Danfoss VLT 3032, Service Manual

Page 1: ...ectifiers 30 Testing for Current Feedback 30 Removing and Replacing the Control Card 31 Removing and Replacing the Interface Board 31 Removing and Replacing Gate Snubber IGBT 32 Removing and Replacing...

Page 2: ...ting charts both in the form of flow and symptom cause Section three describes the various tests and methods used to evaluate the drives condition Section four covers the removal and replacement of th...

Page 3: ...cal parts of the AFD when the AC line is connected After theAC line is disconnected wait at least 15 minutes before touching any of the components 2 When repairs or inspection is made the AC line must...

Page 4: ...4...

Page 5: ...he logic section is the keyboard display mounted on the control card The keyboard provides the interface between the digital logic and the human programmer The LCD Liquid Crystal Display provides the...

Page 6: ...nstalled which can only be activated through the use of a normal remote control start In the same sense that the control card can only respond to commands comes the situation that the control card mak...

Page 7: ...de supply is that it obtains its power from the DC Bus in the event of a power loss the power supply remains active for a longer period of time versus conventional power supplies During the troublesho...

Page 8: ...sible through the shield covering the lower portion of the interface board and as long as it is lit it indicates the DC Bus voltage is greater than 50VDC A fault in the power section will usually resu...

Page 9: ...s proceeds normally the power supplies will come up and provide the control card and all other sections of the unit with low voltage control power At this time the display in the control card will ind...

Page 10: ...t condition CURRENT LIMIT This message will flash in the display when the unit is operating above the current limit setting as recorded in parameter 209 Parameter 310 may be set to provide a fixed tim...

Page 11: ...At an inverter ETR value of 100 the unit trips on Invert Time MOTOR TIME This message will flash if Motor Thermal Protection has been activated in parameter 315 and the motor ETR value has reached 98...

Page 12: ...will be out This fault returns a Trip Locked Also see Testing The Inverter Section page 26 OVER VOLTAGE 2 This message indicates the DC Bus voltage upper limit has been exceeded In addition the High...

Page 13: ...rature condition This fault returns a Trip Also see Overtemp Trips page 39 INVERT TIME 7 This message indicates the unit has delivered greater than 105 of the unit s continuous current rating for too...

Page 14: ...a Ground Fault on the Inverter Output The I0K LED will be off and the control card will indicate Ground Fault OVER TEMP TRIP OTT D3 RED Indicates the heatsink temperature is outside of the specified...

Page 15: ...MK15 on the interface board The I0K LED will be off and the control card will indicate Over Temp POWER SUPPLY FAULT PSF D1 RED Indicates the low voltage power supplies are out of tolerance The I0K LE...

Page 16: ...on the drive is with the motor disconnected In this way a faulty component that was overlooked or the unfortunate slip of a test probe will generally result in a unit trip instead of a component failu...

Page 17: ...YES page 20 See 9 Refer to the section Alarm Messages page 13 7 Is the correct mains supply present at R S T NO YES Also see Section Applications pg 35 3 See Testing the Inverter Section page 26 2 Is...

Page 18: ...re of the fuses F4 F5 or F6 have blown test the soft charge circuit page 23 NO YES 13 The fault may be caused by a short circuit in the control signals Check control wiring for proper connection NO YE...

Page 19: ...ated Is the unit properly grounded to earth NO YES Consult factory 26 Replace the Interface ILD card see page 31 Does the motor run YES NO 23 Attempt to run the VLT in local SEE CAUTION at LEFT Make t...

Page 20: ...otor One inverter phase missing Test output phase balance page 27 One half of one inverter phase missing Test output phase balance page 27 6 Motor Runs Unloaded But Stalls When Loaded Motor may run ro...

Page 21: ...Input line voltage unbalanced Faulty connection on input wiring Fault in plant power transformer Input SCR Diode module faulty or not being gated Open motor winding Faulty motor connection Fault in in...

Page 22: ...circuit is to rule out failures of the Soft Charge Rectifier and Soft Charge Resistors If the soft charge fuses have blown it indicates the possibility of a short circuit of the DC Bus A DC Bus short...

Page 23: ...lead to the soft charge fuses F4 F5 and F6 in turn Each reading should show a diode drop 5 Connect the positive meter lead to the negative terminal of the rectifier Connect the negative meter lead to...

Page 24: ...Each reading should show open 3 Reverse the meter leads connecting the lead to terminal 89 VDC and the lead to terminals 91 R 92 S and 93 T in turn Each reading should show a diode drop 4 Connect the...

Page 25: ...turn Each reading should show a diode drop 4 Connect the positive meter lead to terminal 88 VDC Connect the negative meter lead to terminals 96 U 97 V and 98 W in turn Each reading should show a diod...

Page 26: ...on within the unit itself This can be caused by improper gate drive signals as a result of a faulty interface board or gate drive board A faulty IGBT or loose wire connection between the IGBT and the...

Page 27: ...e the test points are the same This test can be made at the interface board or at each gate card output to its respective IGBT These tests can be made with or without a motor However it is generally s...

Page 28: ...at the gate driver requires that the test leads are connected and then the unit is reassembled to conduct the tests Extreme care must be taken to insure test leads can not come in contact with other p...

Page 29: ...t is proportional to the current being drawn in each respective phase The VLT relies on this feedback for proper waveform control and for providing fault protection A simple test of the signals can be...

Page 30: ...ed to insure they can be returned to the correct location 3 Working around the board release the 11 swag clips with the use of needle nose pliers Gently lift the board clear of the swags as you go 4 I...

Page 31: ...and the Motor Coil Wire to the IGBT to be replaced 6 Loosen the remaining Standoffs but do not remove on the remaining two IGBT s This should allow sufficient clearance to slide the IGBT from beneath...

Page 32: ...s to 18 22 LB IN 2 03 2 49 NM Insure the bus sensing wire marked K is secured to the lower bus bar 9 Install the Phillips screw securing the line connection to the module Torque to 18 22 LB IN 2 03 2...

Page 33: ...rt Compensation 209 Current Limit Parameter 100 An incorrect setting may provide an improper voltage to frequency ratio to the motor with respect to the load demand For example a constant torque CT lo...

Page 34: ...t voltage If multiple motors are connected to a single unit it is usually necessary to increase the start voltage Smaller motors have greater voltage drops at low frequencies so additional start volta...

Page 35: ...nd all associated wiring and connections are captured in the test When reading the results of the Megger test the rule of thumb is any reading less than 500 Megohms should be suspect Solid dry wiring...

Page 36: ...on process from there The amount of current required may be so great and rise so rapidly that the current limit function cannot control the process The result is an OVERCURRENT trip However this situa...

Page 37: ...ative or the factory for assistance in selecting the appropriate Dynamic Brake option for your application Trips due to OVERTEMP can be due to internal or external over temperature conditions Two temp...

Page 38: ...rminals 1 and 2 of MK15 When MK15 is activated the result is a fault trip with the OTT and EOT LED s on the Interface Board being illuminated The Control Card will display OVERTEMP An EOT fault also d...

Page 39: ...addition there are six more codes which may appear in parameter 602 10 Trip Locked Indicates a trip lock fault has occurred 11 CT OP Card Fault Indicates a software fault has occurred in either the C...

Page 40: ...Fuse 175L3830 Soft Charge Fuse 175L3829 Soft Charge Rectifier 175L3832 Input Rectifier 175L3831 Soft Charge Resistor Assembly 175L3833 IGBT Module 3032 175L3836 IGBT Module 3042 52 175L3837 Power Supp...

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