In fact for most service calls the fault condition will be found outside of the frequency converter Most of the warnings and alarms that the frequency converter displays are generated by response to faults outside of the frequency converter This service manual provides techniques and test procedures to help isolate a fault condition whether in the frequency converter or elsewhere Familiarity with the information provided on the display is important Additional diagnostic data can be accessed easily through the LCP 2 2 User Interface 2 2 1 How to Operate the Graphic Local Control Panel LCP The LCP is divided into four functional groups 1 Graphical display with status lines 2 Menu keys and indicator lights LEDs selecting mode changing parameters and switching between display functions 3 Navigation keys and indicator lights LEDs 4 Operation keys and indicator lights LEDs Graphical display The LCD display is back lit with a total of 6 alpha numeric lines All data is displayed on the LCP which can show up to five operating variables whilst in Status mode MG 90 L1 02 VLT is a registered Danfoss trademark 23 2 Operator Interface and Frequency Converter 2 High
156. defective and must be re placed 130BP040 10 Be certain however that the display is completely dark Having a single character in the upper corner of the LCP or just a dot indicates that communications may have failed with the control card This is typically seen when a serial bus communication option has been installed in the frequency converter and is either not connected properly or is malfunctioning If neither indication is available then the source of the problem may be elsewhere Proceed to the No Display test 6 3 1 to carry out further troubleshooting steps 4 5 2 Intermittent Display Cutting out or flashing of the entire display and power LED indicates that the power supply SMPS is shutting down as a result of being overloaded This may be due to improper control wiring or a fault within the frequency converter itself The first step is to rule out a problem in the control wiring To do this disconnect all control wiring by unplugging the control terminal blocks from the control card If the display stays lit then the problem is in the control wiring external to the frequency con verter All control wiring should be checked for shorts or incorrect connections If the display continues to cut out follow the procedure for No Display as though the display were not lit at all 60 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 4 Trouble
157. dications of a failure in this circuit IGBT failures may be caused by the frequency converter being exposed to repeated short circuits or earth faults or by extended frequency converter operation outside of its normal operating parameters Following an IGBT failure it is important to verify the gate frequency converter signals are present and of the correct waveform See the dynamic test section on checking IGBT gate drive signals Gate resistor test Mounted to each IGBT module is an IGBT gate resistor board containing among other compo nents the gate resistors for the IGBT transistors Based on the nature of the failure a defective IGBT can produce good readings from the previous tests In nearly all cases the failure of an IGBT will result in the failure of the gate resistors Located on the gate drive card near each of the gate signal leads is a 3 pin test connector see Illustration 6 17 These are labelled MK 250 350 450 550 650 750 and if the frequency converter is equipped with a brake option 850 For the sake of clarity refer to the 3 pins as one two and three reading left to right Pins 1 and 2 of each connector are in parallel with the gate drive signal sent to the IGBTs Pin 1 is the signal and Pin 2 is common 1 With ohmmeter measure pins 1 and 2 of each test connector Reading should indicate 7 8K ohms for D1 D3 Frames 3 9K ohms for D2 D4 Frames and 2 6K ohms for E1 E2 frames Incorrect reading An incor
158. e fan speed to increase to the maximum If the sensor wire between the IGBT and the gate drive card is disconnected this warning is produced Also check the IGBT thermal sensor see section 6 2 8 ALARM 67 Option module configuration has changed One or more options have either been added or removed since the last power down ALARM 68 Safe stop activated Safe stop has been activated To resume normal operation apply 24 VDC to terminal 37 then send a reset signal via bus digital I O or by pressing the reset key See par 5 19 7 37 Safe Stop ALARM 69 Power card temperature The temperature sensor on the power card is either too hot or too cold See the ratings table in Section 1 9 for the high and low temperatures that can cause this alarm Troubleshooting Check the operation of the door fans Make sure that the filters for the door fans are not blocked Make sure that the gland plate is properly installed on IP21 and IP54 NEMA 1 and NEMA 12 frequency converters ALARM 70 Illegal FC Configuration The current control board and power board combination is illegal WARNI NG ALARM 71 PTC 1 safe stop Safe Stop has been activated from the MCB 112 PTC thermistor card motor too warm Normal operation can be resumed when the MCB 112 applies 24 V DC to T 37 again when the motor temperature reaches an acceptable level and when the digital input from the MCB 112 is deac tivated When this happens a reset signal is sen
159. e motor to ach ieve a controlled end of the active ramp AMA finish OK Enable complete or reduced AMA was selected in par 1 29 Automatic Motor Adaptation AMA The Automatic Motor Adaptation was carried out successfully AMA ready Enable complete or reduced AMA was selected in par 1 29 Automatic Motor Adaptation AMA The Automatic Motor Adaptation is ready to start Press Hand On on the LCP to start AMA running Enable complete or reduced AMA was selected in par 1 29 Automatic Motor Adaptation AMA The AMA process is in progress Braking The brake chopper is in operation Generative energy is absorbed by the brake resistor Braking max The brake chopper is in operation The power limit for the brake resistor defined in par 2 12 Brake Power Limit KW is reached Bus Jog 1 PROFIDrive profile was selected in par 8 10 Contro Word Profile The Jog 1 function is activated via serial communication The motor is running with par 8 90 Bus Jog 1 Speed Bus J og 2 PROFIDrive profile was selected in par 8 10 Contro Word Profile The Jog 2 function is activated via serial communication The motor is running with par 8 91 Bus Jog 2 Speed Catch up The output frequency is corrected by the value set in par 3 12 Catch up slow Down Value 1 Catch up is selected as a function for a digital input parameter group 5 1 The corre sponding terminal is active 2 Catch up was activated via serial communication 1 Coast inv
160. e motor will be unable to reach full speed These parameters must be set according to the requirements of the particular instal lation References are set in the 3 0 parameter group Incorrectly set I O configuration usually results in the frequency converter not responding to the function as commanded It must be remembered that for every control terminal input or output there are corresponding parameters settings These determine how the frequency converter re sponds to an input signal or the type of signal present at that output Utilising an I O function must be thought of as a two step process The desired I O terminal must be wired properly and the corresponding parameter must be set accordingly Control terminals are programmed in the 5 0 and 6 0 parameter groups 5 1 5 Motor Load Problems Problems with the motor motor wiring or mechanical load on the motor can develop in a number of ways The motor or motor wiring can develop a phase to phase or phase to earth short re sulting in an alarm indication Checks must be made to determine whether the problem is in the motor wiring or the motor itself A motor with unbalanced or non symmetrical impedances on all three phases can result in un even or rough operation or unbalanced output currents Measurements should be made with a clamp on style ammeter to determine whether the current is balanced on the three output phases See Output Imbalance of Supply Voltage Test procedure An i
161. e of panel IT Control cables 1 J A Min 200mm Motor cable I between con trol cables 4 ico gt Mains supply motor cable and 11 mains cable L2 L5 ed PE Motor 3 phases and Reinforced protective earth Protective earth Illustration 5 5 Proper EMC Installation MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 Test Procedures 6 1 Introduction Touching electrical parts of frequency converter may be fatal even after equipment has been disconnected from AC power Wait 20 minutes for D frame sizes or 40 minutes for E frame sizes after power has been removed before touching any in ternal components to ensure that capacitors have fully discharged See label on front of frequency converter door for specific discharge time This section contains detailed procedures for testing frequency converters Previous sections of this manual provide symptoms alarms and other conditions which require additional test proce dures to further diagnose the frequency converter The results of these tests indicate the appropriate repair actions Again because the frequency converter monitors input and output signals motor conditions AC and DC power and other functions the source of fault conditions may exist outside of the frequency converter itself Testing d
162. e signal test board into the power card con nector MK104 MG 90 L1 02 VLT is a registered Danfoss trademark 107 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters 4 Connect the negative meter lead to terminal 4 common of the signal board With a positive meter lead check the following terminals on the signal board Terminal Supply Voltage Range 11 18V 16 5 19 5 VDC 12 18V 16 5 19 5 VDC 23 24V 23 25 VDC 24 5V 4 75 5 25 VDC In addition the signal test board contains three LED indicators that indicate the presence of volt age as follows Red LED 18VDC supplies present Yellow LED 24VDC supply present Green LED 5VDC supply present The lack of any one of these power supplies indicates the low voltage supplies on the power card are defective This assumes of course that the proper DC bus voltage was read at power card connector MK105 A and B Replace the power card in accordance with the disassembly pro cedures in Section 7 or 8 6 3 5 Zero DC Bus Voltage Test If no voltage is present at power card connector MK105 A and B check the condition of the DC power supply fuse The fuse is located on the power card mounting plate next to the power card It can be tested without disassembling the unit 1 Remove power to the frequency converter and make sure the DC bus is fully discharged by measuring the voltage at the power card connector MK105 A with
163. e values in the table below are used These values are not intended for SCR diode or IGBT fasteners See the instructions included with those replacement parts for correct values Shaft Size Driver Size Torx Hex Torque in Ibs Torque Nm M4 T 20 7 mm 10 1 0 M5 T 25 8 mm 20 2 3 M6 T 30 10 mm 35 4 0 M8 T 40 13 mm 85 9 6 M10 T 50 17 mm 170 19 2 Table 1 7 Torque Values Table 14 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 1 Introduction 1 8 Exploded Views 130BX167 10 Illustration 1 1 Exploded view D3 Frame size D1 frame is similar 1 Control card PCA1 14 SCR Diode module SCR 1 2 3 2 Control input terminals 15 IGBT output bus bar 3 Local Control Panel LCP 16 Output motor terminals TB2 4 Control card C option 17 Current sensor L2 L3 L4 5 Mounting bracket 18 Fan assembly Fi C1 CBL11 6 Power card mounting plate 19 Fan transformer TR1 7 Power card 3 20 Main AC power input terminals TB1 8 Capacitor bank assembly CBANK1 PCA9 21 AC input bus bar 9 Soft charge fuses 22 Input terminal mounting plate assembly 10 Soft charge card PCA11 23 Fan fuse FU4 11 DC inductor 11 24 Capacitor bank cover plate 12 Soft charge module R1 CBL26 25 IGBT gate drive card 5 13 IGBT module IGBT 1 MG 90 L1 02 VLT is a registered Danfoss trademark 15 high Power Service Manual for VLT
164. e1eds ped Jamod L00SdXxx 3Jepd peo e1eds LOSpdXXx 2Jepd pae 1a wod 100 peo e1eds LGTEdXXx 2Jopd Jamod LOSZdXxx 3Jepd peo e1eds 100 ped 1a wod LO9TdXxx 3Jepd peo e1eds ped L0 9dxxx 3Jepd peo e1eds pied 1a wod L00SdXxx 3Jepd peo e1eds LOSpdXXx 2Jepd ped 1a wod LOOpdXxx 3Jepd peo e1eds LGTEdXXx 2Jopd Jamod LoSZdXxx 3Jepd pes e1eds 100 ped 1e wod LO9TdXxx 3Jepd peo e1eds 22 ped 1a wod L0 9dxxx 3Jepd peo e1eds pied Jamod 1006 peo e1eds LOSpdXXx 2Jepd Jamod
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166. egistered Danfoss trademark 194 10 Spare Parts List eJnso u3 357 sued 9T 0T eiqer High Power Service Manual for VLT9 FC Series Frequency Converters 0041 OOdI 0041 004 Jeued 004 8 849 0041 0041 jaued epis 0041 2 8 9 T T T T pseog AouanbaJJ ubiu 104 pub 4H Pig eds 6 949 0 o o I I p1eoq AouenbaJj 40 pub 4H Pg es4edS 06p839 T dwep 09 09 duiej eds 02 849 1 lt 0954 0054 00 SSEd STEd 0444 0044 0914 0624 JequuinN Jojeu amp isaq 0 94 0954 0054 OStd 00 STEd OScd 0044 09 4 20604 5 Hed webera 0594 0954 0054 OStd 00 STEd 0444 0044 ZOT OA 7 va ca JVA 069 SZS 195 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Frequency Converters 10 Spare Parts List T 06d DESDE T T I DEDE T T T woe T T I _ YE MSZd ASSd 25 4 75 4 ASSd OVA 069 SZS coe 24 zoz 24 c0T
167. ement parts The frequency converter has been de signed to operate within certain specifications Incorrect parts may affect tolerances and result in further damage to the unit 5 Read the instruction and service manuals A thorough understanding of the unit is the best approach If ever in doubt consult the factory or authorised repair centre for as sistance 4 2 Exterior Fault Troubleshooting There may be slight differences in servicing a frequency converter that has been operational for some extended period of time compared to a new installation When using proper troubleshooting procedures make no assumptions To assume a motor is wired properly because the frequency converter has been in service for some time may cause you to overlook loose connections im proper programming or added equipment for example It is best to develop a detailed approach beginning with a physical inspection of the system See Table 4 1 Visual Inspection for items to examine 4 3 Fault Symptom Troubleshooting This troubleshooting section is divided into sections based on the symptom being experienced To start Table 4 1 provides a visual inspection check list Many times the root cause of the problem may be due to the way the frequency converter has been installed or wired The check list provides guidance through a variety of items to inspect during any frequency converter service process Next symptoms are approached as the technician most commonly di
168. en a load problem and a frequency converter problem Should a voltage imbalance in the output be detected with the motor disconnected it is necessary to test the gate drive circuits for proper firing Proceed to the gate drive signals test 6 3 11 If the voltage was balanced but the current imbalanced when the motor was connected then the load is suspect There could be a faulty connection between the frequency converter and motor or a defect in the motor itself Look for bad connections at any junctions of the output wires including connections made to contactors and overloads Also check for burned or open contacts in such devices MG 90 L1 02 VLT is a registered Danfoss trademark 113 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters 6 3 11 I GBT Gate Drive Signals Test This procedure tests the gate drive signals at the output of the gate drive card just prior to them being delivered to the IGBTs A simple test to check for the presence of the gate signals be performed with a DVM however to actually check the waveforms an oscilloscope is required Disable the DC bus when performing this test with Test Cable p n 176F8437 Failure to do so could result in damage to the frequency converter if the probe is inadver tently connected to the wrong pins Additionally AC mains bus bars are in close proximity to these test points Exercise caution when working close to high voltage com
169. erload too high current for too long The counter for electronic thermal inverter protection gives a warning at 98 and trips at 100 while giving an alarm The frequency converter cannot be reset until the counter is below 90 The fault is that the frequency converter is overloaded by more than 100 for too long Troubleshooting Compare the output current shown on the LCP with the frequency converter rated cur rent Compare the output current shown on the LCP with measured motor current Display the Thermal Drive Load on the LCP and monitor the value When running above the frequency converter continuous current rating the counter should increase When running below the frequency converter continuous current rating the counter should decrease Note See the derating section in the Design Guide for more details if a high switch frequency is required WARNI NG ALARM 10 Motor overload temperature According to the electronic thermal protection ETR the motor is too hot Select whether the frequency converter should give a warning or an alarm when the counter reaches 100 in par 1 90 Motor Thermal Protection The fault is that the motor is overloaded by more than 100 for too long Troubleshooting Check if motor is overheating If the motor is mechanically overloaded That the motor par 1 24 Motor Current is set correctly Motor data in parameters 1 20 through 1 25 are set correctly The setting in par 1 91 Motor External F
170. erminals 1 2 3 7 107 15 Current scaling card 4 8 FK103 16 Current scaling card standoff MG 90 L1 02 VLT is a registered Danfoss trademark 125 7 D Frame Sizes Disassembly and Assembly ish Power Service Manual for VLT FC Series Instructions Frequency Converters 7 2 4 Power Card Mounting Plate 1 Remove the control assembly mounting bracket in accordance with procedure 2 power card mounting plate see Illustration 7 1 can be removed with the power card still mounted if so desired If the power card is to be removed remove it in ac cordance with the power card procedure 3 To remove the power card mounting plate with the power card attached unplug con nectors 100 102 MK105 106 107 and 109 see Illustration 7 2 If customer connections are present unplug connectors FK102 FK103 and MK112 Remove the nut 7 mm attaching the MK102 ring lug to the power card mounting plate Remove the 2 connectors one on each end of the DC bus fuse holder e Remove the 2 nuts 10 mm on the right side of the power card mounting plate Two nuts that secure the control assembly mounting bracket also secure the left side of the power card mounting bracket Reinstall in reverse order of this procedure The ring lug for the wire assembly that connects to power card connector MK102 attaches to the right mounting stud on the top of the power card mounting plate The white
171. erse has been selected as a function for a digital input parameter group 5 1 The corresponding terminal e g Terminal 27 is not connected 2 Coast is on 0 on serial communication Control ready PROFIDrive profile was selected in par 8 10 Contro Word Profile FC needs the second part e g 0x047F of the two part start command via serial communication to allow starting Using a terminal is not possible Ctrl Ramp down A function with Ctrl Ramp down was selected in par 14 10 Mains Failure The Mains Voltage is below the value set in par 14 11 Mains Voltage at Mains Fault The FC ramps down the motor using a controlled ramp down Current High In par 4 51 Warning Current High a current limit is set The output current of the FC is above this limit MG 90 L1 02 VLT is a registered Danfoss trademark 31 2 Operator Interface and Frequency Converter 2 High Power Service Manual for VLT Series Control Frequency Converters Current Low In par 4 52 Warning Speed Low a current limit is set The output current of the FC is below this limit DC Hold The motor is driven with a permanent DC current par 2 00 DC Current DC hold is selected in par 1 80 Function at Stop Stop command e g Stop inverse is active DC Stop The motor is momentarily driven with a DC current par 2 01 DC Brake Current for a specified time par 2 02 DC Braking Time 1 DC Brake is activated OFF in par 2 03
172. erters Control 2 2 2 Numeric Local Control Panel NLCP See the FC Series Operating Instructions for instructions for using the numeric LCP 2 2 3 Tips and Tricks For the majority of applications the Quick Menu Quick Set up and Function Set up provides the simplest and quickest access to all the typical parameters required i Whenever possible performing an AMA will ensure best shaft performance Display contrast can be adjusted by pressing Status and for a darker display or by pressing Status and V for a brighter display Under Quick Menu and Changes Made any parameter that has been changed from factory settings is displayed Press and hold the Main Menu key for 3 seconds to access any parameter For service purposes it is recommended to all of the parameters to the LCP see par 0 50 Copy for further information Table 2 1 Tips and tricks MG 90 L1 02 VLT is a registered Danfoss trademark 29 2 Operator Interface and Frequency Converter 7 High Power Service Manual for VLT FC Series Control Frequency Converters 2 3 Status Messages 30 Status messages appear in the bottom of the display see the example below The left part of the status line indicates the active operation model of the frequency converter The centre part of the status line indicates the references site The last part of the status line gives the operation status e g Running Stop
