VSC2000 Service Manual
Contents
1. DATE AUT EC358 DATE 30 WIRING VSC2000 NER PARTS DIAGRAM CONTROL STATION AP12206 CHASSIS 2 DRAWING 2016 SUFFIX LETTER 8 REVISION 30 Warch 997 00073 VSC 2000 Chassis 3 Internal Wiring Diagram REFER TO 5006995 CHASSIS RESISTOR HEATSINK AP12120 VSC 2000 CONTROL BOARD HEATSINK 12205 AP12120 VSC2000 POWER INTERFACE BOARD CONTROL STATION AP12206 A R DRIVE NM L1 L2L3 V Ve W W M1 M2 M3 INTERNAL 12120 5501008 SKN3F20 12 8501008 SKN3F20 12 CHARGE BOARD AP12207 RES tJ BRAKING RESISTOR RES e 20k T T 25W CAP R306007 ap Sur OUTPUT C900002 t E pcr t OUTPUT ASSY MOV ASSEMBLY 480V AP12351 20k BUS TT 25w CAP R306007 RECTIFIER MODULE OPTIONAL DYNAMIC SNUBBER IGBT MODULE S 2 REPEATED FOR EACH RA PAIR CAPACITORS BRAKING COMP2. M1 M2 M3 BRAKING ASSEMBLY 480V E 12350 RECTIFIER MODULE VSC2000 G amp H CHASSIS BUS BUS PCB POWER DCCT RECTIFIER CHOKE INTERFACE BOARD 2x IGBT PRIME 3 X AP12051 AP12001 AP12100 RESISTOR VSC 2000 CONTROL BOARD AP12205 D m o an 20 25W R306007 100n 1250V AP12353 OPTIONAL DYNAMIC IGBT MODULE S BRAKING COMPONENTS 50A AP12354 2 480V DRIVES 100n 1250V AP12353 WIRE COLOURS RD RED BL BLUE 12201 WH WHITE AP12140 AP12204 AP12051 AP12002 2X AP12102 GY GREY BK BLACK OR ORANGE AP12141 AP12200 AP12203 AP12052 AP12003 2 12103 YL YELLOW AP12142 AP12202 AP12204 AP12051 AP12001 2 AP12100 AP12140 AP12204 GN GREEN AP12201 PTY LIMITED AP12051 AP12001 2X AP12101 ZENER ELECTRIC 22 sss ze 366 HORSLEY ROAD MILPERRA PHONE 61 2 9795 3600 N S W 2214 AUSTRALIA FACSIMILE 61 2 9795 3611 AP12143 AP12200 AP12203 3x AP12052 IMO2004 _ AP12002 2 AP12102 COPYRIGHT 1997 Zener Electric Pty Ltd CN NUMBER AP12141 AP12202 AP12204 AUTHORIZED CHECKED 100n 1250V AP12353
3. FOR FAN No amp FAN TYPE SEE TABLE JFO2 JP VSC2000 CHASSIS 4 POWER INTERFACE BOARD VSC 2000 CONTROL 12217 PON BO STATION BOARD AP12206 GATE DRIVE JV JV 11 1213 M1 M2 M3 JB DCCT BOARD 5501008 SKN3F20 12 Jl2 OR51 RFI CAP R306008 BOARD AP42216 ASSEMBLY 111213 B B 36 BRAKING AP42361 RESISTOR POSEE ONERE 25w R306007 SUF C900002 i t 20k E 25 3 X R306007 SNUDBERIS E OPTIONAL DYNAMIC SNUBBER SNUBBER IGBT MODULEIS SNUBBER REPEATED FOR EACH N MP P AP AP PAIR OF CAPACITORS PRANING MENTIS e RECTIFIER MODULE VSC2000 CHASSIS 4 480V DRIVES WIRE COLOURS RD RED BL BLUE WH WHITE 3 x 201A 6 x 150A x 4700UF 42242 AP12218 12303 2 100 GY GREY 12007 AP12054 AP12103 12149 6 OFF 12353 BK BLACK 6 X 100 OR ORANGE X 201A 6 x 200A 10 x 47004 ap42243 4708 12219 12303 API2SSO YL YELLOW AP12007 AP12055 AP12103 AP12150 6 OFF GN GREEN x 201A x 150A 10 4700UF
4. ZENER VSC 2000 SERVICE MANUAL ZENER ELECTRIC Manufacturers of Quality Variable Speed AC Motor Drives amp Soft Starters TABLE OF CONTENTS USE OF THIS MANUAL rbi tabes rose oet estet oed actio 4 EQUIPMENT REQUIRED FOR SERVICING 4 SAFETY WARNINGS rash ci oe en ortae toe die 5 DEFINITION OF TERMS USED IN THIS MANUAL 6 SET UP FOR SERVICING lourde ebur 12 FAULT FINDING PROCEDURES 13 OVER VOLTAGE ALSO APPLIES TO UNDER VOLTAGE TRIP WHEN VSC STOPPED 13 OVER VOLTAGE TRIP WHEN VSC 99999999 14 WINDER VOLTAGE TRIP do tane dp de dotate p ute do tane Up ue 15 OVER CURRENT TRIP POWER UP uate NEP 15 OVER CURRENT TRIP WHEN VSC ENABLED een 15 EARLY CURRENT LIMIT S esseri iei doceo i odi ai tees iie 16 GROUND FAULT iccirco non rx rco cd er 16 OVER TEMPERATURE xod Doa Beet Pep CHEER Beste ota or 16 CHARGE a Eos un LEE Ln ep Eo 17 FUSES BLOW ON APPLICATION OF INPUT 17 PROBLEMS WITH THE COS iesu 18 CHECKING THE DGGT
5. 42214 4208 AP12218 12303 9 X 100 PK PINK AP12007 AP12054 12103 12151 9 OFF P12353 VT VIOLET x 260 x 200A 14 x 4700uF Ap42215 3 2uH AP12219 AP12204 9 100 BR BROWN 12006 2055 12103 12152 9 OFF 12360 VSC2000 CHASSIS 4 ZENER ELECTRIC 52 255 HORSLEY ROAD PLONE 6 21 9796 9606 DRAWN ENER TUS N S W 2214 AUSTRALIA FACSIMILE 61 2 9795 3611 COPYRIGHT 1997 Zener Electric Pty TRACED SPARE PARTS DRAWING NUMBER AUTHORIZED NUMBER CHECKED WIRING DIAGRAM SD16096A DATE SUFFIX LETTER IS REVISION IMO2004 _ 32
