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VSC Service Manual
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1. S SSYHO SLUVd 45 OSA ASVHd TI NIS MHOLSISNYALL TINON HOLIOVdYO ssng Josues y 1213 Josues OSA 2 jo ynduj puo JOQUUINN eu Sog 92045 SALON LITI IVTIOHOL n 8 x 1009 TINGON TT T X ly ab V7 t v T Td f mE ame davog IOMLINOO OSA did NEN page 23 INN VSC Voltage Selection Procedure This procedure is only applicable to MULTI VOLTAGE VSC s These VSC s have a Part Number where the stands for any combination of digits Any VSC with a Part Number that does not end with 3 can not have it s input voltage changed You should have been supplied with a packet containing 4 small plug in links and a sheet of adhesive labels Follow the three steps below to select the input voltage you require e 1 Transformer Tapping Selection Remove the AC Power Supply from the VSC Ensure the filter capacitors are fully discharged Loosen the screw in the lid of the VSC and open the lid Locate the control transformer just abo
2. SALON TAON M3WNOJSNVHI JONINOJ __ 8 5 HOSN3S HOISISNVaL M T300M SLUVd WNHVdS OSA ASOduNd TVUANA NOLSISNYEL a a donee i i SDIOHO 2 Uo ndino i i i i pM T TINTOR cd E cp E Caen H 1 woe L4 NOLIDYdYO a E EE pee rg ATT edd jT H 100 pd inst i i i y LITI i i i i 3NISLV3H cres aqu NO YOSN3S sem TINTOR oi lOLLIM NALES by 8 7 Id davod IONLNOO OSA 22 VSC S Internal Wiring Diagram NO MOSN3S scent 21 WOZOdY soos dy 4 0ZOdY soozoav e00Z0dv 2 0104 vZotodv 0 90010dY 9zolody soos dy 000 20004 S0000dY WaNNOASNVEL
3. VSC Service Manual ZENER TECHNOLOGY AND QUALITY ASSURANCE Since 1978 Zener Electric has supplied many thousands of AC drives to Australian industries These drives have been installed into numerous applications resulting in a wealth of in house experience The Zener VSC AC motor variable speed controller is the culmination of this expertise modern tech nology and industrial applications requirements The Zener Quality Assurance Programme ensures that every VSC manufactured has proven to operate correctly in the production test bay before despatch VSC PRODUCT WARRANTY Zener Electric warrants the VSC against defective workmanship and materials for a period of 24 months from the date of despatch Such defects will be rectified free of charge for both labour and material at Zener Electric s premises subject to 1 Zener Electric s customer raising an order upon Zener for service and or repairs subject to a warranty claim The order is to state particulars of the model and serial number the date of original purchase and invoice delivery docket number 2 All damage resulting from incorrect installation or use other than in accordance with the Instruction Manual issued by Zener Electric is excluded from this warranty 3 The Warranty being rendered invalid if the product is misused or if any unauthorized alteration modification or substitution of any part of the product be made or the serial number of the product is defaced
4. Check that the capacitor module s are fully circuit to 1 PLU and 2 PLU as shown below discharged by carefully measuring between the plus and minus terminals on each module DO Power Supply On VSC Started Speed 100 NOT do any work inside the VSC until this Check that the measured current corresponds to voltage is below 24 Vdc the value shown in the table for your VSC model Remove the three connectors PLU PLV and PLW Speed 0 from their sockets and place them where they power Supply Off VSC Stoppe cannot touch any live wires the control board or Repeat this procedure for the other five base the chassis drive circuits as shown below If any one of the six base drive circuits fails to meet either the Positive OR negative currents required then the Control Board MUST be replaced or further damage may result Positive Base VSC H3 44 to 66 VSC G13 84 to 126 5 53 61 to 93 mA VSC H4 44 to 66 VSC2G17 120 to 180 mA VSC S4 61 to 93 mA Current Measurement VSC H5 44 to 66 VSC G24 120 to 180 mA VSC S5 61 to 93 mA VSC H10 84 to 126 VSC G32 120 to 180 mA VSC H13 120 to 180 VSC G3B 156 to 234 mA VSC H17 120 to 180 VSC G44 158 to 234 mA t VSC H24 120 to 180 VSC G60 204 to 306 mA VSC H32 156 to 234 VSC H38 204 to 308 VSC H44 204 to 306 TET t 2 TET Negative Base VSC H3 31 to VSC G 3 52 to 78 31 to 47 mA VSC H4 31 to VSC G17 64 to 96 3
5. 66 9 E O 01 SHE 3 noon SRE BE vero EA ns i i YNISLW3H RARE NO YOSN3S 2 B VSC H Internal Wiring Diagram 7 It It Bs ES Fea is 512 Gta 912 NS by Ald Md GHVOH IOHLNOO OSA ae Opp oes 9 20 soy 29011038001 seng y puo y 013 94 JOSU S eu OSA jo ndu GUNN SDd ads ueuw SALON M3IDIO4SNYALL TOMLNOD page 21 iagram D iring VSC G Internal W 0 7 T 410054 X I I F ecoosdy 80066dY 00664 v0056dY izoosdv 000 0 coo0sdv 099 OSA indu Opp puo I OOY OBS 20
