Danfoss VLT series Service Manual Download

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VLT is a registered Danfoss trademark

Intro-5

Control card cassette

Control card
PCA1

Power card
PCA3

Interface card
PCA2

Capacitor bank assembly
PCA10

Soft charge card
PCA11

Upper capacitor bank
cover plate

Lower capacitor bank
cover plate

IGBT gate driver card
PCA5

Input terminal mounting
plate assembly

Main AC power
input terminals
TB1

Fan transformer
TR1

AC input bus bar

IGBT output bus bar

Fan assembly
F1 + C1 + CBL11

IGBT module
IGBT1, 2

Current sensor
L2, L3, L4

Output motor terminals
TB2

SCR/Diode module
SCR1, 2, 3

DC inductor
L1

Control input terminals

Capacitor bank assembly
PCA9

Soft charge resistor assy
R1 + CBL26

IGBT snubber
C2, C3, C4, C5, C6, C7

Fan fuse
FU4

Soft charge fuses

Exploded View D2 Frame Size

Summary of Contents for VLT series

Page 1: ...MOTION CONTROLS Service Manual VLT 4152 4652 VLT 5122 5602 VLT 6152 6652 VLT 8152 8652...

Page 2: ...Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary...

Page 3: ...g Shielded Cables 1 11 SECTION 2 INTERNAL DRIVE OPERATION 2 1 GENERAL 2 1 DESCRIPTION OF OPERATION 2 1 LogicSection 2 1 Logic To Power Interface 2 2 PowerSection 2 3 SEQUENCE OF OPERATION 2 4 Rectifie...

Page 4: ...rame Size 5 3 5 1 2 Soft Charge RectifierTest D frame Size 5 5 5 1 3 Soft Charge and Rectifier Circuits Test E frame Sizes 5 6 5 1 4 Soft Charge RectifierTest E frame Size 5 8 5 1 5 Inverter Section T...

Page 5: ...Sensor 6 18 6 14 FanAssembly 6 19 6 15 AC InputTerminals 6 21 6 16 IGBT Modules D2 Units 6 22 6 17 IGBT Modules D1 Units 6 25 SECTION 7 E FRAME SIZES DISASSEMBLY AND ASSEMBLY INSTRUCTIONS 7 1 ELECTRO...

Page 6: ...oft Charge Card Fuse Location 5 6 5 5 Soft Charge Card Connectors 5 8 5 6 Fan Transformer and Fuse Location 5 11 5 7 Fan and DC Bus Fuse Locations 5 12 5 8 Drive Power Terminals D size Frames 5 13 5 9...

Page 7: ...1 Control Card Cassette 7 1 7 2 Interface Card Power Card and Mounting Plate 7 2 7 3 Gate Drive Card 7 3 7 4 Soft Charge CardAssy 7 3 7 5 Upper and Lower Capacitor BankAssemblies 7 4 7 6 InputTermina...

Page 8: ......

Page 9: ...ned 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 s...

Page 10: ...0 110 132 132 160 D1 5202 200 250 132 160 160 200 D2 5252 250 300 160 200 200 250 D2 5302 300 350 200 250 250 315 D2 5352 350 450 250 315 315 355 E1 5452 450 500 315 355 355 400 E1 5502 500 600 355 40...

Page 11: ...ed for 1200 VDC for 690 V units Analog volt meter Oscilloscope Clamp on style ammeter Test cable p n 176F8439 Signal test board p n 176F8437 Shaft Size Driver Size Torx Hex Torque in lbs Torque Nm M4...

Page 12: ...driver card PCA5 Input terminal mounting plate assembly Main AC power input terminals TB1 Fan transformer TR1 AC input bus bar IGBT output bus bar Fan assembly F1 C1 CBL11 SCR Diode module SCR 1 2 3 O...

Page 13: ...r card PCA5 Input terminal mounting plate assembly Main AC power input terminals TB1 Fan transformer TR1 AC input bus bar IGBT output bus bar Fan assembly F1 C1 CBL11 IGBT module IGBT1 2 Current senso...

Page 14: ...t charge card PCA12 Soft charge fuses Input terminal mounting plate assembly AC input bus bar Main AC power input terminals TB1 Current sensor L2 L3 L4 Output motor terminals TB2 IGBT output bus bar F...