173. escribed here will isolate many of these conditions as well Sections 7 and 8 Disassembly and Assembly Instructions describes detailed procedures for removing and replacing frequency converter components as required D or E sized frequency converters respectively Frequency converter testing is divided into Static Tests Dynamic Tests and Initial Start Up or After Repair Drive Tests Static tests are conducted without power applied to the frequency con verter Most frequency converter problems can be diagnosed simply with these tests Static tests are performed with little or no disassembly The purpose of static testing is to check for shorted power components Perform these tests on any unit suspected of containing faulty power com ponents prior to applying power For dynamic test procedures main input power is required All devices and power supplies connected to mains are energised at rated voltage Use extreme caution when conducting tests on a powered frequency converter Contact with powered components could result in electrical shock and personal injury Dynamic tests are performed with power applied to the frequency converter Dynamic testing traces signal circuitry to isolate faulty components Both D frame and E frame size frequency converters are covered here Differences in the proce dures are noted as required However the Soft Charge and Rectifier Circuit Test Soft Charge Rectifier Test and Fan Continuity
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176. f the capacitors and DC coil would be drastically reduced When the input voltage becomes unbalanced or a phase disappears completely the ripple voltage increases causing the frequency converter to trip and issue an Alarm 4 In addition to missing phase voltage increased bus ripple can be caused by a line disturbance or imbalance Line dis turbances may be caused by line notching defective transformers or other loads that may be effecting the form factor of the AC waveform Mains imbalances which exceed 3 cause sufficient DC bus ripple to initiate a trip Output disturbances can have the same effect of increased ripple voltage on the DC bus A missing or lower than normal output voltage on one phase can cause increased ripple on the DC bus Should a mains imbalance trip occur it is necessary to check both the input and output voltage of the frequency converter Severe imbalance of supply voltage or phase loss can easily be detected with a voltmeter Line disturbances most likely need to be viewed on an oscilloscope Conduct tests for input imbalance of supply voltage input waveform and output imbalance of supply voltage as described in the chapter 7roubleshooting 5 1 3 Control Logic Problems Problems with control logic can often be difficult to diagnose since there is usually no associated fault indication The typical complaint is simply that the frequency converter does not respond to a given command There are two basic commands tha
177. for all signals MON 5 AMBT _ Ambient temp Used to control FAN high and low 1 approximately equal to 25C speeds 6 FANO Control Card Signal from the control card to turn the 0 ON command nal fans on and off 5 VDC OFF command 7 INRUSH Control Card sig Signal from the control card to start gating 3 3 VDC SCRs disabled nal the SCR front end 0 VDC SCRs enabled 8 RL1 Control Card sig Signal from Control Card to provide status 0 VDC Relay active nal of Relay 01 0 7 VDC inactive 9 Not used 10 Not used 11 VPOS 18 VDC regula The red LED indicates voltage is 18 VDC regulated supply 16 5 to ted supply 16 5 between VPOS and VNEG terminals 19 5 VDC to 19 5 VDC 12 VNEG 18 VDC regulated The red LED indicates voltage is present 18 VDC regulated supply supply between VPOS and VNEG terminals 16 5 to 19 5 VDC 16 5 to 19 5 VDC 13 DBGATE Brake IGBT gate iota Voltage drops to zero when brake is pulse train i turned off Voltage increases to 4 04 J VDC as brake duty cycle reaches max Jd Varies w brake duty cycle 14 BRT_O IGBT 50 mona 5 10 VDC level with the brake turned N logic level signal E off Voltage decreases to zero as brake ri 1 17 duty cycle reaches max Varies w brake duty cycle 15 Not used 16 FAN TS Control signal Indicates Fan Test switch is activated to 5VDC dis
178. g message Check all brake parameters and ramp down time parameters 2 0 and 3 4 Perform Brake Check 6 3 13 62 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 4 Troubleshooting 4 6 Warning Alarm Messages 4 6 1 Warning Alarm Code List A warning or an alarm is signalled by the LEDs on the front of the frequency converter and by a code on the display A warning indicates a condition that may require attention or a trend that may eventually require attention A warning remains active until the cause is no longer present Under some circumstan ces motor operation may continue A trip is the action when an alarm has appeared The trip removes power to the motor and can be reset after the condition has been cleared by pressing the reset button or through a digital input parameter 5 1 The event that caused an alarm cannot damage the frequency converter or cause a dangerous condition Alarms must be reset to restart operation once their cause has been rectified This may be done in three ways 1 Pressing the reset button on the control panel LCP 2 digital reset input 3 Serial communication optional fieldbus reset signal NB After a manual reset using the RESET button on the LCP the AUTO ON button must be pressed to restart the motor Atrip lock is an action when an alarm occurs which may cause damage to the frequen
179. g studs Step 8 4 Positive output bus bar connecting screw Step 9 2 SCR and diode input bus bar BB41 Step 10 5 Negative output bus bar BB42 Step 9 3 Positive output bus bar BB42 Step 9 6 X Negative output bus bar connecting screw Step 9 MG 90 L1 02 VLT is a registered Danfoss trademark 169 8 E Frame Sizes Disassembly and Assembly ish Power Service Manual for VLT FC Series Instructions Frequency Converters 11 Remove the 6 retaining screws T30 connecting each IGBT module output to the IGBT output bus bars 12 Remove the retaining nut 17 mm connecting the IGBT output bus bar to IGBT over fan bus bar Note that there is one for each of three phases 13 Remove the retaining nut 17 mm or T50 Torx screw depending on the unit type con necting to IGBT over fan bus bar to current sensor bus bar 14 Remove the 3 retaining nuts 17 mm at top and one retaining nut 8 mm at bottom attaching IGBT output bus bar to standoffs Remove the IGBT output bus bar CONTINUED NEXT PAGE 1 2 3 4 62 5 6 T 58 Illustration 8 1 IGBT Modules 3 of 4 Retaining screw Step 11 Retaining nut Step 14 Output bus bar Retaining nut Step 14 Retaining nut Step 12 Over fan bus bar Retaining nut Step 13 NOW 170
180. ge circuit is restricting the DC bus from charging Conduct the input voltage test 6 3 2 to ensure the mains voltage is correct If excessive input power cycling has occurred the PTC resistors on the soft charge card may be restricting the bus from charging If this is the case expect to read a DC bus voltage in the area of 50 VDC 1 Check DC bus voltage by reading power card connector MK105 A with respect to MK105 B If verified disconnect the power from the frequency converter and allow it to cool for approximately 20 minutes 2 Reapply power to the frequency converter after 20 minutes the DC bus voltage If voltage remains a short circuit may exist within the intermediate circuit pre venting it from charging Proceed to static checks 6 2 earlier in this section 6 3 7 Input I mbalance of Supply Voltage Test Theoretically the current drawn on all three input phases should be equal Some imbalance may be seen however due to variations in the phase to phase input voltage and to some degree single phase loads within the frequency converter itself A current measurement of each phase will reveal the balanced condition of the line To obtain an accurate reading it will be necessary for the frequency converter to run at its rated load or or at a load of not less than 40 1 Perform the input voltage test prior to checking the current in accordance with proce dure Voltage imbalances will automati
181. gh frequencies results in an instantaneous voltage at points reputed to be at eart potential This voltage can appear throughout a system as a common mode signal that can interfere with control signals Theoretically these currents will return to the frequency converter s DC bus via the earth circuit and a high frequency HF bypass network within the frequency converter itself However im perfections in the frequency converter earthing or the equipment earth system can cause some of the currents to travel out to the power network MG 90 L1 02 VLT is a registered Danfoss trademark 83 Power Service Manual for VLT9 FC Series 5 Frequency Converter and Motor Applications Frequency Converters Frequency Converter Motor Motor cable Stray capacitance Signal wiring to BMS 130BX139 12 Illustration 5 3 Signal Conductor Currents Unprotected or poorly routed signal conductors located close to or in parallel to motor and mains conductors are susceptible to EMI Signal conductors are especially vulnerable when they are run parallel to the power conductors for any distance EMI coupled into these conductors can affect either the frequency converter or the interconnected control device See Illustration 5 4 While these currents will tend to travel back to the frequency converter imperfections in the system will cause some current to flow in undesirable paths thus exposing other locations to the
182. ght corner transformer in the upper right corner 1 Power card PCA3 9 MK106 2 Mounting plate 10 MK100 3 MK110 11 MK109 4 MK102 12 FK102 5 MK104 13 MK112 terminals 4 5 6 6 MK105 14 MK112 terminals 1 2 3 7 107 15 Current scaling card 4 8 FK103 16 Current scaling card standoff MG 90 L1 02 VLT is a registered Danfoss trademark 155 8 E Frame Sizes Disassembly and Assembly sn Power Service Manual for VLT FC Series Instructions Frequency Converters 8 2 4 Soft Charge Card 1 Disconnect 1 MK2 MK3 and MK4 2 Remove the 4 mounting screws T25 from the standoffs 3 Remove the soft charge card Note the insulation sheet below the soft charge card Re move and keep the insulation with the card for reinstallation Reinstall by mounting the insulation onto the standoffs Mount the soft charge card and tighten the mounting screws to 2 3 Nm 20 in Ibs 130BX155 10 Illustration 8 1 Soft Charge Card 380 480 500 Blue MOV and 8 PTCs 525 690 Red MOV 6 PTCs 1 MK3 4 MK4 2 Mounting screw Step 2 5 MK2 3 MK1 156 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Frequency Converters 8 2 5 Gate Drive Card 8 E Frame Sizes Disassembly and Assembly Instructions 1 Disconnect the cables from connectors on the gate drive card MK100 MK102 MK103 MK104 MK106 and if unit has a brake option MK105 and for 380 500 V uni
183. gistered Danfoss trademark 200 High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 11 Block Diagrams 11 Block Diagrams 11 1 Block Diagrams for D Frames 11 1 1 D1 D3 380 500 VAC 130BX200 10 BRAKE OPTION HS ERE FE g 5 3 x ES x Et L Ey y Bex 55 ges L uz 8 DISC FUSE OPTION MG 90 L1 02 VLT is a registered Danfoss trademark 201 11 Block Diagrams 202 High Power Service Manual for VLT9 Series Frequency Converters MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 11 Block Diagrams 11 1 2 D2 D4 380 500 VAC 130BX201 10 2 LOAD SHARE OPTION HS FAN ASSEMBLY BRAKE IGBT TT 1244 BRAKE OPTION T a ZH H pm BILE z5 A A 5 5 A es Lo LES E rol RE A 22 422 4 7 LA DISABLE MAINS RECTIFIER DISC FUSE OPTION MG 90 L1 02 VLT is a registered Danfoss trademark 203 11 Block Diagrams 204 High Power Service Manual for VLT9
184. h a brake option will have brake cabling from MK105 in addition Disconnect the cables at the con nectors on the IGBT modules 3 Remove the retaining nuts 8 mm from the SCR input bus bars 4 Note the colour coding for each of the three wires attached to the retaining studs Ensure that the correct wire is attached to the applicable stud during reassembly Remove the wiring from the studs 5 Remove screw 125 from terminal 1 of each SCR diode module by accessing the screw through the access hole in the SCR diode input bus bar Remove the SCR input bus bars 6 Remove each IGBT output bus bar by removing the nut 10 mm from the stud Also remove retaining screw T30 at the other end of the IGBT output bus bars not shown CONTINUED ON NEXT PAGE 130BX91 10 2 Sed s 5 2 4 D XN Illustration 7 1 D2 D4 IGBT Modules 1 of 3 SCR diode input bus bar BB21 or BB22 per drive power rating 5 Snubber capacitor SCR diode terminal screw Step 5 6 IGBT output bus bar retaining nut Step 6 SCR diode input bus bar retaining nut and stud Steps 3 amp 4 7 SCR diode terminal screw Step 5 IGBT gate signal input terminal Step 2 8 IGBT output bus bar BB32 Step 6 MG 90 L1 02 VLT is a registered Danfoss trademark 147 7 D Frame Sizes Disassembly and Assembly high Power Service Manual for VLT FC Series Instructions Frequency Converters 7 Remove the 4 10 mm
185. he supply Replace the SCR module which corresponds to the incorrect gate signal reading 112 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 3 10 Output I mbalance of Supply Voltage Test Checking the balance of the frequency converter output voltage and current measures the elec trical functioning between the frequency converter and the motor In testing the phase to phase output both voltage and current are monitored It is recommended that static tests on the inverter section of the frequency converter be conducted prior to this procedure If the voltage is balanced but the current is not this indicates the motor is drawing an uneven load This could be the result of a defective motor a poor connection in the wiring between the frequency converter and the motor or if applicable a defective motor overload If the output current is unbalanced as well as the voltage the frequency converter is not gating the output properly This could be the result of a defective power card gate drive connections between the gate drive card and IGBTs or the output circuitry of the drive improperly connected NB Use an analog voltmeter for monitoring output voltage Digital voltmeters are sen sitive to waveform and switching frequencies and commonly return erroneous readings The initial test can be made with the motor connected and
186. he MK4 connector on the soft charge card 3 Loosen top retaining nut 8 mm on soft charge resistor 4 Remove bottom retaining nut 8 mm on the soft charge resistor 5 Lift the bottom of the soft charge resistor and remove the resistor by sliding it down Reinstall in reverse order of this procedure Tighten the 8 mm retaining nuts to 2 3 Nm 20 in Ibs l e EN 4 d Ly z 4 4 85 4 1 7 4 VA 4 7 A T 3 VA TN 5 A 4 9 d Illustration 8 1 Soft Charge Resistor 1 Soft charge card 4 Soft charge resistor 2 4 connector Step 2 5 Bottom retaining nut Step 4 3 Top retaining nut Step 3 380 480 500V Clear wire leads 525 690 Black wire leads MG 90 L1 02 VLT is a registered Danfoss trademark 161 8 E Frame Sizes Disassembly and Assembly ish Power Service Manual for VLT FC Series Instructions Frequency Converters 8 2 9 SCR and Diode Modules Remove the lower DC capacitor bank in accordance with procedure Remove the input terminal plate in accordance with procedure Remove the wire retaining nut 10 mm from each of the 3 SCR input bus bars BB41 oe esp Note colour coding for each of the 3 wires attached to the retaining studs Ensure that the correct wire is attached to the applicable stud upon reassembly Remove the wiring from the studs 5 Remove the wire retaining
187. hen switched on fans should start and run at high speed The signals at terminals 5 and 10 of the signal board determine fan speed See Section 9 for more on those signals In addition if a heatsink overtemperature trip has occurred the fans will auto matically be switched to high speed Given the fact that the fans should be running if the signal at terminal 6 is correct and the fan test switch activates the fan the control card is defective Otherwise the power card is defective Replace the appropriate assembly in accordance with the disassembly instructions in Section 7 or 8 120 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 3 16 Input Terminal Signal Tests The presence of signals on either the digital or analog input terminals of the frequency converter can be verified on the frequency converter display Digital or analog input status can be selected or read in parameters 16 60 through 16 64 Digital inputs With digital inputs displayed control terminals 18 19 27 29 32 and 33 are shown left to right with a 1 indicating the presence of a signal 130BB038 10 If the desired signal is not present in the display the problem may be either in the external control wiring to the frequency converter or a faulty control card To determine the fault location use a voltmeter to test for voltage at the control terminals Ver
188. his is a removable keypad display mounted on the front of the frequency converter The LCPprovides the interface between the frequency converter s internal digital logic and the operator All the frequency converter s programmable parameter settings can be uploaded into the EEPROM of the LCP This function is useful for maintaining a backup frequency converter profile and pa rameter set It can also be used through its download function in programming other frequency converters or to restore a program to a repaired unit The LCP is removable during operation to prevent undesired program changes With the addition of a remote mounting kit the LCP can be mounted in a remote location of up to ten feet away Control terminals with programmable functions are provided for input commands such as run stop forward reverse and speed reference Additional output terminals are provided to supply signals to run peripheral devices or for monitoring and reporting status 44 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Frequency Converters 3 Internal Frequency Converter Operation The control card logic is capable of communicating via serial link with outside devices such as personal computers or programmable logic controllers PLC The control card also provides two voltage supplies for use from the control terminals The 24 VDC is used for switching functions such as start stop and forward reve
189. hol solution 130BX126 10 DOCS 2 70 Illustration 7 1 D2 D4 IGBT Modules 3 of 3 1 IGBT module 2 Retaining screw Step 13 REASSEMBLY 1 Replace the IGBT module in accordance with the instructions provided with the replace ment unit 2 Reassemble the remaining parts in reverse order of their removal 3 Reinstall the module and mounting screws Tighten the remaining T25 and 8 mm screws to 2 3 Nm 20 in Ibs and T30 and 10 mm to 4 Nm 35 in Ibs MG 90 L1 02 VLT is a registered Danfoss trademark 149 7 D Frame Sizes Disassembly and Assembly high Power Service Manual for VLT FC Series Instructions Frequency Converters 7 2 17 Modules D1 D3 Units 1 Remove the control card cassette per instructions 2 Remove the input terminal mounting plate per instructions 3 Note the IGBT gate signal cables connected between the gate drive card connectors MK100 temperature sensor MK102 U MK103 V and MK104 W and the IGBT module connectors These will need to be reconnected in the same locations during re assembly Units with a brake option will have brake cabling from MK105 in addition Remove the capacitor bank per instructions 4 Disconnect the gate drive cables at the connectors on the IGBT modules Disconnect the cable connected to connector MK100 on the high frequency card 6 Remove the high frequency card by removing 2 retaining screws and 1 retaining nut For uni
190. hooting WARNI NG ALARM 13 Overcurrent The inverter peak current limit approx 200 of the rated current is exceeded The warning lasts about 1 5 sec then the frequency converter trips and issues an alarm If extended mechanical brake control is selected trip can be reset externally Troubleshooting This fault may be caused by shock loading or fast acceleration with high inertia loads Turn off the frequency converter Check if the motor shaft can be turned Make sure that the motor size matches the frequency converter Incorrect motor data in parameters 1 20 through 1 25 See section 1 9 for current trip points ALARM 14 Earth ground fault There is a discharge from the output phases to earth either in the cable between the frequency converter and the motor or in the motor itself See section 1 9 for trip levels Troubleshooting Turn off the frequency converter and remove the earth fault Measure the resistance to earth of the motor leads and the motor with a megohmmeter to check for earth faults in the motor Perform the current sensor test section 6 3 14 See section 5 2 for more details ALARM 15 Hardware mismatch A fitted option is not operational with the present control board hardware or software Record the value of the following parameters and contact your Danfoss supplier par 15 40 Type par 15 41 Power Section par 15 42 Voltage par 15 43 Software Version par 15 45 Actua Typecode String par
191. ibed in this section be performed in the order presented Diode Drop A diode drop reading will vary depending on the model of ohmmeter Whatever the ohmmeter displays as a typical forward bias diode is defined as a diode drop in these procedures With a typical DVM the voltage drop across most components will be around 300 to 500 The opposite reading is referred to as infinity and most DMVs will display the value OL for overload 130BX172 10 Illustration 6 5 Power Card and Mounting Plate 380 480 500V Yellow tape on the main SMPS transformer in the upper right corner 525 690V White tape on the main SMPS transformer in the upper right corner 1 Power card PCA3 9 MK106 2 Mounting plate 10 100 3 110 11 109 4 MK102 12 FK102 5 MK104 13 MK112 terminals 4 5 6 6 MK105 14 MK112 terminals 1 2 3 7 107 15 Scaling card 8 FK103 16 Scaling card standoff 90 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 2 1 Soft Charge and Rectifier Circuits Test D frame Size Both the rectifier and soft charge circuits are tested simultaneously The soft charge circuit is made up of the soft charge rectifier fuses and the soft charge resistor The rectifier circuit is made up of the SCR diode modules The soft charge resistor limits the inrush current when power is applied to the frequency converter The soft