6. BLUE BLACK PINK BLACK BLUE WHITE ORANGE Wire Colours VIOLET WHITE PINK YELLOW WHITE ORANGE BLUE BLACK PINK BLACK RED GREY BROWN ORANGE WHITE ORANGE BLUE BLUE BLACK PINK BLACK Base Drive Connections to VSC Control Board Base Drive Connections to ALL 6 PACK Transistor Modules page 14 Checking the Base Drive Circuits To check the base drive circuits on the control Positive Base Current Check board you will require an ammeter capable of measuring 300 mA DC and a 1 amp 100 SHARE rectifier 194001 circuit to 1 PLU 2 PLU as shown below There are six base drive circuits on the control Power Supply On VSC Started Speed 100 Y board two connected to each of the three Check that the measured current corresponds to Sockets PLU PLV and PLW as shown below the value shown in the table for your VSC model Connect the Positive Base Current Measuring CS ee Wen To check each base drive circuit the positive Power Supply Off VSC Stopped Speed 0 base current and the negative base current are measured seperately This is achieved by placing the diode in series with the ammeter Repeat this procedure for the other five base drive circuits as shown below Negative Base Current Check Power Supply Off VSC Stopped Speed 0 Connect the Negative Base Current Measuring Base Current Measurement Proce Power Supply Off VSC Stopped Speed 0
7. is firmly plugged into its socket CHECK ALL WIRING CAREFULLY BEFORE APPLYING INPUT POWER OR TRANSISTOR MODULE DAMAGE MAY RESULT VSC CONTROL BOARD REPLACEMENT PROCEDURE Power Supply Off VSC Stopped Speed 0 Remove all the plugs from the old control board Remove all the wiring from the terminal strip Make sure you can put it all back With a SMALL pair of pliers carefully squeeze each of the plastic stand offs gently lifting under each one at the same time When all the stand offs have been released remove the old control board Locate the Model Number and Voltage Rating of the new control board on the left hand side about 150 mm from the front edge of the board just above the large IC Make sure it is the same as the board you are replacing If the model number and voltage rating are blank you will have to set up the board for your particular VSC model There will be an instruction sheet and a packet of plug in component networks supplied with the new board Follow the instructions carefully to set the board up for your VSC model Place the new control board on the stand offs making sure they are all poking through the mount ing holes Gently push down around each of the stand offs so that they all push through and lock down over the board Be careful not to bend any components Replace all the plugs into their sockets Re connect all the wiring to the terminals on the control board CHECK THAT ALL THE PLUGS HAVE BEEN INSERT
8. 1 to 47 mA Current Measurement VSC HS 31 to VSC G24 64 to 96 31 to 47 mA VSC H10 52 to VSC G32 64 to 96 VSC H13 64 to VSC G38 76 to 114 VSC H17 64 to VSC G44 76 to 114 VSC H24 64 to VSC G60 84 to 126 VSC H32 76 to 114 VSC H38 84 to 126 VSC H44 84 to 126 vy O 3778 e 15 CHECKING THE CAPACITOR MODULES Before removing the capacitor module s from the chassis check that the relay driver circuit is functioning properly by following the procedure below Power Supply Off VSC Stopped Speed 0 Make sure the small plug in connector is secured in its socket on each of the modules Check that all wiring to each module is properly connected Observe the large relay s on the module as you apply input power to the VSC Approximately 1 second after application of input power the relay s should energize and stay energized until input power is removed If the relay s do not energize or if they take longer than 2 seconds to energize then the module is not functioning properly and must be replaced before proceeding any further Warning If the capacitor module s discharge circuit has failed it may take several minutes for the voltage to discharge to a safe level If the relays energize properly remove power from the VSC and observe the neon indicator on the capacitor module Time the period between turning the power off and the neon going out If itis longer t
9. CCT INPUT RECTIFIER REPLACEMENT PROCEDURE Power Supply Off VSC Stopped 0 Note carefully the orientation of the rectifier module on the heatsink Also note the connections to the module Remove the mounting screw s from the module and lift it from the heatsink 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 Replace the mounting screw s and re connect the wires carefully If the wires connect to push on terminals make sure they all make a tight connection TRANSISTOR MODULE REPLACEMENT PROCEDURE Power Supply Off VSC Stopped Speed 0 Before removing the old transistor module make a note of all the connections to it Pay careful attention to the connection of the Base Drive wires Remove the wires from the transistor module If there are three modules remove the Buss bars from the transistors WITHOUT removing the wires connecting the Buss bars to the capacitor modules Remove the mounting screws from the module s and then remove the old module s Apply a thin smear of heatsink grease to the base of the new module s Place the new transistor on the heatsink and insert the mounting screws Turn all the screws up finger tight and then turn them up a little at a time DO NOT over tighten the screws or the transistor module may crack Replace the wiring and check it carefully page 19 SENSOR WIRING REPLACEMENT PROCEDURE