6. VSC 2000 This manual is intended as a guide to finding and repairing faults in the Zener VSC 2000 For the experienced service person it provides all the information necessary to isolate a faulty module and replace it This manual does not contain information regarding the repair of faulty modules as we recommend that all faulty modules be returned to Zener Electric or an authorised distributor for repair This is because each module is complex and in order to be sure they function properly they must conform to comprehensive test specifications otherwise further damage could result Procedures described in this VSC 2000 service manual should only be performed by qualified personnel who have experience working safely with exposed high voltages and power electronic equipment The following pages list faults by their symptoms It is impossible to list every symptom individually therefore it may be necessary to read the procedures for more than one symptom in order to determine the best course of action If you are directed to check a module refer to the Checking Procedure for that module If you need to replace a module refer to the Replacement Procedure for that module EQUIPMENT REQUIRED FOR SERVICING A digital or analog multimeter with the following ranges AC Volts up to 500 V range DC Volts up to 1000 V range Resistance 0 to 50 000 ohms ranges Diode Test Range AC current clamp meter 0 to 1 1 times motor name plate current A t
7. and unplug the connector JT from the Power Interface board e Remove the bus sensing wires noting carefully where they connect Now the old Sensor Wiring may be removed Fit the new Sensor in reverse to the removal procedure Ensure segregation from High Voltage circuits is maintained This completes the replacement of the Sensor Wiring CONTROL BOARD REPLACEMENT PROCEDURE Power Supply VSC Stopped Speed 096 e Remove all the plugs earth wire and terminal strips from the control board with all the field wiring still in place in the terminal strip e Remove the two EPROMS and the data card e Remove all ten mounting screws from the control board Fit new control card in reverse procedure CHECK THAT ALL THE TERMINALS AND EPROMS HAVE BEEN RE INSERTED PROPERLY MAKE SURE NONE OF THEM ARE DISPLACED BY ONE PIN IM02004 28 POWER INTERFACE BOARD REPLACEMENT PROCEDURE Power Supply Off VSC Stopped Speed 096 Ensure the power interface board is replaced with a board of identical assembly number to the original e Note carefully the wiring colour codes and their points of connection as there is quite a number of connections to be handled in replacing the board e When board replacement is completed check all the new connections against the notes you made to ensure they are all correct INPUT RECTIFIER REPLACEMENT PROCEDURE Power Supply VSC Stopped Speed 0 Note carefully the orientation of the rectifier module s
8. Circuit Note ANY FAILED IGBT INDICATES THAT THE POWER INTERFACE BOARD OR GATE DRIVE BOARDS ASSOCIATED WITH THE FAILED IGBTs SHOULD ALSO BE REPLACED OTHERWISE FURTHER FAILURES MAY RESULT ALL SLOW CHARGE RELAY AND RESISTORS SHOULD BE CHECKED IMO2004 _ 24 CHECKING THE INPUT RECTIFIER MODULE M z S 41719 6 1 Photo 15 Chassis 3 rectifier module Second type IM02004 25 e Elcon 4 Q Photo 16 Chassis 4 rectifier module IM02004_ 26 For the diode tests on the bridge rectifier modules we have defined the Red and Black leads of the multi meter as described below Red Lead Source of conventional current or positive lead Black Lead Sink of conventional current or negative lead Power Supply Off VSC Stopped Speed 0 Note the connections to bridge rectifier module then remove the ve DC bus wiring from it Set the multimeter to the diode test range and measure between each of the terminals shown in the table below If the result of each test is not as shown then the bridge rectifier module must be replaced Red Lead Black Lead Result T Open Circuit Charging Caps approx 0 80 Vdc 2 diode drops L1 L2 L3 Open Circuit L1 L2 L3 approx 0 40 Vdc 1 diode drop L1 L2 L3 approx 0 40 Vdc 1 diode drop L1 L2 L3 Open Circuit REPLACEMENT OF CAPACITOR MODULES Power Supply Off VSC Stopped Speed 0 Disconnect the power supply from the VSC 2000