192. ible problems that must be diagnosed in a different manner The following discusses many of the most common of these problems 5 2 1 Overtemperature Faults In the event that an overtemperature indication is displayed determine whether this condition actually exists within the frequency converter or whether the thermal sensor is defective Of course this can easily be detected by feeling the outside of the unit if the overtemperature con dition is still present If not the temperature sensor must be checked This can be done with the use of an ohmmeter in accordance with the thermal sensor test procedure 5 2 2 Current Sensor Faults When a current sensor fails it is indicated sometimes by an overcurrent alarm that cannot be reset even with the motor leads disconnected Most often however the frequency converter will experience frequent false earth fault trips This is due to the DC offset failure mode of the sensors To explain this it is necessary to investigate the internal makeup of a Hall effect type current sensor Included inside the device is an op amp to amplify the signal to usable levels in the re ceiving circuitry Like any op amp the output at zero input level zero current flow being measured should be zero volts exactly half way between the plus and minus power supply vol tages A tolerance of 15mv is acceptable In a three phase system that is operating correctly the sum of the three output currents should always
193. ies Danfoss Frequency Converters 11 Block Diagrams 11 2 2 1 E2 525 690 VAC 130BX205 10 gt gt 2 or Rl Dl r AME g un i E FEE FUSE an E rion eni S MG 90 L1 02 VLT is a registered Danfoss trademark 209
194. ify the control voltage power supply is correct as follows 1 With a voltmeter measure voltage at control card terminal 12 13 with respect to terminal 20 The meter should read between 21 and 27 VDC If the 24 V supply voltage is not present conduct the Control Card Test 6 3 17 later in this section If 24 Vis present proceed with checking the individual inputs as follows 2 Connect the negative meter lead to reference terminal 20 3 Connect the positive meter lead to the terminals in sequence The presence of a signal at the desired terminal should correspond to the digital input display readout A reading of 24 VDC indicates the presence of a signal A reading of 0 VDC indicates no signal is present Analog inputs The value of signals on analog input terminals 53 and 54 can also be displayed The voltage or current in mA depending on the switch setting is shown in line 2 of the display 130BB039 10 If the desired signal is not present in the display the problem may be either in the external control wiring to the frequency converter or a faulty control card To determine the fault location use a voltmeter to test for a signal at the control terminals Verify the reference voltage power supply is correct as follows 1 With a voltmeter measure the voltage at control card terminal 50 with respect to terminal 55 The meter should read between 9 2 and 11 2 VDC If the 10 V supply voltage is not present conduc
195. inal 7 of the signal board A reading of 0 VDC indicates the inrush signal is active and the SCRs are being gated A reading of 5 VDC indicates the inrush signal is inactive and the SCRs are not gated With a reading of 5 VDC and proper mains applied to the frequency converter it would be likely that the control card is defective If the control card is suspect replace it in accordance with the disassembly procedures in Section 7 or 8 Should the above tests check correctly proceed to testing the SCR gate signals To view the gate signals an oscilloscope and a current probe are required 8 Run the frequency converter while under some degree of load At least a 30 load may be required to consistently see gate signals produced since SCRs are only gated when the DC bus falls below the peak of line 9 Connect the current probe in sequence to each positive SCR gate wire white leads marked S and at power card connector MK100 The waveform should appear as in Illustration 6 16 130BX145 10 Illustration 6 16 SCR Gate Signal The current pulse should have a waveform as shown 1 gt 11 2 gt 0 40 T1 300 us Given all the other tests above were successful a missing gate signal indicates the power card is defective Replace the power card in accordance with the disassembly procedures in Section 7 or 8 A distorted signal may be due to a defective gate on that particular SCR that is loading down t
196. inals 1 and 3 Approximately 20 ohms should be read 2 Measure between CN2 terminals 1 and 2 Approximately 8 ohms should be read 3 Measure between CN2 terminals 2 and 3 Approximately 12 ohms should be read Incorrect reading An incorrect reading would indicate a defective fan transformer Replace the fan transformer When finished be sure to reconnect CN2 Ohm test of fans 1 Measure between terminals 11 and 13 of power card connector MK107 A reading of 20 ohms should be indicated 2 OnIP21 and IP 54 units Disconnect the spade connectors from the door fan and repeat the measurement A reading of 21 ohms should be indicated 3 On IP21 and IP 54 units Read the door fan terminals with the wires disconnected A reading of 400 ohms should be indicated 4 Reconnect the wires to the door fan Incorrect reading An incorrect reading of one or both of the fans indicates a defective fan Replace the defective fan 130BX80 10 Illustration 6 10 Fan Transformer and Fuse Location 380 480 500 White label on fan transformer 525 690 Orange label on fan transformer 1 Fan transformer 3 Fan fuse 2 CN2 102 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 2 10 Fan Continuity Tests E frame Size Make all continuity checks using an ohmmeter set to Rx1 scale A digital or analog ohmmeter can be used Some instabili
197. indicate additional faults Replace the fuse and continue the fan checks Checking continuity of connections For the following tests read the plug end of connector CN2 that is not connected to the trans former 1 Measure from T to CN2 terminal 1 A reading of 1ohm should be indicated 2 Measure from L2 S to CN2 terminal 3 A reading of 1 ohm should be indicated oe Measure from CN2 terminal 2 to terminal 12 on the power card connector MK107 A reading of lt 1 ohm should be indicated Incorrect reading An incorrect reading would indicate a faulty cable connection Replace the cable assembly Ohm test of transformer 380 500V For the following tests read the plug end of connector CN2 that is connected to the transformer 1 Measure between CN2 terminals 1 and 3 Approximately 15 ohms should be read 2 Measure between CN2 terminals 1 and 2 Approximately 12 ohms should be read 3 Measure between CN2 terminals 2 and 3 Approximately 4 ohms should be read Incorrect reading An incorrect reading would indicate a defective fan transformer Replace the fan transformer MG 90 L1 02 VLT is a registered Danfoss trademark high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters When finished be sure to reconnect CN2 Ohm test of transformer 525 690V For the following tests read the plug end of connector CN2 that is connected to the transformer 1 Measure between CN2 term
198. ion from power unit Missing power unit data from power unit Missing SW version from power unit Missing io statepage from power unit The power card configuration is deter mined to be incorrect at power up A power card has stopped communicating while main power is applied The power card configuration is deter mined to be incorrect after the power card register delay Too many power card locations have been registered as present Power size information between the power cards does not match No communication from DSP to ATACD No communication from ATACD to DSP state running Stack overflow of control board module Scheduler slow tasks Fast tasks Parameter thread LCP Stack overflow Serial port overflow USB port overflow cfListMempool to small Parameter value is outside its limits Option in slot A Hardware incompatible with control board hardware Option in slot B Hardware incompatible with control board hardware Option in slot CO Hardware incompatible with control board hardware Option in slot C1 Hardware incompatible with control board hardware Out of memory The signal from the IGBT thermal sensor is not available on the power card The problem could be on the power card on the gate drive card or the ribbon cable between the power card and gate drive card WARNI NG 40 Overload of Digital Output Terminal 27 Check the load connected to terminal 27 or remove the short circuit connection Check par 5 00
199. is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 4 Troubleshooting 4 4 1 Troubleshooting Tips Before attempting to repair a frequency converter here are some tips to follow to make the job easier and possibly prevent unnecessary damage to functional components 1 Note all warnings concerning voltages present in the frequency converter Always verify the presence of AC input voltage and DC bus voltage before working on the unit Some points in the frequency converter are referenced to the negative DC bus and are at bus potential even though it may appear on diagrams to be a neutral reference Remember that voltage may be present for as long as 40 minutes on E frame size frequency converters or 20 minutes on D frame size frequency converters after removing power from the unit See the label on the front of the frequency converter door for the specific discharge time 2 Never apply power to a unit that is suspected of being faulty Many faulty components within the frequency converter can cause damage to other components when power is applied Always perform the procedure for testing the unit after repair as described in Section 5 Test Procedures 3 Never attempt to defeat any fault protection circuitry within the frequency converter That will result in unnecessary component damage and may cause personal injury 4 Always use factory approved replac
200. is still running The motor will start after the delay time has expired Start fwd rev Enable start forward and Enable start reverse were selected as functions for two different digital inputs parameter group 5 1 To start the motor a direction dependent start signal has to be given and the corresponding terminal has to be active Start inhibit PROFIDrive profile was selected in par 8 10 Contro Word Profile The start inhibition is active The FC needs the first part e g 0x047E of the two part start command via serial communication to allow starting See also operation status control ready Stop Off was pressed on the LCP or Stop inverse was selected as a function for a digital input Group 5 1 The corresponding terminal is not active Trip An alarm occurred It is possible provided the cause of the alarm is cleared to reset the alarm via a Reset signal Reset key on the LCP a control terminal or serial communication Trip lock A serious alarm occurred It is possible provided the cause of the alarm was cleared to reset the alarm after the mains have been switched off and on again This can be done via a reset signal Reset on the LCP a control terminal or serial communication Unit Drive not ready PROFIDrive profile was selected in par 8 10 Contro Word Profile control word is sent to the FC via serial communication with Off 1 Off 2 and Off 3 active Start inhibit is active To enable start see operati
201. issipated braking power is higher than 100 Warning There is a risk of substantial power being transmitted to the brake resistor if the brake transistor is short circuited 68 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 4 Troubleshooting WARNI NG ALARM 27 Brake chopper fault The brake transistor is monitored during operation and if it short circuits the brake function dis connects and issues a warning The frequency converter is still able to run but since the brake transistor has short circuited substantial power is transmitted to the brake resistor even if it is inactive Turn off the frequency converter and remove the brake resistor This alarm warning could also occur should the brake resistor overheat Terminal 104 to 106 are available as brake resistor Klixon inputs see section Brake Resistor Temperature Switch WARNI NG ALARM 28 Brake check failed Brake resistor fault the brake resistor is not connected or not working Check par 2 15 Brake Check ALARM 29 Heatsink temp The maximum temperature of the heatsink has been exceeded The temperature fault will not be reset until the temperature falls below a defined heatsink temperature The trip and reset point are different based on the frequency converter power size Troubleshooting Ambient temperature too high Motor cable too long Incorrect clearance above a
202. k FC 100 200 only In par 1 80 Function at Stop the function Motor check was selected A stop command e g Stop inverse is active To ensure that a motor is connected to the FC a permanent test current is applied to the motor Off1 PROFIDrive profile was selected in par 8 10 Contro Word Profile The OFF 1 function is activated via serial communication The motor is stopped via the ramp Off2 PROFIDrive profile was selected in par 8 10 Contro Word Profile The OFF 2 function is activated via serial communication The output of the FC is disabled immediately and the motor coasted Off3 PROFIDrive profile was selected in par 8 10 Contro Word Profile The OFF 3 function is activated via serial communication The motor is stopped via the ramp OVC control Overvoltage Control is activated in par 2 17 Over vol tage Control The connected motor is sup plying the FC with generative energy The Overvoltage Control adjusts the UF ratio to run the motor in controlled mode and to prevent the FC from tripping PowerUnit Off Only with frequency converters with installed option ext 24 V supply The mains supply to the frequency converter is cut off but the control card is still supplied with 24 V Pre magnetize Pre magnetization is selected in par 1 80 Function at Stop A stop command e g Stop inverse is activated A suitable constant magnetizing current is applied to the motor Protection md The FC 100 200 300 has detected a
203. k per instructions Remove the input terminal plate per instructions Remove the retaining nuts 8 mm from the SCR input bus bars one for each input phase oe Note the colour coding for each of the three wires attached to the retaining studs Ensure that the correct wire is attached to the applicable stud during reassembly Remove the wiring from the studs 5 Remove screw T30 from terminal 1 of each SCR diode module by accessing the screw through access hole in the SCR diode input bus bar Remove the SCR input bus bars 6 Remove each IGBT output bus bar by removing the nut 13 mm from the stud Also remove the retaining screw T40 at other end of the IGBT output bus bars not shown CONTINUED NEXT PAGE 130BX161 10 SOR Illustration 7 1 D2 D4 SCR Diode Module 1 of 4 1 SRC diode input bus bar retaining nut and stud Steps 3 amp 4 4 IGBT output bus bar retaining nut Step 6 2 SRC diode terminal screw Step 5 5 SRC diode terminal screw Step 5 3 SRC diode input bus bar BB21 or BB22 per drive power rating 6 IGBT output bus bar BB32 Step 6 136 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 7 Remove twelve T30 screws from the output lower side of the IGBT modules 8 Remove the retaining nut 8 mm from each intermediate IGBT output bus bar
204. k to Display mode from either the Quick Menu mode the Main Menu mode or Alarm mode Also use the Status key to toggle single or double readout mode Quick Menu allows quick set up of the frequency converter The most common functions can be pro grammed here The Quick Menu consists of My Personal Menu Quick Set up Function set up Changes Made Loggings The Function set up provides quick and easy access to all parameters required for the majority of applications Among other features it also includes parameters for selecting which variables to display on the LCP 26 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 7 42 Operator Interface and Frequency Converter Frequency Converters Control Main Menu is used for programming all parameters The Main Menu parameters can be accessed immediately unless a password has been created via par 0 60 0 61 0 65 or 0 66 Parameter shortcut can be carried out by pressing down the Main Menu key for 3 seconds The parameter shortcut allows direct access to any parameter Alarm Log displays an Alarm list of the five latest alarms numbered A1 A5 To obtain additional details about an alarm use the arrow keys to find the alarm number and press OK Information is displayed about the condition of the frequency converter before it enters the alarm mode The Alarm log button on the LCP allows access to both the Ala
205. l test board the actual reading may be higher due to meter lead resistance Absence of resistance indicates a missing scaling card 11 Reapply power to the frequency converter 12 Using a DVM connect the negative meter lead to terminal 4 common of the signal test board 13 Run the frequency converter with a zero speed reference 14 Measure the AC voltage at terminals 1 2 and 3 of the signal test board in sequence These terminals correspond with current sensor outputs U V and W respectively Expect a reading near zero volts but no greater than 15 mv If the control card parameters are set up to provide holding torque while at zero speed the current displayed will be greater than expected To perform this test disable such parameters MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures The current sensor feedback signal at this point in the circuit will read approximately 400 mv at a 100 frequency converter load so any reading above 15 mv while the frequency converter is at zero speed has a negative effect on the way the frequency converter interprets the feedback signal A reading of greater than 15 mv suggests that the corresponding current sensor be replaced See the disassembly instructions in Section 7 or 8 Resistance Voltage AC FC 102 FC202 FC 302 Ohms 380 500 P110 110 P90K 4 5 380 500 P132 P132 P110 3 8
206. lators Table 10 15 Spare Parts List Bus Bars Table 10 16 Spare Parts List Enclosure Table 10 17 Spare Parts List PCA Semiconductors and Resistors Table 10 18 Table 10 19 Spare Parts List Disconnects and Cables MG 90 L1 02 VLT is a registered Danfoss trademark 12 12 13 0 13 0 14 29 39 41 54 54 55 59 63 64 103 119 Values 0 178 179 180 181 182 183 184 185 186 188 189 190 191 192 194 195 196 Spare Parts List Capacitors Fans Fuses and Inductors amp Current Sensors 197 198 Contents Danfoss ih Power Service Manual for VLT FC Series Contents Frequency Converters Table 10 20 Spare Parts List Terminals Labels amp Insulators 199 Table 10 21 Spare Parts List Bus Bars and Enclosure 200 10 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 1 Introduction 1 Introduction 1 1 Purpose The purpose of this manual is to provide detailed technical information and instructions to enable a qualified technician to identify faults and perform repairs on FC series frequency converters in the D and E frames It provides the reader with a general view of the unit s main assemblies and a description of the internal processing With this information technicians should have a better understanding of the frequency converter s operation to assist in troubleshooting and repair This manual provides instruction
207. lts per division vertical scale 50 microseconds per division time scale Unit running at 30 Hz An incorrect reading of a gate signal indicates the gate drive card is defective or the signal has been lost prior to it arriving at the gate card The gate signals can then be checked with the signal test board to verify their presence from the control card to the power card as follows 12 Insert the signal test board into power card connector MK104 13 With scope probe earth connected to terminal 4 common of signal board measure six gate signals at signal board terminals 25 through 30 14 Place the frequency converter in run at 30 Hz The waveform should appear as in Illustration 6 19 MG 90 L1 02 VLT is a registered Danfoss trademark 115 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters 8 00 1 47 10 6 00 4 00 2 00 0 00V 2 0 4 0 6 0 8 0 7100 0 us 5 us Div Illustration 6 19 Gate Signal Waveform from Signal Test Board IGBT Gate Signal measured with the Signal Test Board 2 volts per division vertical scale 50 microseconds per division time scale Unit running at 30 Hertz 15 Using a DVM again check these same signal board terminals DVM should read 2 2 to 2 5 An
208. lue and climb toward infinity as capacitance is charged within the frequency converter MG 90 L1 02 VLT is a registered Danfoss trademark 99 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters Incorrect reading An incorrect reading on any of the above tests indicates that the brake IGBT is defective Replace the brake IGBT in accordance with the disassembly procedures in Section 7 or 8 The failure of any IGBT may also lead to a failure of the gate drive circuit supplying that device Following the replacement of an IGBT always ensure the gate drive signals are tested in accord ance with the procedures in the dynamic test section 6 2 7 Intermediate Section Tests The intermediate section of the frequency converter is made up of the DC bus capacitors the DC coils and the balance circuit for the capacitors 1 Test for short circuits with the ohmmeter set on Rx100 scale or for a digital meter select diode 2 Measure across the positive DC terminal and the negative DC terminal B on connector 105 on the power card Observe the meter polarity 3 The meter will start out with low ohms and then move towards infinity as the meter charges the capacitors 4 Reverse meter leads on connector MK105 on the power card 5 meter will peg at zero while the capacitors are discharged by the meter The meter then begins moving slowly toward two diode drops as the meter charge
209. mbly support bracket 6 Unplug the ribbon cable from the back of the control card Reinstall in reverse order of this procedure The red conductor on the ribbon cable between the control card and the power card should be on the bottom of the connector Tighten the control card mounting plate screws to 1 Nm 8 in Ib MG 90 L1 02 VLT is a registered Danfoss trademark 123 7 D Frame Sizes Disassembly and Assembly ish Power Service Manual for VLT FC Series Instructions Frequency Converters 130BX183 11 Illustration 7 1 Control Card Access 380 480 500V Yellow tape on the main SMPS transformer in the upper right corner 525 690 White tape on the main SMPS transformer in the upper right corner 1 Local control panel LCP Step 2 8 Power card PCA3 2 LCP cradle Step 3 9 102 ring lug connection 3 C option if installed 10 DC bus fuse 4 Mounting screws Step 5 11 Control card mounting plate 5 Control assembly support bracket 12 Control card terminal block 6 Attaching hardware 13 Control card under LCP 7 Power card mounting plate 7 2 2 Control Assembly Support Bracket 1 Remove the control card mounting plate in accordance with procedure 2 Remove the 6 mounting nuts 10 mm see Illustration 7 1 3 Remove the control assembly support bracket Reinstall in reverse order of this procedure Tighten the mounting screws to 4 Nm 35 in Ibs 124 MG 90 L1 02 VLT is a registered Danfoss