10. ED PROPERLY MAKE SURE NONE OF THEM ARE DISPLACED BY ONE PIN Power Supply On VSC Stopped 0 Locate VR13 I zero ten turn trimpot Refer to the VSC Control Board Layout for its location page 18 4 6 Measure between 2 CN4 3 CN4 DC millivolts range Adjust until the meter reads 0 00 30 mVdc Note If measured at another time this voltage may be 300 mVdc due to temp erature drift This is not a problem and there is no need to re adjust it Power Supply Off VSC Stopped Speed 0 This completes the installation of the new control board DCCT REPLACEMENT PROCEDURE Power Supply Off VSC Stopped Speed 0 Locate the small 10 turn adjustment trim pot on the DCCT and note which end of the wire or Buss bar is adjacent to it Remove the wire or Buss bar which goes through the DCCT Remove the DCCT and replace it with the new one so that the adjustment trim pot is on the same side of the conductor as with the old DCCT Power Supply On VSC Stopped Speed 0 Locate a 10 turn trimpot I zero Refer to page 5 for its location Measure between 2 CN4 and 3 CN4 on DC millivolts range Adjust VR13 until the meter reads 0 00 Vdc 300 mVdc Note If measured at another time this voltage may be 300 mVdc due to temperature drift This is not a problem and there is no need to re adjust it Power Supply Off VSC Stopped Speed 096 This completes the installation of the new D
11. ELECTRIC SHOCK SAFETY WARNINGS The VSC contains voltage levels in excess of 700 Vdc These voltages also appear on the control board Great care must be taken at all times whenever AC power is applied to avoid electric shock or damage to the VSC While using a multimeter to measure voltages in the VSC be very careful not to short the probes together or to any point other than the ones being measured It is essential that all components in the VSC are installed whenever the AC power supply is connected DO NOT OPERATE the VSC with any components or modules removed unless directed to do so by the service procedure In particular the DCCT ELCT and the Capacitor Modules must be properly connected AT ALL TIMES or severe damage may result Before doing any work inside the VSC always be sure that the AC power supply is safely disconnected and that the Capacitor Modules are fully discharged Always measure the DC Buss voltage and wait until it falls below 24 Vdc before proceed ing with any work inside the VSC page 3 GLOSSARY OF TERMS In order to keep this procedure concise we have used terms which may be unfamiliar The following list defines these terms for our service procedure Reset Period DC Buss Buss Voltage DCCT ELCT Input Voltage PCB Insulation Tester When the input power supply is connected and turned on the Control Board waits 3 seconds while power supplies are established and the DC Buss capacitors ar
12. Power Supply Off VSC Stopped Speed 0 The Sensor Wiring consists of the Buss voltage sensing wires connector PLB the temperature sensor 355 connector PLT the ELCT connector PLE If any one of these items needs replacing the Sensor Wiring should be replaced Carefully observe the location mounting and connection of the ELCT Temperature Sensor and Buss Sensing Wires Remove the ELCT by removing the wires which pass through it and sliding it over the end of them Remove the Temperature Sensor by removing the screw from the clamp holding it to the heatsink Remove the Buss sensing wires noting carefully where they connect Unplug the connectors PLE PLT and PLB from the control board Now the old Sensor Wiring may be removed Fit the new Sensor Wiring by sliding the ELCT over the wires which passed through the old ELCT and re connecting those wires Place the Temperature Sensor on to the heatsink with the flat side face down Replace the clamp and screw it into place Connect the Buss sensing wires to the DC buss Plug connectors PLE PLT and PLB into their sockets on the contro board This completes the replacement of the Sensor Wiring page 20 t 4 190629 6 08024 6 0424 it reme 0066dv 4 0ZZdY ZZ0 ZdY ZOZZav 900 ezozzev 0066d
13. SSY 0859 PLI PLT PLE PLP 4 4 4 2 4 4 1 lo o ol fo Io lo ol lo al o a n I a PLTST an 12929939 4 VRIO VR12 VR13 wa as elele PLF zs 1 ZERO sync 4 2 4 g 1 ACCEL DECEL F FN PN DEB OO Es we ACCEL DECEL Vz Gx TME TME o FWD REV EN mem p iiim ove E 6 8820000 ZERO oT SPD OCc RT H 1 2 3 4 5 7 8 Location Key Component Networks Connectors Switches Trimpots F7 1 PLP D8 VRIO E4 G6 CN1B 2 PLS G7 VR11 E4 CNIC PLT D6 VR12 E4 D6 CNID 4 PLU A2 VR13 E6 D5 A5 PLV A4 VR14 AB 7 PLW A6 PLTST D2 5 VSC SET UP FOR SERVICING For ease of servicing we recommend that you reconnect the control circuitry to the minimum required for VSC operation The following connections are recommended VSC Control Board 10 11 12 13 14 15 16 17 Close to Start 135 ohm to 5000 ohm Start Stop Switch Speed Control Potentlometer In each step of the service procedure will appear a Status Line as shown below Power Supply Off VSC Stopped 0 It is important that you observe this line carefully throughout the procedure to obtain the correct result at each step Power Supply Off Mains AC sup