9. capacitor voltage sharing e Measure the voltages across capacitor terminals CAP to and to BUS on the slow charge card and ensure readings are within 10 of each other If sharing is not correct check voltage share resistors 20k ohm and replace as required If voltage share resistors are OK replace DC bus capacitors following the procedure Replacement of Capacitor Modules Checking the slow charge circuit e Make sure the small plug in connector is secured in it s socket on each of the modules and that all wiring to each module is properly connected e Measure the resistance of the slow charge resistors on each of the modules between terminals Bus and Cap They should be 33 ohms if not replace the slow charge card Approximately 2 seconds after power up the voltage measured across Bus and CAP should be zero if not replace the slow charge card Snubber Sharing Resistor Resistors Photo 8 Chassis 2 Sharing and Snubber resitors Not e Chassis 3 has the same layout of resistors but a greater quantity IM02004 20 Sharing Resistors Snubber Resistor IM02004 21 CHECKING THE IGBT MODULES B2 B1 feces f E F f ere Photo 11 Chassis 2 IGBT and Rectifier terminals IM02004 22 C2E1 E2 F 20 Photo 13 Chassis 4 IGBT terminals Note Each IGBT has the same type of terminal IM02004 23 The IGBT Modules come in Two Pack modules
10. on the heatsink Also note the connections to the module e Remove the mounting screw s from the module and lift it from the heatsink e Apply a light smear of heatsink grease to the base of the new module and place it on the heatsink in the same position as the old module e Replace the mounting screw s and re connect the wires carefully IGBT MODULE REPLACEMENT PROCEDURE Power Supply Off VSC Stopped Speed 0 Before removing the old IGBT module make a note of all the connections to it Pay careful attention to the connection of the Gate Drive wires Chassis 2 IGBT s have a zener diode soldered across Gate Emitter Chassis IGBT s have a zener diode soldered across Gate Emitter Chassis 4 the gate drives are connected via small printed circuit boards mounted on top of the IGBT e Remove the wires and bus bars from the IGBT module e Remove the mounting screws from the modules Apply a thin smear of heatsink grease to the base of the modules and place the IGBT back on the heatsink e Insert and tighten the mounting screws e Replace the wiring and check carefully IF YOU REPLACE A FAULTY IGBT YOU MUST ALSO REPLACE THE POWER INTERFACE BOARD OR FURTHER DAMAGE MAY OCCUR IM02004 29 AP12120 HEATSINK INTERNAL AP12120 L1 L2L3 VSC 2000 Chassis 2 Internal Wiring Diagram 8 SEE 5006995 AP12358 TEMP SENSOR CHASSIS RESISTOR VSC2000 POWER INTERFACE BOARD GATE DRIVE SNUBBER
11. then follow the procedures to Checking the Input Rectifier Modules and Checking the Capacitor Modules e Follow the procedure Checking the DCCT board Ground Fault Trip Power Supply Off 5 Stopped Speed 0 The ground fault circuit is located on the Control board and DCCT board The sum of all three motor currents at any one instant as sensed by the DCCT will be zero unless there is a ground fault e Disconnect the motor from the motor output terminals M1 M2 M3 Use an Insulation Tester 1000 V to check the motor cables and the motor insulation to ground earth e Follow the procedure Checking the DCCT board e If the VSC 2000 still trips on Ground Fault replace the Control board Note Variable Speed Drives with excessive motor cable lengths may have ground fault trips due to the capacitance of the motor cabling Due to the high switching frequencies in the output voltage waveform the motor cable capacitance causes some current to flow to earth and this may result in ground fault trips with longer 240m cables This be reduced by selecting the lowest AUDIBLE FREQUENCY of 2 kHz for output switching frequency or if necessary by fitting chokes on the output to reduce the dV dt of the power waveform This phenomenon can also disrupt the operation of external earth leakage devices Over Temperature Trip Power Supply On VSC Stopped Speed 096 The over temperature trip circuit consists of the Power Interface