Page 15: ...0 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 2619 3309 4163 4977 6107 Power loss High...

Page 16: ...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 7630 7701 8879 9428 Power loss High overload W 6005 6960 7...

Page 17: ...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 Power loss Normal overload W 3...

Page 18: ...kVA 690 V 490 598 681 Typical shaft output kW 550 V 315 400 450 HP 575 V 400 500 600 kW 690 V 400 500 560 Power loss Normal overload W 7249 8727 9673 Power loss High overload W 5818 7671 8715 Limits...

Page 19: ...cal shaft output kW 550 V 30 37 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 Limi...

Page 20: ......

Page 21: ...line 2 The large display line 2 shows a value in this case the drive output in hertz The setup number and direction of motor rotation is also shown The bottom line line 4 is the status line This line...

Page 22: ...e indication as part of the display title Tables 1 1 and 1 2 list the displays shown in the status line and define their meaning Because the VLT 5000 series and VLT 4000 6000 8000 series have differen...

Page 23: ...feedback signal higher than value set in parameter 228 Warning High Feedback Drive will continue to operate FEEDBACK LOW Warning of a feedback signal lower than value set in parameter 227 Warning Low...

Page 24: ...nal 27 high Start command via remote digital input or serial communication is overridden REM QSTOP Remote control selected and drive stopped via a quick stop signal on terminal 27 or serial communicat...

Page 25: ...xed frequency set in parameter 209 Jog Frequency JOG REQ Start command to run at jog frequency given but motor will not start until a Run Permission signal is received via a digital input NOT READY Dr...

Page 26: ...indication will change to TRIP RESET and allow for manual digital or serial bus reset Line 2 displays alarm and the associated number while line 3 identifies the alarm in plain language ALARM 12 SETUP...

Page 27: ...X 15 Switch mode power fault SWITCH MODE FAULT X X 16 Short circuit CURR SHORT CIRCUIT X X 17 Serial communication timeout STD BUSTIMEOUT X X 18 HP field bus timeout HPFB TIMEOUT X X 19 Fault in EEPR...

Page 28: ...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...

Page 29: ...arameter associated with it The setting selected in the parameter enables the function of the terminal See the Operator s Manual for details Term 16 17 18 19 27 29 32 33 53 54 60 42 45 1 3 4 5 Para 30...

Page 30: ...C power supply is used to power an external transducer which provides an analog input signal terminal 55 must be wired to terminal 39 60 Programmable 0 to 20 mA or 4 to 20 mA analog current input Resi...

Page 31: ...other interface device is different electrical noise may occur that can disturb the entire system This can be resolved by fitting an equalizing cable next to the control cable Minimum cable cross sect...

Page 32: ......

Page 33: ...ut the mechanical stress associated with a line start In its basic form the drive can be divided into four main sections rectifier intermediate circuit inverter and control and regulation see Figure 2...

Page 34: ...d to 30 VDC at 1 Amp The logic circuitry on the control card allow for the addition of option modules for synchronizing control serial communications additional relays the cascade pump controller or c...

Page 35: ...on 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 line harmonics The DC bus capacitors are arranged into a capacitor bank alon...

Page 36: ...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 prevent sign...

Page 37: ...2 5 VLT is a registered Danfoss trademark Figure 2 4 Rectifier Circuit No RFI relay on 525 690V units E1 units have 2 RFI cards...

Page 38: ...des a current path for discharging the capacitors once power has been removed from the drive Also located in the intermediate section is the high frequency HF filter card It contains a high frequency...

Page 39: ...2 7 VLT is a registered Danfoss trademark Figure 2 5 Intermediate Section No RFI relay on 525 690V units E1 units have 2 door fans...

Page 40: ...o 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 empl...

Page 41: ...2 9 VLT is a registered Danfoss trademark Figure 2 7 Inverter Section...

Page 42: ...y a result of an overhauling load causing regenerative energy to be returned to the DC bus This occurs for example when the load drives the motor causing the voltage to return to the DC bus circuit Fi...