14. arge up the resistance increases and when the leads are reversed they should discharge and then re charge the resistance appears to go negative drop to zero and increase again If the module fails either of these two tests it must be replaced AFZ B083290 B083212 B083260 This is a six or eight capacitor module used in VSC G and VSC H models Locate the four black tubular power resistors 120 ohm ASW5 150 ohm ASW5 Measure across each one on ohms range for 65 to 80 ohms Set the multimeter to the 30 kohm or 50 kohm range Arrange the wires so that they cannot touch each other or the PCB Measure between the plus push on terminal and the minus push on terminal on the capacitor module The meter should start from zero ohms and slowly increase to about 20 kohms in approximately 60 seconds Reverse the meter leads The meter should go from minus 20 kohms to zero and then increase to 20 kohms again in approximately 60 seconds The charging times and resistances given above may vary depending upon the meter used The important thing is that the capacitors should charge up the resistance increases and when the leads are reversed they should discharge and then re charge the resistance appears to go negative drop to zero and increase again If the module fails either of these two tests it must be replaced page 17 AGH 8084090 B084012 B084060 B084061 This is a two three or four capacitor module used in
15. ating dry cold solder joints or arcing Check the relay contacts for signs of arcing pitting or excessive heating Check that the push on connectors on each wire are firmly connected to the module If any physical damage is observed the entire capacitor module including wiring should be replaced Capacitor Module Multimeter Check There are three different PCB s Check the underside of the capacitor module and locate the part number This is a three letter code and a seven character code Choose the appropriate procedure below to perform the multimeter tests on your module page 16 7 AFY B083190 B083112 B083160 This is a two or four capacitor module used in VSC G and VSC H models Locate the two black tubular power resistors 120 ohm ASW5 150 ohm ASW5 Measure across each one on ohms range for 110 to 160 ohms Set the multimeter to the 30 kohm or 50 kohm range Arrange the wires so that they cannot touch each other or the PCB Measure between the plus push on terminal and the minus push on terminal on the capacitor module The meter should start from zero ohms and slowly increase to full scale in approximately 20 seconds Reverse the meter leads The meter should go from minus full scale to zero and then increase to full scale again in approximately 30 seconds The charging times and resistances given above may vary depending upon the meter used The important thing is that the capacitors should ch
16. cuit C1 B1 Open Circuit C2E1 B2 Open Circuit Set the multimeter to the Ohms range 100 to 1 000 Ohms B1 E1 50 to 800 ohms B2 E2 50 to 800 ohms If the module passes this test replace all the wiring Refer to the VSC Base Wiring diagram for details of the base connections Checking the Bridge Rectifier Module For the diode tests on the bridge rectifier modules we have defined the Red and Black leads of the multimeter 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 all 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 If the module passes the test replace all the wiring Red Lead Black Lead Result KM AM Open Circuit 0 60 to 1 2 2 diode drops KM AC1 AC2 AC3 Open Circuit AC1 2 0 30 to 0 60 1 diode drop AC1 2 0 30 to 0 60 1 diode drop AC1 AC2 AC3 AM Open Circuit page 13 VSC BASE DRIVE WIRING Wire Colours PINK YELLOW WHITE VIOLET BROWN Base Drive Connections ORANGE to ALL 2 PACK Transistor Modules GREY RED
17. e charged During this period the VSC cannot be started and the output is disabled Also known as the DC link this is simply the AC mains input supply rectified and filtered ready for the transistor inverter to convert back to a variable frequency variable voltage AC supply This is the voltage level of the DC Buss It is nominally 1 41 times the input line to line voltage During motor regeneration over hauling loads the DC Buss voltage may rise above this nominal level The Over Voltage protective circuit disables the VSC 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 Current Transformer This current transformer senses an imbalance in the current flowing in the ve and ve DC Buss wires Any imbalance indicates a fault current to Earth The input voltage is the line to line voltage between terminals LI L2 L2 L3 LI L3 Printed Circuit Board Is a device for measuring insulation resistance applies 500 between its terminals and measures the insulation resistance in megohms millions of Ohms We recommend that an electronic insulation tester be used Definitions Used Throughout This Manual Frequently you will be asked to measure a voltage on a particular plug socket or component network The following definitions apply when measuring val