12. 1 L 4 JC CCS Data H Option Cable ao oe eo ji Extended Connector L 1 Features Board 1 3 4 SWA oooooooQ o o 906060606066 6 70 T1 182 485 492 Du m Ae 5 LL OUT 2 INPUTS OUTPUTS COM 1 3 4 ANALOG CONTROL O 1121 3 4 5 6 112 3 4 2 POWER OooOoo0000 000000005 O0 00000005055 00 00000009 99909606 9999999998 999999999968 12 450 10 11 12 13 14 1520 T3037 4017477 44454647484950 40 47 4243444546 LS tS cow Sd tS TRES A BC D E F G H 24V 60 1 RX IN 1 IN 2 OUT 169 INPUTS 59 Ri 5 USER SERIAL PORT ANALOG CONTROL IMO2004 _ VSC 2000 Module Locations 1 DATA CARD 2 EXTENDED FEATURE CARD OPTION 3 CONTROL BOARD 4 CAPACITOR MODULES 5 POWER INTERFACE BOARD FOR CHASSIS 2 amp 3 THE POWER INTERFACE BO
13. ARD 6 BUSS CHOKE IS LOCATED UNDER THE CONTROL BOARD 7 IGBT MODULE 8 BRIDGE RECTIFIER 9 DCCT BOARD 10 SWITCH MODE POWER SUPPLY BOARD 11 VOLTAGE SHARING RESISTORS 12 SNUBBER RESISTORS 3 03697 01 IMO2004 _ 8 Gate Drive Boards IGBT Module DCCT Board Rectifier Module dm Bus Line Input Capacitor Terminal Motor Output Terminal it dios a ADS control board Photo 1 Chassis 2 internal view without IM02004 9 Slow Charge Boards mounted on Bus capacitors Gate Drive Boards IGBT Module DCCT Board Line Input Motor Output Terminal Terminal Rectifier Module xe Tu Bats Me Photo 2 Chassis 3 internal view with control board removed IM02004 10 Control Board SMPS1 Supplies internal fans and control board Line Input Terminal Rectifier Modules IM02004 f Zu 5 gt nN Photo 3 Chassis 4 internal view with covers removed 11 DCCT Board Power Interface Board SMPS2 Supplies heatsink fans Motor Output Terminal IGBT Modules SET UP FOR SERVICING For ease of servicing we recommend that you use the MANUAL mode of operation by pressing the MAN push button on the CCS front panel You can then use the FWD and STOP push buttons and the SPEED pot to operate the VSC 2000 during tests Note To allow Manual operation the enable terminals must be linked terminals 40 to 48 on Control Inputs Comprehensive Con
14. BOARD aperte 18 CHECKING OUTPUT t peperere xr ie es eoa suena 18 CHECKING THE CAPACITOR MODULES 5 heir eere cena 18 CHECKING THE IGBT MODULDES 1 rette HOMI ERI HER 22 CHECKING THE INPUT RECTIFIER MODULE traite I retrace eei et eti ty 25 REPLACEMENT OF CAPACITOR 27 DCCT BOARD REPLACEMENT PROGEDURE rre ttc ttes 28 SENSOR WIRING REPLACEMENT 28 CONTROL BOARD REPLACEMENT PROCEDURE 28 POWER INTERFACE BOARD REPLACEMENT 29 INPUT RECTIFIER REPLACEMENT PROGCEDJURE otn re ert es 29 IGBT MODULE REPLACEMENT PROCEDURE 29 Im02004 docIM02004_ 18 May 2000 2 TABLE OF FIGURES AND PHOTOS VSC 2000 Control Board Layout ues caet to Ite po EE Reo beet Rab bnt Ele aet ees 7 VSC 2000 Module Locations e EO Ree e Ra e EE 8 Photo 1 Chassis 2 internal view without control 9 Photo 2 Chassis internal view with control board 10 Photo 3 Chassis 4 internal view with covers 11 CCS front panel with Touch Screen Push Buttons and Speed reference Pot 12 Photo 4 VSC 2000 C
15. CB Frequently you will be network The following Plug Socket ese terms for our service procedure Also known as the DC link this is simply the AC mains input supply rectified and filtered ready for the transistor inverter stage to convert back to a variable frequency variable voltage AC supply This is the voltage level of the DC bus as measured on the output transistors It is approx 1 41 times the input line to line voltage During motor regeneration over hauling loads the DC Bus Voltage may rise above this nominal level The Over Voltage protective circuit disables the VSC 2000 if this voltage rises above an internal preset level Direct Current Current Transformer This is a current sensing device which is able to sense DC current levels in a conductor while still maintaining isolation Earth Leakage is detected via the DCCT board The current transformer senses an imbalance in the current flowing in the 3 output phases Any imbalance indicates a fault current to Earth The input voltage is the line to line voltage between terminals L1 L2 12 13 and L1 L3 Printed Circuit Board asked to measure a voltage on a particular plug socket or component definitions apply when measuring values in the VSC 2000 The part of the connector which is attached to the wires The part of the connector soldered into the PCB SIGNAL COM Control Board Power Ground Use the screw head available on top of the Data Card as a convenien