210. minal A 525 550 V 137 162 204 253 303 360 MAX 60 sec A 525 550 V 206 243 306 380 455 540 Nominal A 551 690 V 131 155 192 242 290 344 MAX 60 sec A 551 690 V 197 233 288 363 435 516 Output Nominal 550 V 131 154 194 241 289 343 Nominal kVA 575 V 130 154 191 241 289 343 Nominal kVA 690 V 157 185 229 289 347 411 Typical shaft output kW 550 V 90 110 132 160 200 250 HP 575 V 125 150 200 250 300 350 kW 690 V 110 132 160 200 250 315 515 582 614 Power loss Normal overload W 3114 3612 4293 5 1 9 427 487 518 Power loss High overload W 2665 2953 3451 5 5 5 Limits and Ranges Overcurrent Warning VLT AR S Qut 256 329 483 483 585 734 Overcurrent Alarm 1 5 sec delay VLT ARMS Out 256 329 483 483 585 734 Earth Ground Fault Alarm 5 Out 66 78 96 121 145 172 Short Circuit Alarm VLT AR S Out 325 420 614 614 742 932 Heatsink Overtemperature Degrees C 85 90 110 110 110 110 Heatsink Undertemperature Warning Degrees C 0 0 0 0 0 0 Power Card Ambient Overtem perature Degrees C 60 60 60 60 60 60 Power Card Ambient Under temperature Degrees C 20 20 20 20 20 20 Mains Phase Warning 5 sec delay DC Bus Ripple VAC 70 70 70 70 70 70 Mains Phase Alarm 25 sec de lay DC Bus Ripple VAC 70 70 70 70 70 70 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters Mains supply 3 x 525 690 V Model number F
211. modules which make up the inverter section In conjunction with the SCR diode modules the soft charge circuit limits the inrush current when power is first applied and the DC bus capacitors are charging This is accomplished by the SCRs in the modules being held off while charging current passes through the soft charge resistors thereby limiting the current The DC bus circuitry smooths the pulsating DC voltage created by the conversion from the AC supply The DC coil is a single unit with two coils wound on a common core One coil resides in the positive side of the DC bus and the other in the negative The coil aids in the reduction of mains harmonics The DC bus capacitors are arranged into a capacitor bank along with bleeder and balancing cir cuitry Due to the requirement for higher power capacity some frequency converters have two capacitor banks connected in parallel The inverter section is made up of six IGBTs commonly referred to as switches One switch is necessary for each half phase of the three phase power for a total of six The six IGBTs are contained in a single module Due to higher current handling requirements some models contain two or three larger six pack style modules In these units each switch half phase is made up of two or three IGBTs in parallel A Hall effect type current sensor is located on each phase of the output to measure motor current This type of device is used instead of more common current transf
212. n the unit may cause the meter to indicate a small neg ative voltage drop Incorrect Reading An incorrect reading indicates some of the IGBTs are not turning on Replace the IGBT module according to the disassembly instructions in Section 7 or 8 6 3 13 Brake I GBT Test Use the signal test board to test the operation of the dynamic brake IGBT and gate drive circuitry The following procedure can be used to force the brake circuit to activate for testing 1 Connect the signal test board to connector MK104 on the control card 2 Setthe voltage test switch labelled Over V to the ON position 3 Turn the potentiometer on the test board until the brake circuit activates This causes the brake IGBT to turn on and off at approximately 1 2 KHz Duty cycle pulse width increases as the potentiometer is increased 4 Using an oscilloscope or DVM measure at terminal 13 Terminal 13 represents the gate signal to the brake IGBT This should be 4 04 VDC when brake is OFF and drop to zero when brake is ON 5 Use an oscilloscope or DVM at terminal 14 Terminal 14 is a logic level 5V signal rep resenting voltage across brake IGBT This should measure 5 1 VDC when brake is OFF and drop to zero when brake is ON Incorrect Reading If the signal on terminal 13 is not correct first check that the frequency converter is correctly programmed for dynamic braking parameter 2 10 If the programming is correct replace the control card in acco
213. nally The sensor is wired from the IGBT module to the gate drive card connector MK100 For frequency converters with two IGBTs the sensor on the right module is used For frequency converters with three IGBT modules the centre module is used On the gate drive card the resistance signal is converted to a frequency signal The frequency signal is sent to the power card for processing The temperature data is used to regulate fan speed and to monitor for over and undertemperature conditions 1 Use ohmmeter set to read ohms 2 Unplug connector MK100 the gate drive card see Illustration 6 17 and measure the resistance across the cable leads The relationship between temperature and resistance is nonlinear At 25 the resistance will be approximately 5k Ohms At 0 C the resistance will be approximately 13 7k Ohms At 60 C the resistance will be approximately 1 5k Ohms The higher the temperature the lower the resistance 6 2 9 Fan Continuity Tests D frame Size Make all continuity checks using an ohmmeter set to Rx1 scale Digital or analog ohmmeter can be used To aid in making the measurements unplug the connector CN2 from its mate CN2 terminals correspond to the terminal numbers labelled on the transformer Connector CN2 is located near the fan transformer on the input plate See Illustration 6 10 Fan Fuse test 1 Testthe fan fuse on the input plate by checking the continuity across the fuse An open fuse could
214. ncorrect mechanical load will usually be indicated by a torque limit alarm or warning Discon necting the motor from the load if possible can determine if this is the case Quite often the indications of motor problems are similar to those of a defect in the frequency converter itself To determine whether the problem is internal or external to the frequency con verter disconnect the motor from the frequency converter output terminals Perform the output imbalance of supply voltage test procedure 6 3 10 on all three phases with an analog voltmeter If the three voltage measurements are balanced the frequency converter is functioning correctly The problem therefore is external to the frequency converter 80 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series 7 44 Frequency Converters 5 Frequency Converter and Motor Applications If the voltage measurements are not balanced the frequency converter is malfunctioning This typically means that one or more output IGBT is not switching on and off correctly This can be a result of a defective IGBT or gate signal from the gate drive card Perform the IGBT gate signal test 6 3 11 5 2 Internal Frequency Converter Problems The vast majority of problems related to failed frequency converter power components can be identified by performing a visual inspection and the static tests as described in the test section There are however a number of poss
215. nd below the frequency converter Dirty heatsink Blocked air flow around the frequency converter Damaged heatsink fan For the D E and F Frame frequency converters this alarm is based on the temperature measured by the heatsink sensor mounted inside the IGBT modules For the F Frame frequency converters this alarm can also be caused by the thermal sensor in the rectifier module See the rating table in Section 1 9 for the trip point Troubleshooting Check fan resistance see section 6 2 9 or 6 2 10 Check soft charge fuses see section 6 2 1 or 6 2 3 IGBT thermal sensor see section 6 2 8 ALARM 30 Motor phase U missing Motor phase U between the frequency converter and the motor is missing Turn off the frequency converter and check motor phase U ALARM 31 Motor phase V missing Motor phase V between the frequency converter and the motor is missing Turn off the frequency converter and check motor phase V ALARM 32 Motor phase W missing Motor phase W between the frequency converter and the motor is missing Turn off the frequency converter and check motor phase W ALARM 33 I nrush fault Too many power ups have occurred within a short time period Let the unit cool to operating temperature WARNI NG ALARM 34 Fieldbus communication fault The fieldbus on the communication option card is not working WARNI NG ALARM 35 Out of frequency range This warning is active if the output frequency has reached the high limit set
216. nder these circumstances nuisance tripping may occur par 14 25 7rip Delay at Torque Limitworks in conjunction with torque limit This parameter selects the length of time the frequency converter operates in torque limit prior to a trip The factory default value is off This means that the frequency converter will not trip on torque limit but it does not mean it will never trip from an overload condition Built into the frequency converter is an internal inverter thermal protection circuit This circuit monitors the output load on the inverter If the load exceeds 100 of the continuous rating of the frequency converter a timer is activated If the load remains excessive long enough the frequency converter will trip on inverter time Adjustments cannot be made to alter this circuit Improper parameter settings effecting load cur rent can result in premature trips of this type The timer can be displayed 5 1 1 Overvoltage Trips This trip occurs when the DC bus voltage reaches its DC bus alarm voltage high see ratings tables in introductory section Prior to the trip the frequency converter will display a high voltage warn ing Most times an over voltage condition is due to fast deceleration ramps with respect to the inertia of the load During deceleration of the load inertia of the system acts to sustain the running speed Once the motor frequency drops below the running speed the load begins overhauling the motor At this point the mot
217. ndicate a diode drop 3 Leave the positive meter lead connected to cable MK105 and run the frequency con verter at 30 Hz 4 In sequence again connect the negative meter lead to the frequency converter output terminals U V and W The meter should effectively indicate a short circuit or around a 0 035 diode drop which indicates lower IGBTs are turned on and shorting the meter to a negative bus 116 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures NB Some voltage leakage within the unit may cause the meter to indicate a small neg ative voltage drop 5 Repeat the test for positive or upper IGBTs 6 With the frequency converter in stop mode connect the negative meter lead to the white lead of MK105 cable disconnected from the power card 7 Sequence connect the positive meter lead to the frequency converter output ter minals U V and W The meter should indicate a diode drop 8 Leave the negative meter lead connected to cable MK105 and run the frequency con verter at 30 Hz 9 sequence again connect the positive meter lead to the frequency converter output terminals U V and W The meter should effectively indicate a short circuit or around a 0 035 diode drop which indicates upper IGBTs are turned on and shorting the meter to a positive bus NB Some voltage leakage withi
218. nfinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the frequency converter being charged by the meter Incorrect reading With the Part IV test connection the diodes in the main diode modules are reversed biased If a short circuit exists the diode module is damaged Continue to Soft Charge Rectifier Tests E frames 96 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 2 4 Soft Charge Rectifier Test E frame Size The DC cable at connector MK3 remains disconnected for this procedure Since the rectifier test requires the soft charge resistor to be in the circuit verify the resistor is good before proceeding 1 Measure the resistance between pins A and B of connector MK4 on the soft charge card It should read 27 ohms 10 for 380 500 V frequency converters or 68 ohms 10 for 525 690 V frequency converters A reading outside this range indicates a defective soft charge resistor Replace the resistor according to the disassembly proce dures in Section 8 Continue tests Should the resistor be defective and a replacement not readily available the remainder of the tests can be carried out by disconnecting the cable at connector MK4 on the soft charge card and placing a temporary jumper across pins A and B This provides a path for continuity for the re maining tests Ensure any temporar
219. ns 8 E Frame Sizes Disassembly and Assembly In structions 8 1 Electrostatic Discharge ESD Frequency converters contain dangerous voltages when connected to mains voltage No disassembly should be attempted with power applied Remove power to the fre quency converter and wait at least 40 minutes to let the frequency converter capacitors fully discharge Only a competent technician should carry out service ELECTROSTATIC DISCHARGE ESD Many electronic components within the frequency converter are sensitive to static electricity Vol tages so low that they cannot be felt seen or heard can reduce the life affect performance or completely destroy sensitive electronic components Use proper electrostatic discharge ESD procedures to prevent damage to sensitive components when servicing the frequency converter NB Frame size is used throughout this manual where ever procedures or components differ between frequency converters based upon the unit s physical size Refer to the tables in the Introduction section to determine E frame size definitions 8 2 Instructions 8 2 1 Control Card and Control Card Mounting Plate 1 Open the front panel door or remove the front cover depending on the unit type 2 Illustration 8 1 Unplug the LCP ribbon cable not shown from the control card or remove the LCP depending on the unit type The LCP can be removed by hand 3 Remove the LCP cradle L
220. ntrol wiring is a common service issue for a motor not operating or the frequency converter not re sponding to a remote input MG 90 L1 02 VLT is a registered Danfoss trademark 37 2 Operator Interface and Frequency Converter 7 High Power Service Manual for VLT FC Series Control Frequency Converters 2 6 Control Terminals 38 Control terminals must be programmed Each terminal has specific functions it is capable of per forming and a numbered parameter associated with it See table below The setting selected in the parameter enables the function of the terminal It is important to confirm that the control terminal is programmed for the correct function Parameter settings are displayed by pressing Mai the Status key on the LCP eu 29 130BP045 10 Use the arrow keys 4 Y gt and lt on the LCP to scroll through parameters h atus Menu Menu Log See the Programming Guide for details on changing parameters and the functions available for each control terminal In addition the input terminal must be receiving a signal Confirm that the control and power sources are wired to the terminal Then check the signal Signals can be checked in two ways Digital input can be selected for display by pressing status key as discussed previously or a voltmeter may be used to check for voltage at the control ter minal See procedure details at Input Terminal Te
221. odules Remove the 3 snubber capacitors 10 Remove the IGBT bus bar assy 11 At the bottom end of a IGBT module remove the 6 retaining screws 2 each for U V and W intermediate IGBT output bus bars 12 Remove the retaining nut 8 mm from the 3 intermediate IGBT output bus bars Remove the intermediate IGBT output bus bars 13 Remove the IGBT module 14 Clean the heatsink surface with a mild solvent or alcohol solution REASSEMBLY 1 Replace the IGBT module in accordance with the instructions enclosed with the replace ment module 2 Tighten the remaining T25 and 8 mm screws to 2 3 Nm 20 in Ibs T30 and 10 mm to 4 Nm 35 in Ibs 3 Reassemble the frequency converter in reverse order of disassembly and tighten the attachment hardware in accordance with the torque tables 130BX159 10 4 Illustration 7 1 D1 D3 IGBT Module 2 of 2 1 IGBT module 5 Retaining screw Step 9 2 Snubber capacitor Step 9 6 Retaining nut Step 11 3 IGBT bus bar assembly Step 8 7 Intermediate IGBT output bus bar Step 11 4 Retaining nut Step 8 MG 90 L1 02 VLT is a registered Danfoss trademark 151 8 E Frame Sizes Disassembly and Assembly Power Service Manual for VLT FC Series Instructions Frequency Converters 152 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 8 E Frame Sizes Disassembly and Assembly Frequency Converters Instructio
222. om the mounting studs Reinstall in reverse order of this procedure Tighten the electrical connection nuts 8 mm to 2 3 Nm 20 in Ibs and the mechanical connection nuts 10 mm to 4 Nm 35 in Ibs Lower Capacitor Banks 1 Remove the soft charge card in accordance with procedures 2 The capacitor bank connection to the DC bus bars can be seen recessed in the gap be tween the upper and the lower capacitor banks A minimum extension of 150 mm 6 in is required Remove the 6 electrical connection nuts 8 mm for the lower capacitor bank from the DC bus bars Remove the 4 retaining nuts 10 mm from the capacitor bank 4 Note that the weight of the capacitor bank is approximately 9 kg 20 Ibs Remove the capacitor bank by pulling free from the mounting studs Reinstall in reverse order of this procedure Note DO NOT overtorque Tighten the electrical con nection nuts 8 mm to 2 3 Nm 20 in Ibs and the mechanical connection nuts 10 mm to 4 Nm 35 in Ibs 158 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 8 E Frame Sizes Disassembly and Assembly Frequency Converters Instructions 130BX95 11
223. on on LCP MG 90 L1 02 VLT is a registered Danfoss trademark 7i high Power Service Manual for VLT FC Series 4 Troubleshooting Frequency Converters WARNING 61 Tracking error An error has been detected between the calculated motor speed and the speed measurement from the feedback device The function for Warning Alarm Disable is set in par 4 30 Motor back Loss Function error setting in par 4 31 Motor Feedback Speed Error and the allowed error time in par 4 32 Motor Feedback Loss Timeout During a commissioning procedure the function may be effective WARNING 62 Output frequency at maximum limit The output frequency is higher than the value set in par 4 19 Max Output Frequency ALARM 63 mechanical brake Low The actual motor current has not exceeded the release brake current within the start delay time window WARNING 64 Voltage limit The load and speed combination demands a motor voltage higher than the actual DC link voltage WARNI NG ALARM TRI P 65 Control card overtemperature Control card overtemperature The cutout temperature of the control card is 80 C WARNI NG 66 Heatsink temperature low This warning is based on the temperature sensor in the IGBT module See the ratings table in Section 1 9 for the temperature reading that will trigger this warning Troubleshooting The heatsink temperature measured as 0 C could indicate that the temperature sensor is defec tive thereby causing th
224. on status Start inhibit 34 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 7 42 Operator Interface and Frequency Converter Frequency Converters Control 2 4 Service Functions Service information for the frequency convert 4 234 6 9648 T er can be shown on display lines 3 and 4 ALES 15 0 15 04 Over Temp z Included in the data are counters that tabulate operating hours power ups and trips fault logs that store frequency converter status val ues present at the 20 most recent events that stopped the frequency converter and fre quency converter nameplate data The service information is accessed by displaying items in 1308 173 10 the frequency converter s 15 parameter group Parameter settings are displayed by pressing m the MAIN MENU key on the LCP e S EA 130 045 10 130 027 10 Use the arrow keys 4 Y gt and on the LCP to scroll through parameters Alarm Log Main Menu 1 1 Quick see P Menu See the FC Series Operating Instructions for detailed information on accessing and displaying parameters and for descriptions and procedures for service information available in the 15 parameter group MG 90 L1 02 VLT is a registered Danfoss trademark 35 2 Operator Interface and Frequency Converter 2 High Power Service Manual for VLT Series Control Frequenc
225. onductor directly between the frequency converter and the running motor is recommended Cable routing Avoid routing motor wiring mains wiring and signal wiring in parallel If parallel routing is un avoidable try to maintain a separation of 200 mm 6 8 inches between the cables or separate them with a earthed conductive partition Avoid routing cables through free air Signal cable selection Signal cable selection Single conductor 600 volt rated wires provide the least protection from EMI Twisted pair and screened twist pair cables are available which are specifically designed to min imise the effects of EMI While unscreened twisted pair cables are often adequate screened twisted pair cables provide another degree of protection The signal cable s screen should be ter minated in a manner that is appropriate for the connected equipment Avoid terminating the screen through a pigtail connection as this increases the high frequency impedance and spoils the effectiveness of the screen Refer to Section 2 8 Earthing Screened Cables A simple alternative is to twist the existing single conductors to provide a balanced capacitive and inductive coupling thus cancelling out differential mode interference While not as effective as true twisted pair cable it can be implemented in the field using the materials on hand Motor cable selection The management of the motor conductors has the greatest influence on the EMI characteristics of the sy