18. e below If the result of each test is not as shown then the transistor module must be replaced Set the multimeter to Diode Test Range Red Lead Black Lead Required Result P N Open Circuit N P 0 4 to 1 0 2 diode drops P U V W Open Circuit N U V W 0 20 to 0 50 Vdc 1 diode drop U V W P 0 20 to 0 50 1 diode drop U V W N Open Circuit P BuP BvP BwP Open Circuit U BuN Open Circuit BvN Open Circuit W BwN Open Circuit Set the multimeter to Ohms Range 100 to 1 000 Ohms BuP EuP 300 to 800 ohms BvP EvP 300 to 800 ohms BwP EwP 300 to 800 ohms BuN EuN 300 to 800 ohms BvN EvN 300 to 800 ohms BwN EwN 300 to 800 ohms If the module passes this test replace all the wiring Refer to the VSC Base Wiring diagram for details of the base connections 12 Testing Two Pack Modules Power Supply Off VSC Stopped Speed 0 Carefully note the connections to the three transistor modules and then remove all wiring from each one For each transistor module set the multimeter to the appropriate 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 transistor module must be replaced Set the multimeter to the Diode Test Range Red Lead Black Lead Result C1 2 Open Circuit E2 C1 0 80 to 1 00 Vdc 2 diode drops C1 C2E1 Open Circuit C2E1 C1 0 20 to 0 50 1 diode drop E2 C2E1 0 20 to 0 50 Vdc 1 diode drop C2E1 E2 Open Cir
19. e but VSC will not start Speed Reference selector does not function Remote Trip led stays illuminated when terminals 5 and 6 are bridged Speed Reference inputs do not work Speed Output does not work Load Output does not work Control Board relay does not function properly page 11 CHECKING THE TRANSISTOR MODULES The Transistor Modules come two different packages Six Pack Modules and Two Pack Modules Six Pack Modules contain six power transistors so only is required to make up the three phase inverter bridge Two Pack Modules contain two power transistors and so three are required to make up the three phase inverter bridge To check transistor modules you will require a multimeter with a diode test range This range measures the forward biased voltage drop of a semiconductor junction You will also need to be able to measure resistance on the 100 to 1 000 Ohms range For the diode tests on the transistor modules we have defined the Red and Black leads of the multimeter as described below Red Lead Source of conventional current or positive lead Black Lead Sink of conventional current or negative lead Testing Six Pack Modules Power Supply Off VSC Stopped 0 2 Carefully note the connections to the transistor module and then remove all the wiring from it Set the multimeter to the appropriate range and measure between each of the terminals shown in the tabl
20. erms Definitions VSC Set Up for Servicing List of Symptoms Module Checking Procedures Transistor Module Bridge Rectifier Module Base Drive Modules Capacitor Module Module Replacement Procedures Capacitor Module Control Board DCCT Input Rectifier Module Transistor Module Sensor Wiring TABLE OF FIGURES VSC Control Board Layout VSC Module Locations VSC Base Wiring internal Wiring and Spare Parts List VSC H Internal Wiring and Spare Parts List VSC G Internal Wiring and Spare Parts List VSC S VSC Voltage Selection Procedure Model Numbers VSC H3 VSC G13 VSC S3 VSC H4 VSC G17 VSC S4 VSC H5 VSC G24 VSC S5 VSC H10 VSC G32 VSC H13 VSC G38 VSC H17 VSC G44 VSC H24 VSC G60 VSC H32 VSC H38 VSC H44 page 1 USE OF THIS MANUAL This manual is intended as a guide to finding and repairing faults in the Zener VSC 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 authorized 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 It is assumed that the person attempting to service the VSC has some knowledge of electronic components
21. han 60 seconds then the discharge circuit has failed and the module must be replaced Carefully measure between the plus and minus terminals on the capacitor module with a multimeter on 1 000 Vdc range Wait until this voltage is below 24 Vdc before doing any work inside the VSC Warning If there is more than one capacitor module in the VSC measure the voltage on each one to be sure that they have all discharged before doing any work inside the VSC Disconnect the power supply from the VSC input terminals Locate the wires connecting the capacitor module to the transistor module s Make a note of where each wire connects to the transistor module so that you can replace it properly Disconnect the wires at the transistor module end leaving them connected to the capacitor module If the Capacitor module is mounted to the bottom of the chassis remove the four flange nuts and carefully lift the module from the studs If the module is mounted on the side of the chassis remove the four screws from the outside of the chassis while supporting the module on the inside Remove the capacitor module from the chassis complete with wiring and check the following Inspect the body of each capacitor for physical damage such as dents small holes bubbles in the aluminium case particularly the top or any sign of excessive heat melted plastic etc Check the underside of the PCB for damage such as broken tracks scorching excessive he