16. ONENTS d 4 VSC2000 CHASSIS 3 480V DRIVES G amp H db TER BL BLUE IGBT R BUS BUS PCB POWER OUTPUT OUTPUT SNUBBER BRAKING WH WHITE DRIVE 1200V ECTIFIER CHOKE INTERFACE CHOKE ASSY CAP IGBT GY GREY 1 4X 75 BLACK 055 NIL AP12300 AP12353 AP12355 OR ORANGE YL YELLOW 3x 1x 4x P12145 5 100 GN GREEN 12054 12009 1 2208 AP12353 12356 API2055 API2005 API2103 ACTU pau ale AP T2148 AP12302 AP 12360 AP 12387 VSC2000 CHASSIS 3 3x 1 2x AP 12146 3x 75 Aptosa Aries ZENER ELECTRIC a T ZENER 3x 1X 4x 5x 100A 366 HORSLEY ROAD MILPERRA PHONE 61 2 9795 3600 AUG 97 12054 AP12009 AP12102 AP12144 12209 NIL 12301 12353 12356 NSW 2214 AUSTRALIA FACSIMILE 61 21 9795 3611 4 X 150 COPYRIGHT 1997 Zener Electric Pty Ltd SPARE PARTS DRAWING NUMBER 12055 12005 1240 _ 2145 12210 AFAZMB 12302 12360 AP12357 AUTHORIZED CN NUMBER CHECKED WIRING DIAGRAM S 21 6096A DATE AUT EC358 DATE SUFFIX LETTER IS REVISION IM02004 31 12053 12008 12102 12144 AP12208 VSC 2000 Chassis 4 Internal Wiring Diagram 5 HEATSINK FANS INTERNAL FANS M1 M2 M3 HSK HSK HSK A000171 A 7 EE SD06995 893579 A699972 A699972 A699972 900699 CHASSIS RESISTOR
17. These contain two power IGBTs At least three or more are required to make up the three phase inverter bridge To check IGBT modules you will require a multimeter with a diode test range This range measures the forward biased voltage drop of a semiconductor junction Disconnect the Motor from M1 M2 M3 Power Supply Off VSC Stopped Speed 0 Carefully note the connections to the IGBT modules and then remove the gate wiring from each one For each IGBT module measure between each of the terminals shown in the table below If the result of each test is not as shown then the IGBT module must be replaced Set the multimeter to the Diode Test Range Note that in some measurements which are Open Circuit the multimeter will read differently during the charging of the bus caps This is because wiring is still attached Once the capacitors are charged the open circuit reading will be seen For the diode tests on the IGBT modules we have defined the Red and Black leads of the multi meter as described below Red Lead Source of conventional current or positive lead Black Lead Sink of conventional current or negative lead Red Lead Black Lead Result C1 E2 Open Circuit Charging Caps E2 C1 approx 0 7 Vdc 2 diode drops C1 C2E1 Open Circuit Charging Caps C2E1 C1 approx 0 35 Vdc 1 diode drop E2 C2E1 approx 0 35 Vdc 1 diode drop C2E1 E2 Open Circuit Charging Caps C1 B1 Open Circuit C2E1 B2 Open Circuit B1 E1 Open Circuit B2 E2 Open
18. ary If there is any damage to the transistor module s then the Power Interface board must be replaced as a precautionary measure e Follow the procedure Checking the Capacitor Modules and replace as necessary IM02004 17 Problems with the CCS e Ensure that the EPROM in the CCS is the correct revision level to suit those in the Control board Refer to Application note IM 10005 e f the CCS is flashing replace the CCS If the CCS continues to flash replace the Control board e If the CCS is blank check the 24 volt supply located on customer terminal strip e 24volt on the Control board is OK check the CCS cable if OK replace the CCS If the 24 volt supply is not present replace the Power Interface board for chassis 2 and 3 or the Power Supply board SMPS 1 in chassis 4 CHECKING THE DCCT BOARD The Direct Current Current Transformer DCCT is used to sense motor current Measure the current feedback signals from the DCCT at JI on the on the Control board With respect to SIGNAL COMMON JI pins 5 7 9 on the right hand most side at the back of the connector should each be 2 5 V 0 1 V If not replace the DCCT board CHECKING OUTPUT IMBALANCE Output imbalance trip indicates motor current and or voltage is out of balance e Check motor current balance within 10 e Check motor voltage balance motor connected or disconnected If the output voltage balance is OK e Follow the procedure Ch