Page 43: ...low the temperatures as listed above Load Sharing Units with the built in load sharing option contain terminals 89 DC and 88 DC Within the drive these terminals connect to the DC bus in front of the D...

Page 44: ...cts are rated for a maximum of 240 VAC 2 Amps and a minimum of 24VDC 10mA or 24 VAC 100mA The relay can be programmed via parameter 323 to indicate drive status The interface card FK100 terminals 35 a...

Page 45: ...make many assumptions To assume a motor is wired properly because the drive has been in service for some time may overlook loose connections improper programming or added equipment for example It is b...

Page 46: ...r carbon deposits that were the result of a catastrophic component failure Check for cracks or breaks in the housings of power semiconductors or pieces of broken component housings loose inside the un...

Page 47: ...l wiring or a fault within the drive 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 co...

Page 48: ...indicates that a run command has been given to the drive but the reference speed command is zero or missing Check control wiring to ensure that the proper reference signal is present at the drive inpu...

Page 49: ...op operation check PID settings Perform Input Terminal Signal Test in section 5 to check for faulty reference signals Perform Output Phase Imbalance Test in section 5 to check for loss of motor phase...

Page 50: ...input AC line and the output to the motor may be the first step to restoring proper operation of the drive Refer to section 5 Dynamic Test Procedures Input Voltage Test Input Phase Imbalance Test Outp...

Page 51: ...motor It is also possible that the connection has been broken Check for overheated motor if Thermistor function is being used Check for open connection by measuring voltage between corresponding termi...

Page 52: ...Faulty connection in communication wiring or faulty control node PLC in communication network Check connections on serial communication cable WARNING 20 EE ERROR CTRL CARD Fault in the EEPROM on the c...

Page 53: ...g the shaft and restart AMA WARNING ALARM 23 BRAKE TEST FAILED Not applicable for the VLT 4000 6000 8000 When a unit with braking is powered up and a stop command is present a brake test is performed...

Page 54: ...ve and motor or a faulty motor Check motor wiring See Output Phase Imbalance Test 5 2 8 in Section 5 ALARM 31 MISSING MOT PHASE V The unit has detected an open circuit in the V phase This fault may be...

Page 55: ...Check the motor and setting and choose Continue or Stop If stop is selected AMA will have to be started over WARNING 42 MOTORTOO SMALL AMA function has detected an error in calculating motor data The...

Page 56: ...ent This is a customer programmable indicator of operating conditions No corrective action needed WARNING 65 FEEDBACK FDB LOW The resulting feedback value is lower than the value programmed in paramet...

Page 57: ...drive a run command and slowly increase reference speed command to approximately 40 Hz 6 Using an analog volt meter or a DVM capable of measuring true RMS measure phase to phase output voltage on all...

Page 58: ......

Page 59: ...g demands of the application Parameter 107 activates the automatic motor adaptation AMA function When AMA is performed the drive measures the electrical characteristics of the motor and sets various d...

Page 60: ...e level become too high the drive switches the resistor across the DC bus and dissipates the unwanted energy into the resistor bank This will actually increase the rate of deceleration Less often is t...

Page 61: ...expected of it In such cases setting the correct values to these parameters and performing the automatic motor adaptation AMA function will usually solve the problem Any references or limits set incor...

Page 62: ...els in the receiving 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 voltages A...

Page 63: ...on 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 effect...

Page 64: ...ts in an instantaneous voltage at points reputed to be at ground potential This voltage can appear throughout a system as a common mode signal that can interfere with control signals Theoretically the...

Page 65: ...should be as short and direct as practical Flat braided cable has lower HF impedance than round cable Simply mounting the drive or motor onto a painted surface will not create an effective ground con...

Page 66: ...ill provide some degree of protection This technique will not be as effective as shielded cable due to the unavoidable contact of the conduit with various points within the equipment Serial communicat...

Page 67: ...input power is required All line powered devices and power supplies are energized at rated voltage Use extreme caution when conducting tests on a powereddrive Contactwithpoweredcomponents couldresult...

Page 68: ...PCA and 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 optional and not...

Page 69: ...nd F3 located on the soft charge card are good Figure 5 2 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...

Page 70: ...ne 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...