22. igher than this then electrical noise may be present on the AC mains See the section below regarding electrical noise If the DC Buss voltage is correct measure between 1 PLP and 3 PLP You should get 30 Vac 3 Vac If not check the control transformer and it s wiring for damage and replace it if necessary If the voltage at PLP is correct replace the Control Board Refer to the Control Board Replacement Procedure Over Voltage Trip When ZSP LED Goes Out Power Supply Off VSC Stopped Speed 0 Locate the Capacitor Module s and the relay s on them Turn the AC Power Supply on and check that ALL the relays energize approximately 1 second after power is applied If any of the relays do not energize replace the Capacitor module immediately or further damage may result Check each capacitor module Replace as necessary Intermittent Over Voltage Tripping Power Supply On VSC Stopped Speed 0 Intermittent OV tripping could be caused by one of two things Either there is an intermittent fault in the Control Board or there is electrical noise on the main power supply The latter is most common and can usually be verified by observing the Decel Limit LED on the control board with the VSC powered up but not operating If the Decel Limit LED flashes occasionally and these flashes correspond to OV trips then there is probably electrical noise on the AC mains power supply f Electrical Noise There is no simple solution for electrical noise pr
23. o not operate properly replace the control board BEFORE proceeding any further or transistor damage may result Power Supply On VSC Stopped Speed 0 Remove the plug from connector PLI Measure between 1 PLI and 3 PLI on the control board it should be 12 Vdc 0 1 If not replace the control board If OK insert the plug back into connector PLI Measure the voltage between 2 PLI and 3 PLI it should be 6 Vdc 0 5 If not replace the DCCT Measure between 2 CN4 3 CN4 on the millivolts range It should be 0 0 Vdc 300 mV If it is outside this range adjust VRI3 on the control board until the meter reads 0 0 Vdc 30 mV If you cannot achieve this replace the DCCT If the VSC still trips on or OC when the ZSP led goes out replace the Control Board Earth Fault Trip Power Supply Off VSC Stopped Speed 096 Inspect the ELCT for physical damage Remove the plug from PLE and measure between 1 PLE and 2 PLE on the plug with a multimeter on ohms range It should be a short circuit If not replace the Sensor Wiring If the ELCT is OK plug it back into PLE If your model VSC has output chokes refer to the Internal Wiring diagrams remove the choke wires from the Transistor Modules Use an Insulation Tester 500 V to check between each of the output terminals MI M2 M3 and the Earth terminal Replace any choke connected to an output terminal which is less than 50 kohms to Earth If
24. oblems The best approach is to analyse the noise for typical amplitude and duration characteristics then design an appropriate filter to remove the noise If you think you have noise problem please contact our sales personnel to discuss the best solution for your particular problem Over Current Plus or Over Current Minus at End of Reset Period Power Supply On VSC Stopped Speed 0 Whenever the transistor drivers are disabled no current can flow therefore the fault lies in the control board or the DCCT Remove the plug from connector PLI Measure between 1 and 3 PLI on the control board it should be 12 Vde 0 1 If not replace the control board If OK insert the plug back into connector Measure the voltage between 2 3 PLI it should be 6 Vdc 0 5 If not replace the DCCT Measure between 2 CN4 3 CN4 on the dc millivolts range It should be 0 0 Vdc 300 mV If it is outside this range adjust on the control board until the meter reads 0 0 Vdc 30 mV If you cannot achieve this replace the DCCT If the VSC still trips on or at the end of the reset period replace the Control Board page 8 Over Current Plus or Over Current Minus when ZSP LED Goes Power Supply Off VSC Stopped Speed 0 Check the Power Transistors If one or more is faulty replace the transistor module s as necessary Check the Base Drive Circuits If any of the six circuits d
25. or altered 4 The cost of transportation both ways is to be met by the owner if it is necessary to return the product or any part of it to Zener Electric s premises 5 charge being accepted by the owner for travelling time and expenses incurred in connection with warranty service at the user s site as requested by the owner 6 If the product was not purchased from Zener Electric directly then a warranty claim must be lodged with the original supplier in the first instance Repairs will not be effected by Zener Electric unless approved by the original supplier 7 Goods not of our own manufacture incorporated in our supply or merchanted by us carry their maker s warranty only 8 Goods returned for claim under warranty will be accepted on the condition that should the claim be rejected then all costs including inspection will be charged to the customer s account SAFETY Your VSC must be applied installed and operated in a safe manner It is the responsibility of the user to ensure compliance with all regulations and practices covering the installation and wiring of your VSC This Instruction Manual should be completely read and understood before attempting to connect or operate the VSC Only skilled personnel should install this equipment THE CONTENTS OF THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE TABLE OF CONTENTS Use of this Manual Equipment Required for Servicing Safety Warnings Glossary of T