19. board e Turn on the AC Power Supply and check that ALL the relays energise approximately 2 seconds after power is applied e Check relays are energised by measuring for closure of the relay contacts with the multimeter ie zero volts across the relay contacts terminals Bus and If any of the relays do not energise replace the Cap Charge board power interface board on chassis 2 immediately or further damage may result IM02004 14 Under Voltage Trip Power Supply On VSC Stopped Speed 096 Under voltage trips will occur when the DC bus voltage falls below 239Vdc for A 240Vac series controllers 397 for G 480Vac series controllers 505Vdc for J 660Vac series controllers e Follow the procedure Over Voltage trip Over Current Trip on Power Up Power Supply VSC Stopped Speed 096 The over current trip circuit consists of the control card and DCCT board This trip will normally occur when excessive current to the motor is sensed Whenever the controller hence the transistor gate drivers is disabled no motor current should flow If an over current occurs in this state e Select Meter Readouts from the CCS menu and check the Amps which should be zero If not follow the procedure Checking the DCCT board e fthe DCCT voltages are correct replace the Control board Over Current Trip when VSC Enabled Power Supply VSC Started Speed 096 Check the VSC 2000 output for voltage balance Power do
20. board and Temperature Sensors located on each heatsink IMO2004 _ 16 Photo 5 VSC 2000 Temperature Sensor e Check that all the fans external and internal are operating properly and that the vents and heatsinks openings are not blocked with any foreign matter If the VSC 2000 is in an enclosure check all filters and grills for blockages and check that the enclosure fan s if fitted are operating e Each fan in the VSC 2000 can be tested via the CCS using the Service menu as described in the VSC 2000 User s Manual Turn the fans on via the CCS to confirm operation Replace any non operable fans or fans that are noisy or not running at full speed e Use the CCS THERMAL DISPLAY menu to check the temperatures registered by of each of the sensors The heatsink temperature trip point is 90 If any sensor is showing 127 C then it is faulty and should be replaced Charge Relay Fault The Slow Charge Relay is located on the Power Interface board on chassis 2 controllers or on the Slow Charge boards for all other controllers e Follow the procedure Checking the Capacitor Modules if OK replace power interface card Fuses Blow On Application of Input Power This indicates an excessive current draw on power up which may caused by a internal short circuit or damaged slow charge circuit Follow the procedure Checking the Input Rectifier and replace as necessary e Follow the procedure Checking the IGBT and replace as necess
21. bus voltage reading Vdc It should be approx 1 4 x Input voltage If not measure the DC Bus voltage on the DC bus bars on the Output IGBTs It should be approx 1 4 x Input voltage If the DC bus voltage is wrong check the Input Rectifiers If the CCS reading is wrong do the following checks Measure the voltage at pin 7 on IC 55 on the Control Board with respect to the SIGNAL COMMON on the Control board See Definition of Terms This should equal the measured DC bus V 100 for A series 240Vac controllers V 200 for G series 480Vac controllers V 250 for J series 600Vac controllers If not check the Power Interface board and it s wiring for damage and replace it if necessary If the voltage at PIN 7 is correct replace the Control Board following the procedure Control Board replacement IMO2004 _ 13 Jl 55 Eprom VSC 2000 CTL Data Card Eprom VSC 2000 PWM 4 pm i 4 44 17 z s TIL S en E 24 5 FERT T Ba olo 40004 442 RTI 21 72 gt eret un 2 LUN 25300 Photo 4 VSC 2000 Control Board Over Voltage Trip when VSC Enabled Power Supply Off VSC Stopped Speed 0 Check the DC bus smoothing circuit e Locate the Capacitor Module s and the slow charge relay s on them If the VSC 2000 is a chassis 2 size the slow charge relays are located on the Power Interface