226. oor mounted fans isolate the faulty fan as follows a Disconnect the wiring from the fan terminals b Read across the fan terminals on each fan A reading of 400 ohms is expected Replace any defective fans OL vY8LX80 L Illustration 6 11 Fan and DC Bus Fuse Locations 1 Power card 4 Mounting plate 2 DC bus fuse 5 MK107 3 Fan fuse 104 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 3 Dynamic Test Procedures Refer to the terminal locations in Illustration 6 10 for performing dynamic test procedures NB Test procedures in this section are numbered for reference only Tests do not need to be performed in this order Perform tests only as necessary Never disconnect the input cabling to the frequency converter with power applied due to danger of severe injury or death Take all the necessary safety precautions for system start up prior to applying power to the frequency converter 130BX79 10 Illustration 6 12 Drive Power Terminals D size Frames 1 Main 3 phase AC power to frequency converter 3 Brake resistor connection 2 DC bus load sharing connections 4 3 phase output to motor MG 90 L1 02 VLT is a registered Danfoss trademark 105 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters 6 3 1 No Display Test A f
227. or Stand Dy Other status messages may appear related to the software version and frequency converter type T99RPM 7 83A 36 4 kW 130BB037 10 0 000 53 2 Auto Remote Ramping Hand Local Stop Off Running Jogging Stand b Operation Mode 130BP046 10 Off The FC does not react to any control signal until Auto On or Hand On on the LCP are pressed Auto On The FC is controlled via the control terminals and or the serial communication Hand On Only stop commands alarm resets Reset reversing DC brake and set up selection signals can be applied to the control terminals For further information about the LCD display please see the chapter How to programme in the Programming Guide MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 7 42 Operator Interface and Frequency Converter Frequency Converters Control Reference Site Remote The Reference is given via internal preset references absolute or relative and or ex ternal signals analog or digital and or via serial communication Local The FC uses the reference values set via the LCP For further information please examine parameter 3 13 Operation Status AC Brake AC Brake was selected in par 2 10 Brake Function The motor is slowed down via the active down ramp and feeds the FC with generative energy The AC Brake over magnetizes th
228. or becomes a generator and starts returning energy to the frequency converter This is called regenerative energy Regeneration occurs when the speed of the load is greater than the commanded speed This return voltage is rectified by the diodes in the IGBT modules and raises the DC bus If the amount of returned voltage is too high the frequency converter will trip There are a few ways to overcome this situation One method is to reduce the deceleration rate so it takes longer for the frequency converter to decelerate A general rule of thumb is that the frequency converter can only decelerate the load slightly faster than it would take for the load to naturally coast to a stop A second method is to allow the overvoltage control circuit to take care of the deceleration ramp When enabled the overvoltage control circuit regulates deceleration at a rate that maintains the DC bus voltage at an acceptable level One caution with overvoltage control is that it will not make corrections to unrealistic ramp rates For example if the deceleration ramp needs to be 100 seconds due to the inertia and the ramp rate is set at 3 seconds overvoltage control will initially engage and then disengage and allow the frequency converter to trip This is purposely done so the units operation is not misinterpreted A third method in controlling regen erated energy is with a dynamic brake The frequency converter monitors the level of the DC bus Should the level become too
229. ormer CT devices in order to reduce the amount of frequency and phase distortion that CTs introduce into the signal With Hall sensors the average peak and earth leakage currents can be monitored RECTIFIER INTERMEDIATE INVERTER SCR DIODES CIRCUIT SECTION IGBTs b d bd 1308X135 10 CO ETE L1 57 SOFT CHARGE CIRCUITRY Illustration 3 3 Typical Power Section 46 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Frequency Converters 3 Internal Frequency Converter Operation 3 3 Sequence of Operation 3 3 1 Rectifier Section When input power is first applied to the frequency converter it enters through the input terminals L1 L2 L3 and on to the disconnect or and RFI option depending on the unit s configuration see Illustration 3 4 If equipped with optional fuses these fuses FU1 FU2 FU3 limit damage caused by a short circuit in the power section The SCRs in the combined SCR diode modules are not gated so current can travel to the rectifier on the soft charge card In E frequency converter models the SCR and diode modules are separate Additional fuses located on the soft charge card provide protection in the event of a short in the soft charge or fan circuits Three phase po
230. ove the six retaining screws T25 from the SCR diode modules terminals 2 3 in each module 5 Remove the 4 10 mm retaining nuts from the DC inductor input bus bars and the 4 retaining nuts not shown from the side mounted bus bars Side mounted bus bars are only present on units with load sharing Remove the DC input bus assembly CONTINUED ON NEXT PAGE Y A Bee S RYE 130BX85 10 Illustration 7 1 D1 D3 Soft Charge Resistor 2 of 3 380 480 500V Clear wire leads 525 690 Black wire leads 1 Retaining screws Step 4 2 DC input bus assembly BB3 3 Retaining nuts Step 5 4 Soft charge resistor MG 90 L1 02 VLT is a registered Danfoss trademark 133 7 D Frame Sizes Disassembly and Assembly Power Service Manual for FC Series Instructions Frequency Converters 6 Remove the soft charge resistor by removing the two mounting screws 130BX83 10 Illustration 7 1 D1 D3 Soft Charge Resistor 3 of 3 380 480 500 Clear wire leads 525 690V Black wire leads m Soft charge resistor 2 Mounting screws Step 6 Reassembly 1 Clean the heatsink surface with a mild solvent or alcohol solution 2 Reassemble the remaining parts in reverse order of their removal Tighten the T25 and 8 mm mounting screws to 2 3 Nm 20 in Ibs and T30 and 10 mm to 4 Nm 35 in lbs 134 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual
231. pen loop the frequency converter calculates the torque requirement based on current measurements of the motor par 1 03 7orque Characteristics sets the frequency converter for constant or variable torque op eration It is imperative that the correct torque characteristic is selected based on the application If for example the load type is constant torque such as a conveyor and variable torque is se lected the frequency converter may have great difficulty starting the load if started at all Consult the factory if uncertain about the torque characteristics of an application Parameters 1 20 through 1 25 configure the frequency converter for the connected motor These are motor power voltage frequency current and rated motor speed Accurate setting of these parameters is very important Enter the motor data required as listed on the motor nameplate For effective and efficient load control the frequency converter relies on this information for cal culating the output waveform in response to the changing demands of the application par 1 29 Automatic Motor Adaptation AMA activates the automatic motor adaptation AMA function When AMA is performed the frequency converter measures the electrical characteristics of the motor and sets various frequency converter parameters based on the findings Two key parameter values set by this function are stator resistance and main reactance parameters 1 30 and 1 35 If unstable motor operation is
232. ply SMPS test 2 Measure the 10 V DC control voltage at terminal 50 with respect to terminal 55 The meter should read between 9 2 and 11 2 VDC An incorrect reading here could indicate the supply is being loaded down by a fault in the customer connections Unplug the terminal strip and repeat the test If this test is successful then continue Remember to check the customer connections If still unsuccessful proceed to the SMPS test A correct reading of both control card voltages would indicate the LCP or the control card is de fective Replace the LCP with a known good one If the problem persists replace the control card in accordance with the disassembly procedures in Section 7 or 8 6 3 4 Switch Mode Power Supply SMPS Test The SMPS derives its power from the DC bus The first indication that the DC bus is charged is the DC bus charge indicator light located on the power card being lit This LED however can be lit at a voltage still to low to enable the power supplies First test for the presence of the DC bus 1 Using a voltmeter read DC bus voltage at power card connector MK105 A with respect to MK105 B The meter should indicate approximately 1 35 x AC input voltage to the frequency converter 2 Ifthe voltage is correct proceed to set 3 If voltage is present but out of range proceed to DC Undervoltage test If voltage is at zero proceed to Zero DC Bus Voltage test 3 Test the remaining power supplies Insert th
233. ponents Prior to beginning the tests ensure that power is removed from the unit and that the DC Bus capacitors have been discharged Check for the presence of DC bus voltage by measuring power card connector MK105 A with respect to MK105 B The voltage should be zero 0 before proceeding 1 For D frame size units follow the procedure in Section 7 for soft charge card removal and disengage the soft charge card far enough to disconnect the cable plugged into the 2 Disconnect the cable from the MK3 connector on the soft charge card and connect one end of the test cable into the MK3 For D frame size units reinstall the soft charge card Disconnect connectors MK100 and MK105 on the power card Connect the free end of test cable into MK105 Connect the SCR gate shorting plug included with test cable 176F8437 into the cable that was removed from MK100 gv Ur A 3 pin test connector is located on the gate drive card near each gate signal lead These are labelled MK250 MK350 MK450 MK550 MK650 MK750 and if the frequency converter is equip ped with a brake option MK850 see Illustration 6 17 For the sake of clarity refer to the 3 pins as one two and three reading left to right Pins 1 and 2 of each connector are in parallel with the gate drive signal sent to the IGBTs Pin 1 is the signal and pin 2 is common D Reconnect AC power to the frequency converter 8 In stop mode apply power to
234. quire visual inspection as part of any initial troubleshooting procedure Inspect For Auxiliary equipment Cable routing Control wiring Description Look for auxiliary equipment switches disconnects or input fuses circuit breakers that may reside on the input power side of frequency converter or the output side to motor Examine the operation and condition of these items for possible causes of operational faults Check the function and installation of pressure sensors or encoders etc that provide feedback to the frequency converter Avoid routing motor wiring mains wiring and signal wiring in parallel If parallel routing is unavoidable try to maintain a separation of 6 8 inches 150 200 mm between the cables or separate them with an earthed conductive partition Avoid routing cables through free air Check for broken or damaged wires and connections Check the voltage source of the sig nals Though not always necessary depending on the installation conditions the use of screened cable or a twisted pair is recommended Ensure the screen is terminated correctly Refer to the section on earthing screened cables in Section 2 Drive cooling Check the operational status of all cooling fans Check the door filters on NEMA 12 54 units Check for blockage or constrained air passages Make sure the bottom gland plate is installed Drive display Warnings alarms drive status fault history and many other important items are avail
235. r Heatsink Fan Assembly AC Input Motor Load Sharing or Regen Terminals IGBT Modules 9 Special Test Equipment Test Equipment Test Cables and SCR Shorting Plug Kit p n 176F8439 Signal Test Board p n 176F8437 Signal Test Board Pin Outs Description and Voltage Levels 10 Spare Parts List Spare Parts List General Notes Spare Parts Lists 11 Block Diagrams Block Diagrams for D Frames D1 D3 380 500 VAC D2 D4 380 500 VAC D1 D3 525 690 D2 D4 525 690 MG 90 L1 02 VLT is a registered Danfoss trademark 136 140 143 144 146 147 150 153 153 153 153 154 155 156 157 158 160 161 162 165 166 167 168 173 173 173 174 174 177 177 177 178 201 201 201 203 205 207 High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters Contents Block Diagrams for E Frames 208 E1 E2 380 500 VAC 208 E1 E2 525 690 VAC 209 MG 90 L1 02 VLT is a registered Danfoss trademark 5 Contents high Power Service Manual for VLT FC Series Frequency Converters Contents Illustration Illustration 1 1 Illustration 1 2 Illustration 1 3 Illustration 2 1 Illustration 2 2 Illustration 3 1 Illustration 3 2 Illustration 3 3 Illustration 3 4 Illustration 3 5 Illustration 3 6 Illustration 3 7 Illustration 3 8 Illustration 5 1 Illustration 5 2 Illustration 5 3 Illustration 5 4 Illustration 5 5 Illustration 6 1 Illustration 6 2 Illustration 6 3
236. r diodes in the soft charge rectifier are open Should that occur replace both diodes Main rectifier circuit test part I V 1 Reverse meter leads by connecting the negative meter lead to the negative DC bus connector MK105 B on the power card 2 Connect the positive meter lead to L1 L2 and in sequence Each reading should show infinity Each reading should show infinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the frequency converter being charged by the meter 92 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures Incorrect reading With the Part IV test connection the diodes in the SCR diode modules are reversed biased as well as the lower diodes in the soft charge rectifier If a short circuit exists it would be possible that either the diodes in the SCR diode modules or the lower diodes in the soft charge rectifier are shorted To isolate between SCRs or the soft charge rectifier perform the Soft Charge Rectifier Test 6 2 2 6 2 2 Soft Charge Rectifier Test D frame Size Testing the soft charge rectifier requires access to the soft charge card connectors It requires removing the control card and power card mounting plate Refer to removal instructions for soft charge card in Section 7 Do not remove the soft charge card completely or unplug any connectors no
237. rcurrent Warning VLT ARMS Out 893 1169 1169 1301 Overcurrent Alarm 1 5 sec delay VLT ARMS Out 893 1169 1169 1301 Earth Ground Fault Alarm VLT ARMS Out 265 322 352 405 Short Circuit Alarm VLT ARS Out 1138 1490 1490 1654 Heatsink Overtemperature Degrees C 95 95 95 95 Heatsink Undertemperature Warning Degrees C 0 0 0 0 Power Card Ambient Overtemperature Degrees 68 68 68 68 Power Card Ambient Undertemperature Degrees C 20 20 20 20 Mains Phase Warning 5 sec delay DC Bus Ripple VAC 70 70 70 70 Mains Phase Alarm 25 sec delay DC Bus Ripple VAC 70 70 70 70 MG 90 L1 02 VLT is a registered Danfoss trademark 19 1 Introduction 20 High Power Service Manual for VLT9 Series Frequency Converters Mains supply 3 x 525 690 V Model number FC102 202 P25 P31 P40 P132 P160 P200 0 5 0 FC302 P20 P25 P31 P110 P132 P160 0 0 5 Normal overload current ratings 11096 Output current Nominal A 525 550 V 162 204 253 303 360 418 MAX 60 sec A 525 550 V 178 224 278 333 396 460 Nominal A 551 690 V 155 192 242 290 344 400 MAX 60 sec A 551 690 V 171 211 266 319 378 440 Output Nominal kVA 550 V 154 194 241 289 343 398 Nominal kVA 575 V 154 191 241 289 343 398 Nominal kVA 690 V 185 229 289 347 411 478 Typical shaft output kW 550 V 110 132 160 200 250 315 HP 575 V 150 200 250 300 350 400 kW 690 V 132 160 200 250 315 400 High overload torque 16096 Output current No
238. rdance with procedures in Section 7 or 8 If the signal on terminal 13 is correct but the signal on terminal 14 is not the brake IGBT gate signal must be checked to determine whether the fault lies in the IGBT or the gate drive card See Gate Drive Signal Tests MG 90 L1 02 VLT is a registered Danfoss trademark 117 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters 6 3 14 Current Sensors Test 118 The current sensors are Hall effect devices that send a signal proportional to the actual output current waveform to the power card The current scaling card attached to the power card scales the signals from the current sensors to the proper level for monitoring and processing motor control data A defective current sensor can cause erroneous earth faults and overcurrent trips In such instances the fault will usually only occur at higher loads If the incorrect current scaling card is installed the current signals will be improperly scaled This could cause erroneous over current trips If the current scaling card is not installed the frequency converter will trip A couple of simple checks can be made to determine the status of the sensors 1 Apply power to the frequency converter 2 Ensure that motor check pre magnetizing DC hold DC brake or other parameter setups are disabled that create a holding torque while at zero speed Current displayed will exceed 1 to 2 amps if such parameters
239. re 500 VAC 478 5 VAC and 478 5 VAC then 500 VAC is Vmax 478 5 VAC is Vmin and 485 7 VAC is Vavg resulting in an imbalance of 396 Although the frequency converter can operate at higher mains imbalances the lifetime of com ponents such as DC bus capacitors will be shortened 106 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures Incorrect reading Open blown input fuses or tripped circuit breakers usually indicate a more serious problem Prior to replacing fuses or resetting breakers perform static tests described in section 6 2 An incorrect reading here requires that the main supply be investigated further Typical items to check would be Open blown input fuses or tripped circuit breakers Open disconnects or line side contactors Problems with the power distribution system If the Input Voltage Test was successful check for voltage to the control card 6 3 3 Basic Control Card Voltage Test 1 Measure the control voltage at terminal 12 with respect to terminal 20 The meter should read between 21 and 27 VDC An incorrect reading here could indicate the supply is being loaded down by a fault in the customer connections Unplug the terminal strip and repeat the test If this test is successful then continue Remember to check the customer connections If still unsuccessful proceed to the Switch Mode Power Sup
240. rect reading indicates that either the gate signal wires are not connected from the gate drive card to the gate resistor board or the gate resistors are defective Connect the gate signal wires or if the resistors are defective the entire IGBT module assembly requires replacement Replace the IGBT module according to the disassembly procedures in Section 7 or 8 6 2 6 Brake I GBT Test This test can only be carried out on units equipped with a dynamic brake option If a brake resistor is connected to terminals 81 and 82 disconnect it before proceeding Use an ohmmeter set on diode check or Rx100 scale Brake I GBT test part 1 1 Connect the positive meter lead to the brake resistor terminal 82 2 Connect the negative meter lead to the brake resistor terminal R 81 The reading should indicate infinity The meter may start out at a value and climb toward infinity as capacitance is charged within the frequency converter Brake I GBT test part 11 1 Connect the positive meter lead to the brake resistor terminal R 81 2 Connect the negative meter lead to the brake resistor terminal 82 The reading should indicate a diode drop Brake I GBT test part 111 1 Connect the positive meter lead to the brake resistor terminal R 81 2 Connect the negative meter lead to the negative DC bus connector MK105 B on the power card The reading should indicate infinity The meter may start out at a va
241. requency converter Contact with powered components could result in electrical shock and personal injury 1 DO NOT touch electrical parts of frequency converter when connected to mains After disconnecting from mains wait 20 minutes before touching any components in D frame size units or 40 minutes for E frame size units See the label on the front of the frequency converter door for specific discharge time 2 When repair or inspection is made mains must be disconnected MG 90 L1 02 VLT is a registered Danfoss trademark 11 1 Introduction The STOP key on the control panel does not disconnect mains High Power Service Manual for VLT9 FC Series Frequency Converters 4 During operation and while programming parameters the motor may start without warning Activate the STOP key when changing data When performing service use proper ESD procedures to prevent damage to sensi tive components 1 4 Electrostatic Discharge ESD Many electronic components within the frequency converter are sensitive to static electricity Vol tages so low that they cannot be felt seen or heard can reduce the life affect performance or completely destroy sensitive electronic components 1 5 Frame Size Definitions 12 380 480 VAC Power Model FC 102Drive and FC 202 VLT AQUA Drive kW 9400 VAC HP 2460 Frame Size P110 110 150 Di D3 P132 132 200 D1 D3 P160 160 250 D2 D4 P200 200 300 D2
242. requency converter with no display can be the result of several causes Verify first that there is no display whatsoever A single character in the display or a dot in the upper corner of the display indicates a communication error and is typically caused by an option card not properly installed When this condition occurs the green power on LED is illuminated If the LCD display is completely dark and the green power on LED is not lit proceed with the following tests First test for proper input voltage 6 3 2 Input Voltage Test 1 Apply power to frequency converter 2 Use the DVM to measure the input mains voltage between the frequency converter input terminals in sequence Li to L2 Li to L3 L2 to L3 For 380 500 V frequency converters all measurements must be within the range of 342 550 VAC Readings of less than 342 VAC indicate problems with the input mains voltage For 525 690 V frequency converters all measurements must be within the range of 446 759 VAC Readings of less than 446 VAC indicate problems with the input mains voltage In addition to the actual voltage reading the balance of the voltage between the phases is also important The frequency converter can operate within specifications as long as the imbalance of supply voltage is not more than 396 Danfoss calculates mains imbalance per an IEC specification Imbalance 0 67 X Vmax Vmin Vavg For example if three phase readings were taken and the results we