26. ply is NOT connected to L1 L2 L3 Power Supply On Mains AC supply IS connected to L1 L2 L3 VSC Stopped Start Stop switch is OPEN VSC Started Start Stop switch is CLOSED Speed 0 to100 Setting of speed control potentiometer 0 zero speed Pot Counter Clockwise 100 full speed Pot Clockwise If it is not possible to connect the VSC as shown above you must determine how best to use your control circuit to achieve the above conditions page 6 VSC MODULE LOCATIONS VSC Module Key CHASSIS VSC Chassis Type High Performance Single Phase 1 TRANSISTOR MODULE VSC H3 VSC G13 2 BRIDGE RECTIFIER VSC H4 A VSC G17 3 FAN VSC H5 A VsC G24 4 TRANSFORMER VSC H10 VSC G32 5 TERMINALS VSC H13 VSC G38 6 CAPACITOR MODULE o 7 TEMPERATURE SENSOR VSC H32 8 SNUBBER BOARD VSC H38 9 OUTPUT CHOKES VSC H44 CHASSIS CHASSIS D NOTE There number of different types of DCCT They are not interchangeable EARTH LEAKAGE CURRENT TRANSFORMER NOTE There a number of different types of ELCT They are not interchangeable page 7 Over Voltage Trip at End of Reset Period Power Supply On VSC Stopped Speed 0 Measure the Input Voltage and check that it is within 10 to 15 of the nameplate voltage Measure the DC Buss voltage between 1 PLB and 3 PLB It should be 1 4x Input voltage If it is h
27. rresponds to 80 If the voltage at PLT is less than 3 52 Vdc and the OT LED illuminates replace the control board Power LED Does Not Illuminate Power Supply On VSC Stopped Speed 0 Measure between 1 PLP and 2 PLP on the control board for 15 Vack2 Vac Measure between 3 PLP and 2 PLP for 15 Vac 2 Vac If not replace the control transformer Power Supply Off VSC Stopped Speed 0 If the voltage at PLP is OK then remove the plug from connector PLI If the Power On LED illuminates replace the DCCT If the Power On LED still fails to illuminate replace the Control Board Fuses Blow On Application of Input Power Check the Bridge Rectifier and replace if necessary Check the Transistor Module s and replace if necessary If there is any damage to the transistor module s then check the control board base drive circuits Check the Capacitor Module s and replace if necessary Power Supply Off VSC Stopped Speed 0 Remove the plug from connector PLP Use an Insulation Tester to check between the control transformer primary winding and Earth Replace the contro transformer if the winding is less than 500 k ohms to Earth Repeat the test between the secondary winding and Earth If the transformer is OK plug it back into connector PLP Motor Phase Voltage or Current Imbalance Check the Transistor Module s for an open circuit transistor and replace if necessary Check the Control Board Base Drive Circuits and replace if necessary If no faul
28. sufficient at least to identify capacitors resistors transistors etc and the modules which they make up in the VSC chassis The following pages list faults by their symptoms It is impossible to list every possible symptom individually and so 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 Service of the VSC should only be attempted by people with experience working with exposed high voltages The Trouble Shooting Guide in the VSC Instruction Manual should be followed carefully before using this manual to ensure that the fault observed is not an external one Many hours can be wasted looking in the wrong place for the fault A Glossary of Terms and a page of Definitions are also included EQUIPMENT REQUIRED FOR SERVICING A digital or analog multimeter with the following ranges AC Volts up to 500 V range DC Volts up to 1 000 V range DC Amps 300 mA range Resistance 30 to 50 000 ohms ranges Diode Test Range An Electronic Insulation Tester 500 Vdc A 1 amp 100 V rectifier diode Slotted and Philips head screwdrivers M4 7 mm AF M5 8 mm AF and M6 10 mm AF Socket Drivers A good working knowledge of these tools is very important page 2 ae amp 7 CAUTION RISK
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30. t is found in either the transistor module s or the base drive circuits replace the control board Motor Instability Check the Capacitor Module s In particular if there is more than one Capacitor module check that the wiring to all the modules is intact and that one or more capacitors are not damaged page 10 Accel Limit Current Limit Circuit Activates Too Early Power Supply Off VSC Stopped Speed 0 Inspect the DCCT for physical damage Power Supply On VSC Stopped Speed 0 Remove the plug from connector PLI Measure between 1 PLI and 3 on the control board it should be 12 Vdc 0 1 Vdc If not replace the contro board If OK insert the plug back into connector Measure the voltage between 2 and 3 PLI it should be 6 Vdc 0 5 If not replace the DCCT Measure between 2 CN4 and 3 CN4 the millivolts range It should be 0 0 Vdc 300 mV If it is outside this range adjust on the contro board until the meter reads Vdc 30 If you cannot achieve this replace the DCCT Check the Capacitor Module s If there is more than one module check the wiring to all modules If the DCCT and the Capacitor Module s are OK then replace the Control Board The following list of symptoms indicate a Control Board Failure Enabled LED does not illuminate when the VSC is enabled Direction LED does not illuminate when a direction is selected Enabled Direction leds illuminat