22. ecking the DCCT If voltage is balanced and currents are not check motor cables and windings If unable to check motor current and voltage balance due to Output Imbalance Trip e Power down the VSC 2000 and disconnect the motor e Power up and enable the VSC 2000 and run to 50hz Measure 1 M2 for voltage balance If out of balance by more than 5 e Follow the procedure Checking the IGBT Modules Replace the Power Interface Board e Follow the procedure Checking the Input Rectifier Module CHECKING THE CAPACITOR MODULES The DC bus capacitors are used to smooth ripple on the DC bus This configuration incorporates a slow charge circuit used on power up and capacitor voltage share resistors The voltage share resistors are also used to discharge the DC bus capacitors IM02004 18 WARNING THE CAPACITOR MODULE S DISCHARGE CIRCUIT HAS FAILED THE VOLTAGE ON THE CAPACITORS WILL NOT DISCHARGE TO A SAFE LEVEL IF THERE IS MORE THAN ONE CAPACITOR MODULE IN THE VSC 2000 MEASURE THE VOLTAGE ON EACH ONE TO BE SURE THAT THEY HAVE ALL DISCHARGED BEFORE DOING ANY WORK INSIDE THE VSC 2000 IM02004 19 Power Supply Off VSC Stopped Speed 0 Checking the DC buss capacitors and their voltage sharing e Use diode test range on your meter to ensure there is not a short circuit across DC buss capacitors CAP to and to BUS and the reading steadily increases till an open circuit is indicated e Check DC bus
23. input terminals A cap module is made up of 2 x high voltage DC bus capacitors 1 x capacitor slow charge card 2 x capacitor voltage share resistors 20k ohms Note For Chassis 2 a Capacitor Charge board is not used as the slow charge circuit is located on the Power Interface board e Make a note of where each wire connects to the module so that you can replace it properly e Disconnect the Cap and Cap wires and remove the Cap Charge board CHECK ALL WIRING CAREFULLY BEFORE APPLYING INPUT POWER OR IGBT MODULE DAMAGE MAY RESULT IM02004 27 DCCT BOARD REPLACEMENT PROCEDURE Power Supply Off VSC Stopped Speed 0 VSC 2000 controllers fitted with B1007xx DCCT cards e These cards and wiring are a calibrated sub assembly which MUST be replaced in its entirety Make a note of the wiring connections before removing the existing wiring and DCCT board Remove wiring and DCCT subassembly and replace with the new one reconnecting as before This completes the installation of the new DCCT VSC 2000 controllers fitted with L E M DC current sensing devices chassis 4 and up e DCCT card B1040xx is a plug in replacement SENSOR WIRING REPLACEMENT PROCEDURE Power Supply VSC Stopped Speed 0 The Sensor Wiring consists of the temperature sensors connector JT Carefully observe the location mounting and connection of the sensing wires e Remove the Temperature Sensor by withdrawing it out from lug holding it to the heatsink
24. ontrol oe tet tae cette bt Eod ead 14 Photo 5 VSC 2000 Temperature Sensor 17 Photo 6 Chassis slow charge card on bus capacitors 19 Photo 7 Chassis 4 slow charge cards and bus 19 Photo 8 Chassis 2 Sharing and Snubber resitors 20 Photo 9 Chassis 4 Sharing kl Ur re e Fa ene n 21 Photo 10 Chassis 4 Snubber resistor 21 Photo 11 Chassis 2 IGBT and Rectifier 22 Photo 12 Chassis SIGBT terminals ace e este teeth quad e te 23 Photo 13 Chassis 4 IGBT terminals eee Hr eae tuit n x 23 Photo 14 Chassis 3 rectifier module 1 25 Photo 15 Chassis rectifier module Second 1 25 Photo T6 Chassis 4 rectifier module i dt tei ea e adiit teure tnus 26 VSC 2000 Chassis 2 Internal Wiring 30 VSC 2000 Chassis Internal Wiring Diagram 31 VSC 2000 Chassis 4 Internal Wiring Diagram 32 IMO2004 _ 3 USE OF THIS MANUAL The Trouble Shooting Guide in the VSC 2000 Instruction Manual should be followed carefully before using this manual to ensure the fault observed is not a fault external to the
25. t ground reference for measurements JS Chassis Resistor connector on Power Interface board JF1 thru 5 Fan connectors on Power Interface board JT1 thru 16 Temperature Sensor connectors on Power Interface board L1 L2 L3 Supply Line inputs on Power Interface board M1 M2 M3 Motor Output inputs on Power Interface board U V W Gate drive output signals on Power Interface board Jl DCCT Current Feedback connector on Control board JC CCS Control Station connector on Control board Refer to the VSC 2000 Control Board Layout on page 7 and the Internal Wiring Diagrams at the back of this manual for the location of each of these connectors on the control board Where the fault finding procedure instructs you to check a module refer to the Checking Procedures at the end of theFault Finding Procedure section When it is necessary to replace a module refer to the Module Replacement Procedures at the end of this manual 102004 6 VSC 2000 Control Board Layout RL2 n n n JP Jl JH BO986 Ribbon Cable Connectors VSC 2000 Control Board