Page 71: ...ion of the tests For the following tests set the meter to diode check or Rx100 scale 4 Connect negative meter lead to positive MK3 A DC output to DC bus and connect positive meter lead to MK1 terminal...

Page 72: ...F2 and F3 located on the soft charge card are good An open fuse could indicate a problem in the soft charge curcuit Continue test procedures Figure 5 4 shows the soft charge card and the location of...

Page 73: ...w A short indicates a shorted SCR module 5 1 3 4 Main Rectifier CircuitTest E frames Part III 1 Connect positive meter lead to negative DC bus connector MK105 B on power card 2 Connect negative meter...

Page 74: ...ests 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 2 Connect negative meter lead to positive MK3 A DC outp...

Page 75: ...to U V and W in turn Each reading should show infinity The meter will start at a low value and slowly climb toward infinity due to capacitance within the drive being charged by the meter Incorrect Rea...

Page 76: ...5 1 8 HeatsinkTemperature SensorTest The temperature sensor is an NTC negative temperature coefficient device As a result high resistance means low temperature As temperature decreases resistance inc...

Page 77: ...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 trans...

Page 78: ...1 Measure between terminals 3 and 5 of power card connector MK107 Should read approx value D in Table 5 1 Incorrect Reading For fans without an inductor replace the fan For drives with a fan and induc...

Page 79: ...t need to be performed in this order Perform tests only as necessary Figure 5 8 Drive PowerTerminals D size Frames Main 3 phase AC power to drive 3 phase output to motor DC bus loadsharing connections...

Page 80: ...g 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 conta...

Page 81: ...oper DC bus voltage was read at power card connector MK105 A and B Replace the power card in accordance with the disassembly procedures in Section 6 or 7 5 2 3 Zero DC Bus Voltage Test If no voltage i...

Page 82: ...ncorrect with one of other two phases 6 Reapply power to drive and place it in run 7 Repeat current measurements If the phase imbalance moves with swapping the leads then the main supply is suspect Ot...

Page 83: ...drive 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 p...

Page 84: ...input voltage waveform before forming a conclusion The current waveform will follow the voltage waveform If the voltage waveform is incorrect proceed to investigate the reason for the AC supply probl...

Page 85: ...has caused the SCRs to be disabled Given the connection at FK102 has been verified the control card would be suspect Check the inrush signal as follows 7 Connect positive meter lead to terminal 7 of s...

Page 86: ...W All three readings should be within 8 VAC of each other The actual value of the voltage depends on the speed the drive is running at The volts hertz ratio is relatively linear except in VT mode so a...

Page 87: ...soft charge card far enough to disconnect cable plugged into MK3 2 Disconnect cable from MK3 connector on soft charge card and connect one end of test cable into MK3 CONTINUED ON NEXT PAGE 3 For D fr...

Page 88: ...e ground connected to terminal 4 common of signal board measure six gate signals at signal board terminals 25 through 30 CONTINUED ON NEXT PAGE Figure 5 14 Gate SignalWaveform from Gate Drive Card 11...

Page 89: ...ving at the power card There is no test to verify the signals directly out of the control card The power card would be suspected if a single gate signal is incorrect The control card would be suspect...

Page 90: ...e IGBTTest 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 C...

Page 91: ...resistance between terminals 1 and 4 2 and 4 and 3 and 4 of signal test board Resistance should be the same for all three readings Table 5 2 shows approximate resistance readings based on drive power...

Page 92: ...m CN2 terminal 1 to terminal 2 Voltage should equal 66 of main AC supply voltage 48 for drives 525 600 690 VAC applied to drive or that of auxiliary supply If voltage is incorrect replace fan transfor...

Page 93: ...A reading of 24 VDC indicates the presence of a signal A reading of 0 VDC indicates no signal is present 5 2 14 2 Analog inputs The value of signals on analog input terminals 53 54 and 60 can also be...

Page 94: ...o drive 4 Wire control terminals as shown in Figure 5 13 5 Reapply power to drive 6 Press OK key on drive keypad 7 Control card test will be carried out automatically Display will indicate a pass or f...

Page 95: ...drive 5 Give drive a run command and slowly increase reference speed command to approximately 40 Hz 6 Using an analog volt meter or a DVM capable of measuring true RMS measure phase to phase output v...