243. respect to MK105 B If the DC power supply fuse is open blown it is not possible to detect the presence of bus voltage at these terminals If uncertain wait 20 minutes for D frame sizes or 40 minutes for E frame sizes to allow the DC bus to fully discharge See label on front of frequency converter door for specific discharge time 2 With the ohmmeter set on a diode scale or Rx100 measure from power card connector MK105 A to any bus bars coming from the DC inductor Bus bars are visible at the lower edge and beneath the power card mounting bracket Depending on the bus bar readout look for a diode drop or a complete short In either case this indicates a fuse is in the circuit providing a path for continuity An open reading indicates an open fuse If the fuse is open it indicates a failure of the power supplies on the power card The power card and fuse require replacement If the fuse checks good there may be a problem with the soft charge circuitry Proceed to the static checks of the soft charge and rectifier circuits earlier in this section 108 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 3 6 DC Undervoltage Test The initial charge of the DC bus is accomplished by the soft charge circuit If the DC bus voltage is below normal it would indicate that either the mains voltage is out of tolerance or the soft char
244. retaining nuts at the top of the IGBT bus bar assy 8 Remove the 12 retaining screws 6 on each module on the upper portion of the IGBT modules These screws also attach the snubber capacitors to the IGBT modules see Illustration 7 22 item 5 for snubber capacitor location Remove the snubber capacitors 9 Remove the 10 mm retaining nut from the IGBT bus bar assy 10 Remove the IGBT bus bar assy 11 the bottom end of the IGBT module remove the 12 retaining screws 4 each for U V and W intermediate IGBT output bus bars 12 Remove the retaining nut 8 mm from the 3 intermediate IGBT output bus bars Remove the intermediate IGBT output bus bars CONTINUED ON NEXT PAGE 130BX98 10 Illustration 7 1 D2 D4 IGBT Modules 2 of 3 1 Intermediate IGBT output bus bar BB30 Step 12 7 IGBT bus bar assembly BB29 Steps 7 amp 10 2 Retaining nut Step 12 8 Retaining nut Step 7 3 Retaining screws Step 11 9 IGBT module 4 IGBT module 10 BB30 5 Retaining screws shown removed Step 8 11 BB31 6 Retaining nut Step 9 148 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Instructions Frequency Converters 13 14 Remove the 2 IGBT modules by removing the 16 retaining screws 8 per module and sliding the modules free from under the bus bars Clean the heatsink surface with a mild solvent or alco
245. ries 6 Test Procedures Frequency Converters 6 2 5 Inverter Section Tests The inverter section is primarily made up of the IGBTs used for switching the DC bus voltage to create the output to the motor IGBTs are grouped into modules comprised of six IGBTs De pending on the size of the unit either one two or three IGBT modules are present The frequency converter also has 3 snubber capacitors on each IGBT module Disconnect motor leads when testing inverter section With leads connected a short circuit in one phase will read in all phases making isolation difficult Before starting tests ensure that meter is set to diode scale If removed previously reinstall the soft charge card and power cards Do not disconnect the cable to connector MK105 on the power card since the path for continuity would be broken Inverter test part 1 Connect the positive meter lead to the positive DC bus connector MK105 A on the power card 2 Connect the negative meter lead to terminals U V and W in sequence Each reading should show infinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the frequency converter being charged by the meter Inverter test part 11 1 Reverse the meter leads by connecting the negative meter lead to the positive DC bus connector MK105 A on the power card 2 Connect the positive meter lead to U V and W in sequence Each reading
246. rm log and Maintenance log Back reverts to the previous step or layer in the navigation structure Cancel last change or command will be cancelled as long as the display has not been changed Info displays information about a command parameter or function in any display window Info pro vides detailed information when needed Exit Info mode by pressing either Info Back or Cancel Info Navigation keys The four navigation arrows are used to navi gate between the different choices available in Quick Menu Main Menu and Alarm Log Use the keys to move the cur sor OK is used for choosing a parameter marked by the cursor and for enabling the change of a parameter 1308T117 10 Operation keys for local control are found at the bottom of the control panel 130BP046 10 MG 90 L1 02 VLT is a registered Danfoss trademark 27 2 Operator Interface and Frequency Converter 2 High Power Service Manual for VLT Series Control Frequency Converters Hand On Enables control of the frequency converter via the LCP Hand On also starts the motor and it is now possible to enter the motor speed data by means of the arrow keys The key can be selected as Enable 1 or Disable 0 via par 0 40 Hand on Key on LCP The following control signals will still be active when Hand On is activated Hand On Off Auto On Reset Coasting stop inverse
247. roceed to testing the input waveform and input SCR in accordance with their procedures MG 90 L1 02 VLT is a registered Danfoss trademark 109 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters 6 3 8 Input Waveform Test Testing the current waveform on the input of the frequency converter can assist in troubleshooting mains phase loss conditions or suspected problems with the SCR diode modules Phase loss caused by the mains supply can be easily detected In addition the rectifier section is controlled by SCR diode modules Should one of the SCR diode modules become defective or the gate signal to the SCR lost the frequency converter will respond the same as loss of one of the phases The following measurements require an oscilloscope with voltage and current probes Under normal operating conditions the waveform of a single phase of input AC voltage to the frequency converter appears as in Illustration 6 13 Input A 130BX142 10 0 0 ms 5 ms Div Illustration 6 13 Normal AC Input Voltage Waveform The waveform shown in Illustration 6 14 represents the input current waveform for the same phase as Illustration 6 13 while the frequency converter is running at 40 load The two positive and two negative jumps are typical of any 6 diode bridge It is the same for frequency converters with SCR diode modules Input B 130BX143 10 0 0 ms 5 ms Div Illustration 6 14 AC Input Current Wa
248. rouped into communi cation words and protocols The RS 485 serial communication connector is wired to terminals 68 69 Terminal 61 is common and may be used for terminating screens only when the control cable run between frequency converters not between frequency converters and other devices See Earthing Screened Cables in this section for correct methods for terminating a screened control cable 2 5 2 Output signals The frequency converter also produces output signals that are carried through either the RS 485 serial bus or terminal 42 Output terminal 42 operates in the same manner as the inputs The terminal can be programmed for either a variable analog signal in mA or a digital signal 0 or 1 in 24 VDC In addition a pulse reference can be provided on terminals 27 and 29 Output analog signals generally indicate the frequency converter frequency current torque and so on to an external controller or system Digital outputs can be control signals used to open or close a damp er for example or send a start or stop command to auxiliary equipment Additional terminals are Form C relay outputs on terminals 01 02 and 03 and terminals 04 05 and 06 Terminals 12 and 13 provide 24 VDC low voltage power often used to supply power to the digital input terminals 18 33 Those terminals must be supplied with power from either terminal 12 or 13 or from a customer supplied external 24 VDC power source Improperly connected co
249. rrent and torque The analog signal is 0 4 to 20 mA at a maximum of 500 digital signal is 24 at a minimum of 500 10 VDC 15 mA maximum analog supply voltage for potentiometer or thermistor Selectable for 0 to 10 VDC voltage input R 10 or analog signals 0 4 to 20 mA at a maximum of 200 O Used for reference or feedback signals A thermistor can be connected here Common for terminals 53 and 54 RS 485 common RS 485 interface and serial communication 27 29 32 33 37 53 54 42 1 3 4 6 5 12 5 13 5 14 5 15 5 19 641 6 2 6 5 5 4 5 4 Table 2 2 Control Terminals and Associated Parameter Control terminals must be programmed Each terminal has specific functions it is capable of per forming and a numbered parameter associated with it The setting selected in the parameter enables the function of the terminal See the FC Series Operating Instructions for details MG 90 L1 02 VLT is a registered Danfoss trademark Control 39 2 Operator Interface and Frequency Converter 2 High Power Service Manual for VLT Series Control Frequency Converters 91 92 95 95 L1L2L3PE U 96 97 98 99 130BA174 10 Illustration 2 2 Control Terminals Electrical Diagram 40 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 7 42 Operator Interface and Frequency Converter Frequency Converters Control 2 8 Earthing
250. rse The 24 VDC supply is also capable of supplying 200 mA of power part of which may be used to power external encoders or other devices A 10 VDC supply on terminal 50 is rated at 17 mA is also available for use with speed reference circuitry The analog and digital output signals are powered through an internal frequency converter supply Two relays for monitoring the status of the frequency converter are located on the power card These are programmable through parameter group 5 4 The relays are Form C meaning it has one normally open contact and one normally closed contact on a single throw The contacts of the relay are rated for a maximum load of 240 VAC at 2 Amps resistance The logic circuitry on the control card allow for the addition of option modules for synchronising control serial communications additional relays the cascade pump controller or custom oper ating software 3 2 2 Logic to Power I nterface The logic to power interface isolates the high voltage components of the power section from the low voltage signals of the logic section The interface section consists of the power card and gate drive card Much of the fault processing for output short circuit and earth fault conditions is handled by the control card The power card provides conditioning of these signals Scaling of current feedback and voltage feedback is accomplished by the control card The power card contains a switch mode power supply SMPS which
251. rter and Motor Applications Torque Limit Current Limit and Unstable Motor Operation Overvoltage Trips Mains Phase Loss Trips Control Logic Problems Programming Problems Motor Load Problems Internal Frequency Converter Problems Overtemperature Faults Current Sensor Faults 55 57 57 57 57 59 60 60 60 61 62 63 63 75 77 77 78 79 79 80 80 81 81 81 Signal and Power Wiring Considerations for Frequency Converter Electromagnetic Compatibility Effect of EMI Sources of EMI EMI Propagation Preventive Measures Proper EMC Installation 6 Test Procedures Introduction Tools Required for Testing Signal Test Board Test Cables Static Test Procedures Soft Charge and Rectifier Circuits Test D frame Size Soft Charge Rectifier Test D frame Size MG 90 L1 02 VLT is a registered Danfoss trademark 82 82 82 83 85 86 87 87 88 88 89 90 91 93 High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters Contents Soft Charge and Rectifier Circuits Test E frame Size 95 Soft Charge Rectifier Test E frame Size 97 Inverter Section Tests 98 Brake IGBT Test 99 Intermediate Section Tests 100 Heatsink Temperature Sensor Test 101 Fan Continuity Tests D frame Size 101 Fan Continuity Tests E frame Size 103 Dynamic Test Procedures 105 No Display Test 106 Input Voltage Test 106 Basic Control Card Voltage Test 107 Switch Mode Power Supply SMPS Test 107 Zero DC Bus Voltage Test 1
252. rvice Manual for VLT FC Series 5 Frequency Converter and Motor Applications Frequency Converters If the signal is present at the terminal the control card is defective and must be replaced If the signal is not present the problem is external to the frequency converter The circuitry providing the signal along with its associated wiring must then be checked 5 1 4 Programming Problems Difficulty with frequency converter operation can be a result of improper programming of the frequency converter parameters Three areas where programming errors may affect drive and motor operation are motor settings references and limits and I O configuration See Drive Inputs and Outputs in Section 2 The frequency converter must be set up correctly for the motor s connected to it Parameters 1 20 1 25 must have data from the motor nameplate entered into the frequency converter This enables the frequency converter processor to match the frequency converter to power charac teristics of the motor The most common result of inaccurate motor data is the motor drawing higher than normal amounts of current to perform the task expected of it In such cases setting the correct values for these parameters and performing the automatic motor adaptation AMA function will usually solve the problem Any references or limits set incorrectly will result in less than acceptable frequency converter performance For instance if maximum reference is set too low th
253. ry supply If the voltage is incorrect replace the fan transformer 2 If the voltage is correct check the fan voltage supplied to the fans themselves The voltage can be read at power card connector MK107 pins 8 and 11 with respect to pin 1 The voltage at pins 8 and 11 correspond to the fan s commanded speed 200 VAC for low speed and 230 VAC for high speed If the correct voltage is available but the fan is not running that fan is defective If no voltage is available verify that the fans should be running If so the power card is defective Replace the fan or power card in accordance with the disassembly instructions in Section 7 or 8 Fan control circuit To verify that the fan control circuit is receiving appropriate commands from the control card the signal test board can be used to verify those signals 1 Remove power from the frequency converter and allow the DC bus to fully discharge Install the signal test board into power connector MK104 2 3 Reapply power to the frequency converter 4 Connect the negative meter lead of a voltmeter to signal board terminal 4 common 5 With a positive meter lead check the signal at terminal 6 of the signal board The meter should read zero 0 volts with the fans set to run 5 VDC if the control card has the fans set to off 6 Verify sequence of operation of the cooling fans to ensure they should be running In addition the signal board contains a fan test switch W
254. s for the frequency converter models and voltage ranges descri bed in the tables on the following page 1 2 VLT FC Product Overview VLT HVAC FC 102 series frequency converters are designed for the HVAC markets They operate in variable torque mode or constant torque down to 15 Hz and include special features and options well suited for fan and pump applications within the HVAC market VLT AQUA FC 202 series frequency converters are designed for water and waste water markets They can operate in either constant torque or variable torque with limited overload capabilities They include specific features and options which make them well suited for use on a variety of water pumping and processing applications VLT AutomationDrive series frequency converters are fully programmable for either constant torque or variable torque industrial applications They are full featured frequency converters ca pable of operating a myriad of applications and incorporating a wide variety of control and communication options These models are available in Chassis IPO0 NEMA 1 IP21 or NEMA 12 IP54 enclosures 1 3 For Your Safety Frequency converters contain dangerous voltages when connected to mains Only a competent technician should carry out service For dynamic test procedures main input power is required and all devices and power supplies connected to mains are energised at rated voltage Use extreme caution when conducting tests in a powered f
255. s lower than the setpoint which may indicate leakage in the pipe system See pa rameter group 22 5 ALARM 95 Broken belt Torque is below the torque level set for no load indicating a broken belt See parameter group 22 6 ALARM 96 Start delayed Motor start has been delayed due to short cycle protection active See parameter group 22 7 WARNI NG 97 Stop delayed Stopping the motor has been delayed due to short cycle protection is active See parameter group 22 7 WARNI NG 98 Clock fault Clock Fault The time is not set or the RTC clock if mounted has failed See parameter group 0 7 WARNI NG 200 Fire mode The input command fire mode is active See parameter group 24 0 WARNI NG 201 Fire mode was active Fire mode has been active See parameter group 0 7 WARNI NG 202 Fire mode limits exceeded One or more warranty voiding alarms have been suppressed during fire mode operation See parameter group 0 7 ALARM 243 Brake I GBT This alarm is only for F Frame frequency converters It is equivalent to Alarm 27 The report value in the alarm log indicates which power module generated the alarm 1 left most inverter module 2 middle inverter module in F2 or drive 2 right inverter module in F1 or F3 drive 3 right inverter module in F2 or drive MG 90 L1 02 VLT is a registered Danfoss trademark 73 high Power Service Manual for VLT FC Series 4 Troubleshooting Frequency Converters
256. s the capacitors in the reverse direction Although the test does not ensure the capacitors are fully func tional it ensures that no short circuits exist in the intermediate circuit Incorrect reading A short circuit could be caused by a short in the soft charge rectifier or inverter section Be sure that the tests for these circuits have already been performed successfully A failure in one of these sections could be read in the intermediate section since they are all routed via the DC bus If a short circuit is present and the unit is equipped with a brake perform the brake IGBT test next The only other likely cause would be a defective capacitor within the capacitor bank There is not an effective test of the capacitor bank when it is fully assembled Although it is unlikely that a failure within the capacitor bank would not be indicated by a physically damaged capacitor if suspect the entire capacitor bank must be replaced Replace the capacitor bank in accordance with the disassembly procedures in Section 7 or 8 100 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures 6 2 8 Heatsink Temperature Sensor Test The temperature sensor is an NTC negative temperature coefficient device As a result high resistance means low temperature As temperature decreases resistance increases Each IGBT module has a temperature sensor mounted inter
257. scovers them reading an unrecognised frequency converter display problems with motor operation or a warning or alarm displayed by the frequency converter Remember the frequency converter processor monitors inputs and outputs as well as internal frequency converter functions so an alarm or warning does not necessary indicate a problem within the frequency converter itself MG 90 L1 02 VLT is a registered Danfoss trademark 57 Power Service Manual for VLT9 FC Series 4 Troubleshooting Frequency Converters Each incident has further descriptions on how to troubleshoot that particular symptom When necessary further referrals are made to other parts of the manual for additional procedures Sec tion 5 Frequency Converter and Motor Applications presents detailed discussions on areas of frequency converter and system troubleshooting that an experienced repair technician should understand in order to make effective diagnoses Finally a list of tests called After Repair Tests is provided These tests should always be performed when first starting a frequency converter when approaching a frequency converter that is sus pected of being faulty or anytime following a repair to the frequency converter 58 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 4 Troubleshooting 4 4 Visual I nspection The table below lists a variety of conditions that re
258. se the SCR and diode modules during installation Reversing the SCR and diode modules can result in equipment damage NB For each AC input phase there is one SCR module and one diode module The SCR is on the left the diode on the right as seen facing the upright unit There are three pairs Only the SCR module has a connection pin for the gate signals 1 Replace SCR and diode modules in accordance with the instructions included with the replacement modules 2 Reassemble in reverse order Attaching Hardware Tightening Torque T50 Per spare part instruction T25 Per spare part instruction 17 mm 19 Nm 170 in Ibs 13 mm 9 5 Nm 85 in Ibs 10 mm 4 Nm 35 in Ibs 8 2 3 Nm 20 in Ibs 164 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 8 E Frame Sizes Disassembly and Assembly Frequency Converters 8 2 10 Current Sensor 1 Remove the input terminal plate in accordance with procedure 2 Remove the retaining nut 17 mm connecting the current sensor bus bar to the motor terminal bus bar 3 Remove the retaining nut 17 mm or T50 screw depending on unit type connecting the current sensor bus bar to the IGBT via the fan bus bar 4 Note which cable is attached to the current sensor Ensure that the correct cable is at tached upon reassembly Unplug the cable from the current sensor being removed 5 Remove the 2 retaining nuts si