31. the VSC S model Locate the black tubular power resistor 120 ohm ASW5 or 150 ohm ASW5 Measure across it on ohms range for 110 to 160 ohms Set the multimeter to the 30 kohm or 50 kohm range Arrange the wires so that they cannot touch each other or the PCB Measure between the plus push on terminal and the minus push on terminal on the capacitor module The meter should start from zero ohms and slowly increase to about 20 kohms in approximately 90 seconds Reverse the meter leads The meter should go from minus 20 kohms to zero and then increase to 20 kohms again in approximately 90 seconds The charging times and resistances given above may vary depending upon the meter used The important thing is that the capacitors should charge up the resistance increases and when the leads are reversed they should discharge and then re charge the resistance appears to go negative drop to zero and increase again If the module fails either of these two tests it must be replaced CAPACITOR MODULE REPLACEMENT PROCEDURE A capacitor module consists of the PCB AND the wires which connect to it Do not swap the wires between modules you have obtained a new module be sure to use the wires supplied with this module To replace the Capacitor Module in the chassis fit it back on its mounting hardware and re connect the wiring to the transistor module s Replace all the wires EXACTLY as they were originally connected Check that the relay
32. the VSC still trips on Earth Fault replace the Control Board Under Voltage Trip Power Supply On VSC Stopped Speed 096 Measure between 1 PLP and 2 PLP on the control board You should read 15 Vac 2 Vac Measure between 3PLP and 2PLP Again you should get 15 2 Vac If not check the control transformer for damage and replace as necessary Measure between 1 CN4 and 3 CN4 for a voltage between 4 18 and 6 88 If this voltage is less than 4 18 check the wiring between the DC Buss and connector also check the Bridge Rectifier Module If the voltage at CN4 is correct replace the Control Board Check the Bridge Rectifier Module Refer to the Checking Bridge Rectifier section Check the Capacitor Module s as described in the Checking Capacitor Module section page 9 Over Temperature Trip Check that the fan if installed is operating properly and that the heatsink is not blocked with any foreign matter If the VSC is in an enclosure check all filters and grills for blockages and check that the enclosure fan s if fitted are operating Power Supply Off VSC Stopped Speed 0 Measure the temperature of the heatsink by touch if you do not have a thermometer Power Supply On VSC Stopped Speed 0 Measure between 1 PLT and 2 PLT The voltage should be V 273 Heatsink Temp C x10 5 If you do not obtain this replace the Sensor Wiring The temperature trip point is 3 52 Vdc which co
33. ues in the VSC Plug Socket PLP PLC PLB PLE PLT PLI PLU PLV PLW CN4 1 PLP 3 CN4 The part of the connector which is attached to the wires The part of the connector soldered into the PCB Control Board Power Supply Connector Capacitor Module Power Supply Connector DC Buss Voltage Sensing Connector ELCT Connector Temperature Sensor Connector DCCT Current Feedback Connector Base Drive Connector for Phase U Base Drive Connector for Phase V Base Drive Connector for Phase W Component Network Socket 5 pin pin 1 of connector PLP etc pin 3 of component network CN4 etc Refer to the VSC Control Board Layout on page 5 for the location of each of these connectors on the control board Where the procedure instructs you to check a module refer to the Checking Procedures at the end of the symptoms section When it is necessary to replace a module refer to the Module Replacement Procedures at the end of this manual page 4 tZ VSC Control Board Layout 1 2 5 4 5 6 7 8 gt E CNIA Jo CN1B CN1C m a CN1D O loo el igesas 85555503 __ 55959 1 8 PL 1 6 1 6 PLV 1 6 1 6 PLW 8 VR14 1 1 i 5 _ Ee ee a etenim 1 VSC A
34. ve the Power Input Motor Output terminals On the top of the transformer is a printed ZENER circuit board with the voltage selection tappings A drawing of this board is shown opposite Remove the tapping carefully VSC INPUT VOLTAGE and replace it on the pin adjacent to the voltage you SELECTION require Close the lid and tighten the lid screw 2 Voltage Selection Links Locate the Voltage Selection Links on the VSC control board Refer to the drawing below for their location From the table below select the input voltage required and plug in the links as shown 3 Input Voltage Label Change Locate the Input Voltage Labe below the Input Output terminals on the VSC chassis Remove the Input Voltage Labels from the packet supplied Select the label with the NEW Input Voltage marked 4 it remove it from the backing paper Stick it down top of the OLD Input Voltage Label input Voltage uz ur NO NO Ys NO NO YES NO Plug In Links ee PLT PLE PLP 5 F234 F34 F553 F54 4 2 loa a lo lo ol lo ol lo 2 224 O em cum pbi OO MIN ACCEL DECEL START sup FWD REV EN PLS EF O O ern cy 0200000 oe SPD
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TIBCO ActiveMatrix Service Bus Installation User`s Manual of WLAN Broadband Router (1T1R) A-4221-0 : LA-240 Copyright © All rights reserved.