Page 96: ......

Page 97: ...isassembly should be attempted with power applied Remove power to drive and wait at least 20 minutes to let drive capacitors fully discharge Only a competent technician should carry out service ELECTR...

Page 98: ...CA2 Interface card mounting screw Power card PCA3 5 Remove current scaling card from power card by pushing in retaining clips on standoffs KEEP THIS SCALING CARD TO REINSTALL ON ANY REPLACEMENT POWER...

Page 99: ...arge Card 1 Remove control card power card mounting plate in accordance with procedure 2 Remove 2 retaining nuts from soft charge card assembly 10mm 3 Slide assembly part way out to access cable conne...

Page 100: ...install in reverse order of this procedure Tighten mounting screws to 35 in lbs 4 Nm 6 7 2 Lower Capacitor Bank D2 Units 1 Capacitor bank connection to DC bus bars can be seen recessed in the gap betw...

Page 101: ...K105 for units with extended brake and MK101 for units with RFI filter Note that IGBT gate drive card can remain attached to cap bank cover plate 4 Remove 4 retaining nuts 10mm from cap bank cover pla...

Page 102: ...isassembly procedure 3 Note that soft charge resistor is located under bus bars and held in place by 2 retaining nuts Bus bars do not need to be removed Loosen right most retaining nut 8mm 4 Remove le...

Page 103: ...ing for each of three wires attached to terminal 1 for each SCR Diode module Ensure that correct wire is attached to applicable stud upon reassembling Remove wiring from studs Remove retaining screw T...

Page 104: ...g nuts from DC inductor input bus bars and four retaining nuts not shown from side mounted bus bars Side mounted bus bars are only present on units with load sharing Remove DC input bus assembly CONTI...

Page 105: ...mounting screws Reassembly 1 Clean heatsink surface with mild solvent or alcohol solution 2 Reassemble remaining parts in reverse order of their removal Tighten T25 and 8mm mounting screws to 20 in l...

Page 106: ...line connector 4 Remove 4 or 5 10mm retaining nuts varies with size from mounting plate CAUTION Input terminal mounting plate weighs approx 15 60 lbs 7 27 kg depending on mounted options 5 Remove enti...

Page 107: ...embling Remove wiring from studs 5 Remove screw T30 from terminal 1 of each SCR Diode module by accessing screw through access hole in SCR Diode input bus bar Remove SCR input bus bars 6 Remove each I...

Page 108: ...0mm two on either side connecting rectifier DC bus bars to main DC bus bars These are located to either side of SCR Diode modules CONTINUED NEXT PAGE Figure 6 10 D2 SCR Diode Module 2 of 4 IGBT output...

Page 109: ...s by removing 3 screws T25 connecting each rectifier DC bus bar to standoffs on SCR Diode modules CONTINUED NEXT PAGE Rectifier DC bus bars BB23 or BB24 per drive power rating Step 10 Retaining screws...

Page 110: ...each module T30 and remove SCR Diode modules SCR Diode module Step 12 SCR Diode module mounting screws Step 12 SCR gate lead connectors Step 11 REASSEMBLY 1 To replace SCR Diode modules follow instruc...

Page 111: ...mounting plate per instructions 3 Remove retaining screw T25 from terminal 1 of each SCR Diode module 4 Remove 8mm retaining nut from bus bar holding bracket and remove bus bar CONTINUED ON NEXT PAGE...

Page 112: ...nuts from DC inductor input bus bars and four retaining nuts not shown from side mounted bus bars Side mounted bus bars are only present on units with load sharing Remove DC input bus assembly CONTINU...

Page 113: ...rake IGBT module to IGBT bus assy Remove SCR Diode mounting screws Mounting screws Step 8 REASSEMBLY 1 To replace SCR Diode modules follow instructions included with replacement module 2 Reinstall mod...

Page 114: ...sensor 4 Disconnect current sensor cable from current sensor 5 Note which cables attach to which sensor for reasembly Remove 2 8mm retaining nuts from stud on chassis baseplate and remove sensor Reins...

Page 115: ...Remove 3 IGBT output bus bars by removing 6 retaining nuts 8mm one from each end of IGBT output bus bars Remove bus bars NOTE Omit steps 3 and 4 for D2 units 3 Use 4 in 100mm minimum extension and re...