259. ser with programmable options These parameters are programmed to enable the frequency converter to meet specific application requirements This data is then stored in an EEPROM which provides security during power down and also allows the flexibility to change the operational characteristics of the frequency converter A custom integrated circuit generates a pulse width modulation waveform which is then sent to the interface circuitry located on the power card Local Control 5 8 a e B U S wc m D 4 ANALOG PROM amp g d PLUS a INPUTS A A 2 CONTROL POWER FEEDBACK POWER DIGITAL a INPUTS 4 D 7 ANALOG OUTPUTS 1 DIGITAL CHANNEL 1 RELAY Illustration 3 2 Logic Section The PWM waveform is created using an improved control scheme called VVCP ss a further devel opment of the earlier VVC Voltage Vector Control system VVCP s provides a variable frequency and voltage to the motor which matches the requirements of the motor Also available is the continuous pulsing SFAVM PWM Selection can be made in parameter group 14 The dynamic response of the system changes to meet the variable requirements of the load Another part of the logic section is the local control panel LCP T
260. shooting 4 5 3 Motor Will not Run In the event that this symptom is detected first verify that the unit is properly powered up display is lit and that there are no warning or alarm messages displayed The most common cause of this is either incorrect control logic or an incorrectly programmed frequency converter Such oc currences will result in one or more of the following status messages being displayed LCP Stop The OFF key has been pressed Line 2 of the display will also flash when this occurs Press the AUTO ON or HAND ON key Standby This indicates that there is no start signal at terminal 18 Ensure that a start command is present at terminal 18 Refer to the Input Terminal Signal Test 6 3 16 Unit ready Terminal 27 is low no signal Ensure that terminal 27 is logic 1 Refer to the Input Terminal Signal Test 6 3 16 Run OK 0 Hz This indicates that a run command has been given to the frequency converter but the reference speed command is zero or missing Check the control wiring to ensure that the proper reference signal is present at the frequency converter input terminals and that the unit is properly programmed to accept the signal provided Refer to the Input Terminal Signal Test 6 3 16 Off 1 2 or 3 This indicates that bit 1 or 2 or 3 in the control word is logic 0 This will only occur when the frequency converter is being controlled via the fieldbus A correct control word mu
261. should show a diode drop Incorrect reading An incorrect reading in any inverter test indicates a failed IGBT module Replace the IGBT module according to the disassembly instructions in Section 7 or 8 It is further recommended for units with two IGBT modules that both modules be replaced even if the second module tests correctly Inverter test part 111 1 Connect the positive meter lead to the negative DC bus connector 105 on the power card 2 Connect the negative meter lead to terminals U V W in sequence Each reading should show a diode drop Inverter test part I V 1 Reverse the meter leads by connecting the negative meter lead to the negative DC bus connector MK105 B on the power card 2 Connect positive meter lead to U V and W in sequence Each reading should show infinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the frequency converter being charged by the meter Incorrect reading An incorrect reading in any inverter test indicates a failed IGBT module Replace the IGBT module according to the disassembly instructions in Section 7 or 8 It is further recommended for units with two IGBT modules that both modules be replaced even if the second module tests correctly 98 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures In
262. shows the soft charge card and the location of the fuses It is for reference only It is not necessary to remove the card to perform the tests Disconnect the MK3 from the soft charge card and leave disconnected until completion of soft charge and rectifier tests Soft charge fuse test Use a digital ohmmeter to test continuity on rectifier fuses F1 F2 and F3 on the soft charge card 1 Measure F1 across fuse Open reading indicates open blown fuse 2 Measure F2 across fuse Open reading indicates open blown fuse 3 Measure F3 across fuse Open reading indicates open blown fuse A measurement of 0 ohms indicates good continuity Replace any open fuse infinite resistance 130BX78 10 Illustration 6 8 Soft Charge Card Fuse Location 380 480 500V Blue MOV and 8 PTCs 525 690V Red MOV and 6 PTCs 1 Fuses F1 F2 and F3 2 MK3 disconnect for soft charge and rectifier tests MG 90 L1 02 VLT is a registered Danfoss trademark 95 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters Main rectifier circuit test E frames part I 1 Connect the positive meter lead to the positive DC bus connector MK105 A on the power card 2 Connect the negative meter lead to terminals L1 L2 and L3 in sequence If a dis connect option is used measure on top side of fuses Each reading should show infinity The meter will start at a low value and slowly climb towards
263. similar to an uncontrolled rectifier When the DC bus capacitors are fully charged the voltage on the DC bus will be equal to the peak voltage of the input mains Theoretically this can be calculated by multiplying the mains value by 1 414 VAC x 1 414 However since AC ripple voltage is present on the DC bus the actual DC value will be closer to VAC x 1 38 under unloaded conditions and may drop to VAC x 1 32 while running under load For example a frequency converter connected to a nominal 460 V line while sitting idle the DC bus voltage will be approximately 635 VDC 460 x 1 38 As long as power is applied to the frequency converter this voltage is present in the intermediate circuit and the inverter circuit It is also fed to the Switch Mode Power Supply SMPS on the power card and is used for generating all other low voltage supplies MG 90 L1 02 VLT is a registered Danfoss trademark 47 Power Service Manual for VLT9 FC Series 3 Internal Frequency Converter Operation Frequency Converters Fr 200000 LI DC INDUCTOR pe senn SCRI SCR2 SCR3 E 5 x 5 DISC FUSE OPTION RFI OPTION _ 5 des Eg my RF CARD Se Tu E 3 e 4
264. st be transmitted to the frequency converter over the communication bus to correct this STOP One of the digital input terminals 18 19 27 29 32 or 33 parameter 5 1 is programmed for Stop Inverse and the corresponding terminal is low logic 0 Ensure that the above parameters are programmed correctly and that any digital input program med for Stop Inverse is high logic 1 Display Indication That the Unit is Functioning but No Output Make sure that par 14 22 Operation Mode is not set to Run With Inverter Disabled If the unit is equipped with an external 24 VDC option check that main power is applied to the frequency converter Note In this case the display will alternately flash Warning 8 MG 90 L1 02 VLT is a registered Danfoss trademark 61 high Power Service Manual for VLT FC Series 4 Troubleshooting Frequency Converters 4 5 4 Incorrect Motor Operation Occasionally a fault can occur where the motor will continue to run but not in the correct manner The symptoms and causes may vary considerably Many of the possible problems are listed below by symptom along with recommended procedures for determining their causes Wrong speed unit will not respond to command Possible incorrect reference speed command Ensure that the unit is programmed correctly according to the reference signal being used and that all reference limits are set correctly as well Perform Input Terminal Signal Test 6 3 16 to
265. st in Section 6 In summary for proper frequency converter functioning the frequency converter in put control terminals must be 1 wired properly 2 powered 3 programmed correctly for the intended function 4 receiving a signal MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series 7 42 Operator Interface and Frequency Converter Frequency Converters 2 7 Control Terminal Functions The following describes the functions of the control terminals Many of these terminals have mul tiple functions determined by parameter settings Some options provide additional terminals See Illustration 2 2 Terminal No 01 02 03 and 04 05 06 12 13 18 19 27 29 32 33 20 37 39 42 50 53 54 Function Two Form C output relays Maximum 240 VAC 2 A Minimum 24 VDC 10 mA or 24 VAC 100 mA Can be used for indicating status and warn ings Physically located on the power card 24 VDC power supply to digital inputs and external transducers The maximum output current is 200 mA Digital inputs for controlling the frequency converter R 2 kohm Less than 5 V logic 0 open Greater than 10 V logic 1 closed Terminals 27 and 29 are programmable as digital pulse outputs Common for digital inputs 0 24 VDC input for safety stop some units Common for analog and digital outputs Analog and digital outputs for indicating values such as frequency ref erence cu
266. stem These conductors should receive the highest attention whenever EMI is a problem Single conductor wires provide the least protection from EMI emissions Often if these conductors are routed separately from the signal and mains wiring then no further consideration is needed If the conductors are routed close to other susceptible conductors or if the system is suspected of causing EMI problems then alternate motor wiring methods should be considered Installing screened power cable is the most effective means to alleviate EMI problems The cable s screen forces the noise current to flow directly back to the frequency converter before it gets back into the power network or takes other undesirable and unpredictable high frequency paths Unlike most signal wiring the screening on the motor cable should be terminated at both ends If screened motor cable is not available then 3 phase conductors plus earth in a conduit will provide some degree of protection This technique will not be as effective as screened cable due to the unavoidable contact of the conduit with various points within the equipment Serial communications cable selection There are various serial communication interfaces and protocols on the market Each of these recommends one or more specific types of twisted pair screened twisted pair or proprietary ca bles Refer to the manufacturer s documentation when selecting these cables Similar recommen dations apply to serial communi
267. sure that the motor ratings coincide with the frequency converters Make sure that the frequency converter s motor parameters 1 20 1 25 are set according to the motor ratings Check for loose connections Check for switching components in the output circuit Check for faulty contacts in the switch gear Make sure that the frequency converter parameter settings are correct according to motor application and I O configuration These frequency converters require adequate top and bottom clearance to ensure proper air flow for cooling in accordance with the frequency converter size Frequency converters with exposed heatsinks out the back of the frequency converter must be mounted on a flat solid surface Although this is a somewhat subjective procedure look for any unusual amount of vibration that the frecuency converter may be subjected to The frequency converter should be mounted solidly or the use of shock mounts employed Table 4 1 Visual Inspection MG 90 L1 02 VLT is a registered Danfoss trademark 59 sn Power Service Manual for VLT FC Series 4 Troubleshooting Frequency Converters 4 5 Fault Symptoms 4 5 1 No Display The LCP display provides two display indica tions One by means of the backlit LCD alpha numeric display The other is three LED indicators lights near the bottom of the LCP If the green power on LED is illuminated but the backlit display is dark this indicates that the LCP itself is
268. t via serial communication digital I O or by pressing reset button on LCP Note that if automatic restart is enabled the motor may start when the fault is cleared ALARM 72 Dangerous failure Safe stop with trip lock Unexpected signal levels on the safe stop and digital input from the MCB 112 PTC thermistor card 72 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 4 Troubleshooting Warning 73 Safe stop auto restart Safe stopped Note that with automatic restart enabled the motor may start when the fault is cleared ALARM 79 Illegal power section config uration The scaling card is the incorrect part number or not installed Also the MK102 connector on the power card is not installed ALARM 80 Drive initialised to default value Parameter settings are initialised to default settings after a manual reset WARNING 81 CSIV corrupt CSIV file has syntax errors WARNING 82 CSIV parameter error CSIV has failed to record a parameter ALARM 91 Analog input 54 wrong settings Switch S202 must be set in the position OFF voltage input when a KTY sensor is connected to analog input terminal 54 ALARM 92 No flow no load situation has been detected in the system See parameter group 22 2 ALARM 93 Dry pump A no flow situation and high speed indicate that the pump has run dry See parameter group 22 2 ALARM 94 End of curve Feedback stay
269. t called out Doing so will break the continuity path of these measurements and may result in a false interpretation of a failure Although an open reading is possible it is unlikely since that indicates that both the diodes in the SCR diode modules and the lower diodes in the soft charge rectifier are open Should that occur replace both diodes 1 Extract the soft charge card far enough to access the connectors 2 Disconnect the DC cable at the connector Since the rectifier test requires the soft charge resistor to be in the circuit verify the resistor is good before proceeding 3 Measure the resistance between pins A and B of connector MK4 on the soft charge card It should read 27 ohms 10 for 380 500 frequency converters and 68 ohms 10 for 525 690 A reading outside this range indicates a defective soft charge resistor Replace the resistor in accordance with disassembly procedures in Section 7 Continue tests Should the resistor be defective and a replacement not readily available the remainder of the tests can be carried out by disconnecting the cable at connector MK4 on the soft charge card and placing a temporary jumper across pins A and B This provides a path for continuity for the re maining tests Ensure any temporary jumpers are removed at the conclusion of the tests For the following tests set the meter to diode check or Rx100 scale 4 Connect the negative meter lead to the positive MK3 A
270. t must be given to any frequency converter in order to obtain an output First the frequency converter must be told to run start command Second the frequency converter must be told how fast to run reference or speed command The frequency converters are designed to accept a variety of signals First determine what types of signals the frequency converter is receiving There are six digital inputs terminals 18 19 27 29 32 33 two analog inputs 53 and 54 and the fieldbus 68 69 The presence of a correct reading will indicate that the desired signal has been detected by the microprocessor of the fre quency converter See the chapter Frequency Converter Inputs and Outputs Using the status information displayed by the frequency converter is the best method of locating problems of this nature By selecting within parameter group 0 2 LCP Display line 2 or 3 of the display can be set to indicate the signals coming in The presence of a correct reading indicates that the desired signal is detected by the microprocessor of the frequency converter This data also may be read in parameter group 16 6 If there is not a correct indication the next step is to determine whether the signal is present at the input terminals of the frequency converter This can be performed with a voltmeter or oscil loscope in accordance with the 6 3 16 Input Terminal Signal Test MG 90 L1 02 VLT is a registered Danfoss trademark 79 ish Power Se
271. t the Control Card Voltage Test earlier in this section MG 90 L1 02 VLT is a registered Danfoss trademark 121 high Power Service Manual for VLT FC Series 6 Test Procedures Frequency Converters If the 10 volts is present proceed with checking the individual inputs as follows 2 Connect the negative meter lead to reference terminal 55 3 Connect the positive meter lead to desired terminal 53 or 54 For analog input terminals 53 and 54 a DC voltage between 0 and 10 VDC should be read to match the analog signal being sent to the frequency converter Or a reading of 0 9 to 4 8 VDC corresponds to a 4 to 20 mA signal Note that a minus sign preceding any reading above indicates a reversed polarity In this case reverse the wiring to the analog terminals 6 4 Initial Start Up or After Repair Drive Tests Following any repair to a frequency converter or testing of a frequency converter suspected of being faulty the following procedure must be followed to ensure that all circuitry in the frequency converter is functioning properly before putting the unit into operation 1 Perform visual inspection procedures as described in Table 4 1 2 Perform static test procedures 6 2 1 6 2 2 and 6 2 5 for D frame size units or 6 2 3 6 2 4 and 6 2 5 for E frame size units to ensure the frequency converter is safe to start 3 Disconnect the motor leads from the output terminals U V W of the frequency con verter 4
272. ternal dynamic brake resistors while also saving energy In theory the number of frequency converters that can be connected in this way is infinite however the frequency converters must be of the same voltage rating In addition depending on the size and number of frequency converters it may be necessary to install DC reactors and DC fuses in the DC link connections and AC reactors on the mains Attempting such a configuration requires specific considerations and should not be attempted without first consulting Danfoss Ap plication Engineering In the second method the frequency converter is powered exclusively from a DC source This is a bit more complicated First a DC source is required Second a means to soft charge the DC bus at power up is required Last a mains voltage source is required to power the fans within the frequency converter Again such a configuration should not be attempted without first consulting Danfoss Application Engineering 3 3 8 Specific Card Connections Connector FK102 terminals 104 105 and 106 located on the power card provide for the con nection of an external temperature switch The input could be used to monitor the temperature of an external brake resistor Two input configurations are possible A normally closed switch may be connected between terminals 104 and 106 or a normally open switch between terminals 104 and 105 Should the input change states the frequency converter would trip on an Alarm 29 O
273. than the low voltage warning limit The limit is dependent on the frequency converter voltage rating The frequency converter is still active See ratings table in Section 1 9 for the voltage limits WARNI NG ALARM 7 DC overvoltage If the intermediate circuit voltage exceeds the limit the frequency converter trips after a time Troubleshooting Connect a brake resistor Extend the ramp time Change the ramp type MG 90 L1 02 VLT is a registered Danfoss trademark 65 high Power Service Manual for VLT FC Series 4 Troubleshooting Frequency Converters Activate functions in par 2 10 Brake Function Increase par 14 26 7rip Delay at Inverter Fault See ratings table in Section 1 9 for the voltage limits See Section 5 1 1 for troubleshooting details WARNI NG ALARM 8 DC undervoltage If the intermediate circuit voltage DC drops below the undervoltage limit the frequency con verter checks if a 24 V backup supply is connected If no 24 V backup supply is connected the frequency converter trips after a fixed time delay The time delay varies with unit size See ratings table in Section 1 9 for the voltage limits Troubleshooting Make sure that the supply voltage matches the frequency converter voltage Perform Input voltage test Section 6 3 2 Perform soft charge and rectifier circuit test Section 6 2 1 or 6 2 3 WARNI NG ALARM 9 Inverter overloaded The frequency converter is about to cut out because of an ov
274. the frequency converter Measure pins 1 and 2 of each test connector Each reading should be approximately 9 VDC indicating all IGBTs are turned off 10 Apply the run command to the frequency converter and 30 Hz reference 11 Ifusing a DVM measure pins 1 and 2 of each connector Waveform to IGBTs is a square wave that goes positive to 14 VDC and negative to 9 VDC Average voltage read by DVM should be 2 2 to 2 5 114 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures za 9 5 0 no n ooo 9 no 0 no n no n 8 o 3 f 07 ri T nl a ooo 0 000 ges ges E 2n fm pet 06 06 00 000 2 2 0 1 2 3 4 5 6 7 8 8 10 11 12 Illustration 6 17 Gate Drive Card Test Connectors 1 Pin 1 7 MK450 2 850 brake 8 MK103 V 3 MK105 brake option 9 MK550 4 MK250 10 MK650 5 MK102 U 11 MK104 W 6 MK350 12 MK750 When using an oscilloscope the readings should appear as in Illustration 6 18 Input A 20 0 1808X146 10 15 0 10 0 50 0 0V 5 0 10 0 15 0 20 0 100 0 us 5 us Div Illustration 6 18 Gate Signal Waveform from Gate Drive Card IGBT Gate Signal measured on the Gate Drive Card 5 vo
275. to ted supply present 5 25 VDC 4 75 5 25 VDC 25 IGBT gate signal aa 2 2 2 5 buffered U phase Ph EL Equal on all phases positive Signal 4 25 originates on Con 74 js i trol Card 2v div 100us div Run 10Hz 26 GUN T IGBT gate signal MA 2 2 2 5 VDC buffered U phase 1 RHR PH EL Equal on all phases negative Signal 4 TP25 TP30 originates on Con m F trol Card bs 2v div 100us div Run 10Hz 27 T IGBT gate signal 2 2 2 5 buffered V phase i 1 PE EE Equal on all phases positive Signal 4 25 originates on Con r4 d m F trol Card oe 2v div 100us div Run 10Hz 28 GVN T IGBT gate signal MA 2 2 2 5 buffered V phase rh F H PH F EL Equal on all phases negative Signal TP25 TP30 originates on Con r4 d T F trol Card 2v div 100us div Run 10Hz 29 GWP T IGBT gate signal MA B 2 2 2 5 VDC buffered Tu F Equal on all phases phase positive TP25 TP30 Signal originates gt 4 l on Control 2v div 100us div Run 10Hz 30 GWN T IGBT gate signal B 2 2 2 5 VDC buffered pH pi Pid Equal on all phases TP25 TP30 phase negative Signal originates 4 Ll T l on Control Card 2v div 100us div Run 10Hz MG 90 L1 02 VLT is a registered Danfoss trademark