26. trol Station vsc 2000 Ai O NA AUTO MAN O REV SPEED AAA ub CCS front panel with Touch Screen Push Buttons and Speed reference Pot In each step of the service procedures a Status Line will be given as shown below Power Supply VSC Stopped Speed 0 It is important that you observe this line and use the settings as indicated throughout the procedure to obtain the correct result at each step Power Supply On Mains AC supply IS connected to L1 L2 L3 Power Supply Off Mains AC supply IS NOT connected to L1 L2 L3 VSC Stopped Stop LED is ON VSC Started FWD or REV LED is ON Speed 0 to 100 Setting of speed control potentiometer 0 zero speed Pot Counter Clockwise 100 full speed Pot Clockwise IMO2004 _ 12 FAULT FINDING PROCEDURES Over Voltage also applies to Under Voltage Trip when VSC Stopped Power Supply On VSC Stopped Speed 0 A over voltage trip will occur when the DC bus voltage exceeds 400Vdc on A 240Vac series controllers 800Vdc on G 480Vac series controllers 1000 on J 600Vac series controllers Check Supply Voltage Measure the Input Voltage at L1 L2 L3 and check that it is within the nameplate voltage specification of the VSC 2000 If Ok check internal causes Check input bus voltage sensing as follows From the CCS menu select Meter Readouts Check the DC
27. wn the VSC 2000 and disconnect motor wiring from terminals M1 M2 M3 Power up the VSC enable and run at 10096 speed If the VSC 2000 trips e Follow the procedure Checking the DCCT board e f the DCCT board tests to be OK replace the Control board If it does not trip measure M1 M2 M3 for voltage balance If out of balance e Follow the procedure Checking the IGBT Modules e Follow the procedure Checking the Input Rectifier Modules f all are OK replace the Power Interface board If outputs are not out of balance e With VSC disabled select METER READOUTS on the CCS and Amps reading which should be zero e f not follow the procedure Checking the DCCT board e f the VSC 2000 still trips replace the Control board IMO2004 _ 15 Early Current Limit The Current Limit setpoint is customer adjustable If the VSC 2000 displays early current limit ensure the correct motor settings are entered in the VSC 2000 and the motor is the within specified range for the size VSC 2000 controller used This is typically from 0 5 to 1 5 times the controllers continuous rated current Early current limit may be caused by any of the following e Check input voltage on L1 L2 L3 for balance 3 e Check output current on M1 M2 M3 for balance If out of balance follow the procedure Checking Output Imbalance e Select Meter Readouts on the CCS If the Amps reading does not agree with measured motor current readings
28. ypically suitable multimeter is a Fluke 77 A typically suitable clamp meter is a Iso tech ICM39 An Electronic Insulation Tester 1000Vdc Slotted and Phillips head screwdrivers M4 7mm AF M5 8mm AF and M6 10mm AF Socket Drivers Appropriate footwear Face shield or safety glasses A good working knowledge of these tools is very important IMO2004 _ 4 SAFETY WARNINGS CAUTION RISK OF LECTRIC SHOCK DANGER HIGH ENERGY CIRCUITS For safety keep covers closed and properly secured or wear face shield if working inside the enclosure with power applied The VSC 2000 contains voltage levels in excess of 700 Vdc Standard electrical safety guidelines are to be adopted at all times when ever AC power is applied to avoid electric shock or damage to the VSC 2000 Before doing any work inside the VSC 2000 always be sure that the AC power supply is safely disconnected and that the DC Capacitor Modules are fully discharged It is essential that all components in the VSC 2000 are installed whenever the AC power supply is connected DO NOT OPERATE the VSC 2000 with any components or modules removed unless directed to do so by the service procedure IMO2004 _ B DEFINITION OF TERMS USED IN THIS MANUAL In order to keep this procedure concise we have used terms which may be unfamiliar The following list defines th DC Bus Bus Voltage DCCT Earth leakage Input Voltage P
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