276. tor 7 Retaining screw Step 16 2 Retaining screw Brake IGBT option Step 20 8 Retaining screw Step 15 3 Retaining nut Step 17 9 IGBT Cap bus bar BB47 4 Retaining nut Step 21 10 IGBT board 5 High Frequency board 11 IGBT retaining screw Step 22 6 Retaining screw Step 18 MG 90 L1 02 VLT is a registered Da nfoss trademark 171 8 E Frame Sizes Disassembly and Assembly ish Power Service Manual for VLT FC Series Instructions Frequency Converters REASSEMBLY 1 Replace the IGBT modules in accordance with instructions included with the replacement modules 2 Reassemble in reverse order Attaching Hardware Tightening Torque 8 mm T25 2 3 Nm 20 in Ibs 10 mm T30 4 Nm 35 in Ibs 13 mm 9 5 Nm 85 in Ibs 17 mm T50 19 Nm 170 in Ibs 172 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 9 Special Test Equipment 9 Special Test Equipment 9 1 Test Equipment Test tools have been developed to aid in troubleshooting these products It is highly recommended for repair and servicing this equipment that these tools be available to the technician Without them some troubleshooting procedures described in this manual cannot be carried out Although some test points can be found inside the frequency converter to probe for similar signals the test tools provide a safe and sure location for making necessary measurements
277. trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 7 2 3 Power Card Remove the control assembly support bracket in accordance with procedure Unplug power card connectors 100 MK102 105 MK106 107 and MK109 If customer connections are present unplug connectors 102 FK103 and MK112 Remove the 7 mounting screws T25 Torx from the power card Remove the power card from the plastic standoff at the top right of the power card Ow OT Remove the current scaling card from the power card by pushing in the retaining clips on the standoffs KEEP THIS SCALING CARD FOR FUTURE REINSTALLATION OF ANY REPLACEMENT POWER CARD The scaling card controls signals operating with this spe cific frequency converter The scaling card is not part of the replacement power card Reinstall in reverse order of this procedure When installing the power card ensure that the in sulator sheet is installed behind the power card Tighten the mounting screws to 2 3 Nm 20 in Ibs 130BX172 10 Illustration 7 1 Power Card and Mounting Plate 380 480 500V Yellow tape on the main SMPS 525 690V White tape on the main SMPS transformer in the upper right corner transformer in the upper right corner 1 Power card PCA3 9 MK106 2 Mounting plate 10 MK100 3 MK110 11 MK109 4 MK102 12 FK102 5 MK104 13 MK112 terminals 4 5 6 6 MK105 14 MK112 t
278. trademark High Power Service Manual for VLT9 FC Series 7 44 Frequency Converters 5 Frequency Converter and Motor Applications equency Converter and Motor Applications 5 1 Torque Limit Current Limit and Unstable Motor Op eration Excessive loading of the frequency converter may result in warning or tripping on torque limit overcurrent or inverter time This is not a concern if the frequency converter is properly sized for the application and intermittent load conditions cause anticipated operation in torque limit or an occasional trip However nuisance or unexplained occurrences may be the result of improperly setting specific parameters The following parameters are important in matching the frequency converter to the motor for optimum operation These setting need careful attention par 1 03 7orque Characteristics sets the mode in which the frequency converter will operate Parameters 1 20 through 1 29 match the frequency converter to the motor and adapt to the motor characteristics Parameters 4 17 and 14 25 set the torque control features of the frequency converter for the application par 1 00 Configuration Mode sets the frequency converter for open or closed loop operation or torque mode operation In a closed loop configuration a feedback signal controls the frequency converter speed The settings for the PID controller play a key role for stable operation in closed loop as described in the Operating Instructions In o
279. ts with an RFI filter MK101 2 Remove the gate drive card by removing the 6 mounting screws T25 Torx from the standoffs Reinstall in reverse order of this procedure Tighten the mounting screws to 2 3 Nm 20 in Ibs 7 oo de z om 000 1 D Illustration 8 1 Gate Drive Card en er rm rm rs CD CD CD CD O CD o0 130BX160 10 e CN 5 5 E E 1 MK100 2 MK101 RFI filter 3 MK106 4 MK105 brake option NOW MK102 U 103 104 W MG 90 L1 02 VLT is registered Danfoss trademark 157 8 E Frame Sizes Disassembly and Assembly ish Power Service Manual for VLT FC Series Instructions Frequency Converters 8 2 6 Capacitor Banks Upper Capacitor Banks 1 Remove the control assembly support bracket and the gate drive card in accordance with the instructions 2 The capacitor bank connection to the DC bus bars can be seen recessed in the gap be tween the upper and the lower capacitor banks A minimum extension of 6 inches 150 mm is required Remove the 6 electrical connection nuts 8 mm for the upper capacitor bank on the DC bus bars Remove the 4 retaining nuts 10 mm from the capacitor bank and remove the air dam 4 Note that the weight of the capacitor bank is approximately 20 pounds 9 kg Remove the capacitor bank by pulling free fr
280. ts with a brake option the DC input bus assembly must be removed to access and remove the bus bars between the IGBT bus bar assembly and the brake IGBT Remove the DC input bus bar assembly per steps 3 5 of SCR Diode Module Removal D1 units 6b For units with brake option remove the bus bars between the IGBT bus bar assembly and brake IGBT by removing two T25 retaining screws on brake IGBT not shown and two 8 mm retaining nuts on the IGBT bus bar assembly not shown 7 Remove the 3 IGBT output bus bars by removing the nut 10 mm from the stud Also remove retaining screw T30 at the other end of the IGBT output bus bars not shown CONTINUED ON NEXT PAGE 130BX90 10 Illustration 7 1 D1 D3 IGBT Module 1 of 2 1 IGBT output bus bar 9 Step 7 6 Retaining nut Step 6 2 DC input bus bar assembly BB3 Step 6A 7 Do not remove Step 6 3 Retaining screw Step 6 8 Gate drive cable glands Steps 3 amp 4 4 High frequency card 9 IGBT module 5 Connector MK100 Step 5 10 IGBT output bus bar retaining nut Step 7 150 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 8 Remove the 4 10 mm retaining nuts at the top of the IGBT bus bar assy 9 Remove the 6 retaining screws on the upper portion of the IGBT modules These screws also attach the snubber capacitors to the IGBT m
281. ty may result when measuring resistance of a transformer with a multi meter This can be reduced by turning off the auto ranging function and setting the measurement manually To aid in making the measurements unplug the MK107 from the power card Checking continuity of connections For the following tests read connector MK107 on the power card 1 Measure from L3 T to MK107 terminal 8 Reading of lt 1ohm should be indicated 2 Measure from L2 S to MK107 terminal 1 Reading of 1 ohm should be indicated Incorrect reading An incorrect reading would indicate a faulty cable connection Replace the cable assembly Fan fuse test 1 Testthe fan fuses on the power card mounting plate by checking the continuity across the fuse An open fuse could indicate additional faults Replace the fuse and continue the fan checks Ohm test of transformer For the following tests read the plug end of the wire connected to MK107 on the power card 1 Measure between MK107 terminals 1 and 8 Should read approximately value A in Table 6 1 2 Measure between MK107 terminals 8 and 12 Should read approximately value B in Table 6 1 3 Measure between MK107 terminals 1 and 12 Should read approximately value C in Table 6 1 AC Voltage Drive Resistance in Ohms Heatsink Fan Fan Inductor FC 102 FC202 FC 302 A B 380 500 315 P315 P250 15 12 4 21 no 380 500 P355 P355 P315 4 3 1 4 yes 380 500 P400 P400 P355 4 3 1 4 yes 380 500 P450
282. veform with Diode Bridge 110 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 FC Series Danfoss Frequency Converters 6 Test Procedures With a phase loss the current waveform of the remaining phases would take on the appearance shown in Illustration 6 15 Input B 130BX144 10 0 0 ms 5 msiDiv Illustration 6 15 Input Current Waveform with Phase Loss Always verify the condition of the input voltage waveform before forming a conclusion The current waveform will follow the voltage waveform If the voltage waveform is incorrect proceed to in vestigate the reason for the AC supply problem If the voltage waveform on all three phases is correct but the current waveform is not then the input rectifier circuit in the frequency converter is suspect Perform the static soft charge and rectifier tests and also the dynamic SCR diode mod ule test 6 3 9 Input SCR Test The SCR can be disabled by the frequency converter for various reasons Check the following before making more complicated tests The SCRs be disabled as a result of an input or lack of input at power card connector FK102 the external brake temperature switch Unless used as an input a jumper must be placed between terminals 104 and 106 of FK102 The SCRs are gated in sequence with the main supply Verify that the voltage reference signal is correct as follows 1 Using a voltmeter measure phase to phase mains voltage
283. vertemperature The input SCRs would also be disabled to prevent further energy from being supplied to the DC bus If no such input is used or the normally open configuration is selected a jumper must be installed between terminals 104 and 106 Connector FK103 terminals 100 101 102 and 103 located on the power card provide for the connection of mains voltage to allow powering the AC cooling fans from an external source This is required when the frequency converter is used in a load sharing application where no AC power is provided to the main input terminals To make use of this provision the jumpers would be removed from terminals 100 and 102 101 and 103 The auxiliary mains voltage power supply would be connected to terminals 100 and 101 MG 90 L1 02 VLT is a registered Danfoss trademark 55 high Power Service Manual for VLT FC Series 3 Internal Frequency Converter Operation Frequency Converters 56 The power card MK112 terminals 1 2 and 3 and 4 5 and 6 provide access to 2 auxiliary relays These are form C sets of contacts meaning one normally open and one normally closed contact on a single throw The contacts are rated for a maximum of 240 VAC 2 Amps and a minimum of 24 VDC 10 mA or 24 VAC 100 mA The relay can be programmed via par 5 40 Function Relay to indicate frequency converter status Terminal positions on the power card labelled MK400 and 103 are reserved for future use MG 90 L1 02 VLT
284. vice Manual for VLT9 Series 7 42 Operator Interface and Frequency Converter Frequency Converters Control 2 5 1 Input signals The frequency converter can receive two types of remote input signals digital or analog Digital inputs are wired to terminals 18 19 20 common 27 29 32 and 33 Analog or digital inputs are wired to terminals 53 or 54 and 55 common The terminal functions are set by a switch found by removing the LCP Some options may include additional terminals Analog signals can be either voltage 0 to 10 VDC or current 0 to 20 mA or 4 to 20 mA Analog signals can be varied like dialling a rheostat up and down The frequency converter can be pro grammed to increase or decrease output in relation to the amount of current or voltage For example a sensor or external controller may supply a variable current or voltage The frequency converter output in turn regulates the speed of the motor connected to the frequency converter in response to the analog signal Digital signals are a simple binary 0 or 1 which in effect act as a switch Digital signals are controlled by a 0 to 24 VDC signal A voltage signal lower than 5 VDC is a logic 0 A voltage higher than 10 VDC is a logic 1 Zero is open one is close Digital inputs to the frequency converter are switched commands such as start stop reverse coast reset and so on Do not confuse these digital inputs with serial communication formats where digital bytes are g
285. w around the main fuses The fan operates anytime the frequency converter is powered All fans are powered by mains voltage which is stepped down by an autotransformer and regulated to 200 or 230 VAC by circuitry provided on the power card On off and high low speed control of the fans is provided to reduce overall acoustical noise and extend the life of the fans Fans are activated by the following causes 60 of nominal current exceeded Specific heatsink temperature exceeded power size dependent DC hold active DC brake active Pre magnetization of the motor Automatic motor adaptation in progress Regardless of the heatsink temperature the fans are started shortly after main input power is applied to the frequency converter Once fans are started they will run for a minimum of 10 minutes 3 3 6 Fan Speed Control The cooling fans are controlled with sensor feedback which regulates fan operation and speed control as described below 1 IGBT thermal sensor measured temperature The fan can be off low speed or high speed based on this temperature IGBT Thermal Sensor D Frame Units E Frame Units Fan Turn On Low Speed 45 C 45 Fan Low Speed to High Speed 50 50 C Fan High Speed to Low Speed 40 C 40 Fan Off from Low Speed 30 C 30 C Table 3 1 IGBT Thermal Sensor 2 Power card ambient temperature sensor measured temperature The fan can be off or high speed based on this temperature
286. wer is also branched off and sent to the power card It provides the power card with a reference of the main supply voltage and provides a supply voltage for the cooling fans During the charging process the top diodes of the soft charge rectifier conduct and rectify during the positive half cycle The diodes in the main rectifier conduct during the negative half cycle The DC voltage is applied to the bus capacitors through the soft charge resistor The purpose of charging the DC bus through this resistor is to limit the high inrush current that would otherwise be present Positive temperature coefficient PTC resistors located on the soft charge card are in series with the soft charge resistor Frequent cycling of the input power or the DC bus charging over an extended time can cause the PTC resistors to heat up due to the current flow Resistance of the PTC device increases with temperature eventually adding enough resistance to the circuit to pre vent significant current flow This protects the soft charge resistor from damage along with any other components that could be damaged by continuous attempts to charge the DC bus The low voltage power supplies are activated when the DC bus reaches approximately 50 VDC less than the alarm voltage low for the DC bus After a short delay an inrush enable signal is sent from the control card to the power card SCR gating circuit The SCRs are automatically gated when forward biased as a result acting
287. will be stopped until a Run permissive signal is received via digital input Running The motor is driven by the FC the ramping phase is done and the motor revolutions are outside the On Reference range Occurs when one of the motor speed limits Par 4 11 4 12 4 13 or 4 14 is set but the maximum reference is outside this range Sleep Boost FC 100 200 only The boost function in parameter 406 Boost setpoint is enabled This function is only possible in Closed loop operation Sleep Mode FC 100 200 The energy saving function in parameter 403 S eep mode timer is enabled This means that at present the motor has stopped but that it will restart automatically when required Speed down The output frequency is corrected by the value set in par 3 12 Catch up slow Down Value 1 Speed down was selected as a function for a digital input parameter group 5 1 The corresponding terminal is active 2 Speed down was activated via serial communication Speed high In par 4 53 Warning Speed High a value is set The speed of the motor is above this value Speed low In par 4 52 Warning Speed Low a value is set The speed of the motor is below this value Standby Auto On The FC starts the motor using a start signal in a digital input if the parameter is pro grammed accordingly or via serial communication Start delay In par 1 71 Start Delay the delay of the starting time was set A Start command was activated and the delay time
288. wire from the DC bus connects to the left end of the DC bus fuse holder The white wire from the power card connector MK105 connects to the right end of the DC bus fuse holder Tighten the 10 mm mounting nuts to 4 Nm 35 in Ibs and the 7 mm nut to 1 Nm 8 in Ibs 7 2 5 Soft Charge Card 126 1 Remove the power card mounting plate in accordance with procedure 2 Remove the 2 retaining nuts from the soft charge card assembly 10 mm 3 Slide the assembly part way out to access the cable glands on the card 4 Disconnect MK1 MK2 MK3 and MK4 5 Remove the soft charge card assembly Reinstall by aligning the soft charge card with fastening clips on the side of the chassis Reattach the connectors Slide into place and tighten the mounting screws to 4 Nm 35 in Ibs MG 90 L1 02 VLT is a registered Danfoss trademark High Power Service Manual for VLT9 Series Danfoss 7 D Frame Sizes Disassembly and Assembly Frequency Converters Instructions 130BX122 10 CA Illustration 7 1 Soft Charge Card Assy 380 480 500V Blue MOV and 8 PTCs 525 690V Red MOV and 6 PTCs 1 MK1 2 Retaining screw Step 2 3 MK2 4 MK4 5 MK3 MG 90 L1 02 VLT is a registered Danfoss trademark 127 7 D Frame Sizes Disassembly and Assembly high Power Service Manual for VLT FC Series Instructions Frequency Converters 7 2 6 Gate Drive Card 1 Disconnect the cables from the connectors on gate drive card 100 102 1
289. y Converters 2 5 Frequency Converter nputs and Outputs The frequency converter operates by receiving control input signals The frequency converter can also output status data or control auxiliary devices Control input is connected to the frequency converter in three possible ways One way for frequency converter control is through the LCP on the front of the frequency converter when operating in local hand mode These inputs include start stop reset and speed reference Another control source is through serial communication from a serial bus A serial communication protocol supplies commands and references to the frequency converter can program the fre quency converter and reads status data from the frequency converter The serial bus connects to the frequency converter through the RS 485 serial port or through a communication option card The third way is through signal wiring connected to the frequency converter control terminals see illustration below The frequency converter control terminals are located below the frequency converter LCP Improperly connected control wiring can be the cause of a motor not operating or the frequency converter not responding to a remote input Terminal Descriptions 1 Digital 1 0 terminals 2 RS 485 EIA 485 terminal 3 Analog I O terminals 4 USB connector 130BA012 11 Illustration 2 1 Control Terminals 36 MG 90 L1 02 VLT is a registered Danfoss trademark High Power Ser
290. y jumpers are removed at the conclusion of the tests For the following tests set the meter to diode check or Rx100 scale 2 Connect the negative meter lead to the positive MK3 A DC output to DC bus and connect the positive meter lead to MK1 terminals R S and T in sequence Each reading should show a diode drop 3 Reverse meter leads with the positive meter lead to the positive MK3 Connect the negative lead to MK1 terminals R S and T in sequence Each reading should show open 4 Connect the positive meter lead to the negative MK3 C Connect the negative meter lead to MK1 terminals R S and T in sequence Each reading should show a diode drop 5 Reverse the meter leads with the negative meter lead to the negative MK3 C Connect the positive meter lead to MK1 terminals R S and T in sequence Each reading should show open An incorrect reading here indicates the soft charge rectifier is faulty The rectifier is not serviced as a component Replace the entire soft charge card in accordance with the disassembly proce dures in Section 8 Reconnect the MK3 on the soft charge card after these tests 130BX120 10 Illustration 6 9 Soft Charge Card Connectors 380 480 500V Blue MOV and 8 PTCs 525 690V Red MOV and 6 PTCs 1 MK1 3 MK4 2 MK3 4 MK2 MG 90 L1 02 VLT is a registered Danfoss trademark 97 high Power Service Manual for VLT FC Se
291. ze varies with model from the stud on the base plate and remove the sensor Reinstall in reverse order of this procedure Tighten the 17 mm retaining nuts or T50 screw to 19 Nm 170 in Ibs 25 4 rw LC D SA aie p nee Ale 2 O 9 1 G9 e 130BX102 10 Illustration 8 1 Current Sensors 1 Current sensor 3 Current sensor mounting screws 2 Step 5 2 IGBT terminal bus bar mounting screw Step 3 4 Output motor terminal bus bar retaining nut Step 2 MG 90 L1 02 VLT is a registered Danfoss trademark Instructions 165 8 E Frame Sizes Disassembly and Assembly ish Power Service Manual for VLT FC Series Instructions Frequency Converters 8 2 11 Heatsink Fan Assembly 1 Remove the input terminal plate in accordance with procedure 2 Remove the retaining nut 17 or 50 Torx screw depending on the unit type con necting each of the 3 IGBT over fan bus bars to the 3 current sensor bus bars 3 Remove the retaining nut 17 mm connecting each of three IGBT over fan bus bars to three IGBT output bus bars 4 Disconnect the in line Molex connector in the fan wiring Cut the tie wrap to free the wiring from frame 5 Remove the fan assembly by removing the 6 retaining nuts 10 mm Note that the fan assembly weighs approximately 11 kg 25 pounds Reinstall in reverse order of this procedure Tighten the 10 mm retaining nuts to 4 Nm 35 in Ibs

Contents 1 Introduction 2 Operator Interface and

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