Page 116: ...ine molex connector Step 6 Retaining nut Step 7 5 Disconnect in line molex connector 6 Remove fan assy by removing 6 8mm retaining nuts from stud Note that fan assy weighs approx 18 lbs 8 kg Reinstall...

Page 117: ...2 Remove R L1 S L2 T L3 terminals by removing 3 retaining screws Reinstall in reverse order of this procedure Tighten mounting nuts per specifications in the unit s instruction manual Figure 6 14 AC I...

Page 118: ...of 3 4 Note the color coding for each of three wires attached to retaining studs Ensure that correct wire is attached to applicable stud upon reassembling Remove wiring from studs 5 Remove screw T25...

Page 119: ...n of IGBT modules These screws also attach the snubber capacitors to the IGBT modules see Figure 6 15 1 of 3 for snubber capacitor location Remove the snubber capacitors 9 Remove 10mm retaining nut fr...

Page 120: ...de modules free from under bus bars 14 Clean heatsink surface with mild solvent or alcohol solution REASSEMBLY 1 Replace IGBT module in accordance with instructions provided with replacement unit 2 Re...

Page 121: ...y card 6 Remove high frequency card by removing 2 retaining screws and 1 retaining nut 6A For units with brake option DC input bus assembly must be removed to access and remove bus bars between IGBT b...

Page 122: ...mbly and tighten attaching hardware in accordance with torque tables 8 Remove 4 10mm retaining nuts at top of IGBT bus bar assy 9 Remove 6 retaining screws on upper portion of IGBT modules These screw...

Page 123: ...e No disassembly should be attempted with power applied Remove power to drive and wait at least 40 minutes to let drive capacitors fully discharge Only a competent technician should carry out service...

Page 124: ...e Interface card PCA2 Interface card mounting screw Power card PCA3 6 Remove current scaling card from power card by pushing in retaining clips on standoffs KEEP THIS SCALING CARD TO REINSTALL ON ANY...

Page 125: ...ghten mounting screws to 20 in lbs 2 25 Nm 7 6 Soft Charge Card 1 Disconnect MK1 MK2 MK3 and MK4 2 Remove 4 mounting screws T25 from standoffs 3 Remove soft charge card Note insulation sheet below sof...

Page 126: ...er cap bank assy retaining nut Step 4 Figure 7 5 Upper and Lower Capacitor Bank Assemblies Gate drive card Lower capacitor bank assy 7 7 2 Lower Capacitor Bank 1 Remove soft charge card in accordance...

Page 127: ...late as follows a Loosen connection nut 17 mm between fuse and disconnect b Remove 4 mounting screws T40 from disconnect Figure 7 6 InputTerminal Mounting Plate Assy with RFI option Input terminals St...

Page 128: ...nut 8 mm on soft charge resistor 4 Remove bottom retaining nut 8 mm on soft charge resistor 5 Lift bottom of soft charge resistor and remove resistor by sliding down Reinstall in reverse order of thi...

Page 129: ...side of bus bars 2 on each bus bar CONTINUED NEXT PAGE 7 10 SCR and Diode Modules 1 Remove lower DC capacitor bank in accordance with procedure 2 Remove input terminal plate in accordance with procedu...

Page 130: ...us bar not shown c Remove load share bus bar Load sharing option retaining stud Step 8 Positive output bus bar BB42 Step 9 9 Remove both positive and negative SCR output bus bars by removing 6 connect...

Page 131: ...input phase there is one SCR module and one diode module The SCR is on the left diode on the right as seen facing upright unit There are three pair Only the SCR module has a connection pin for the ga...

Page 132: ...ar 4 Note which cable is attached to current sensor Ensure that correct cable is attached upon reassembly Unplug cable from current sensor being removed 5 Remove the 2 retaining nuts size varies with...

Page 133: ...BT over fan bus bars to 3 current sensor bus bars 3 Remove retaining nut 17 mm connecting each of three IGBT over fan bus bars to three IGBT output bus bars 4 Disconnect in line Molex connector in fan...

Page 134: ...ar out 4 If terminal block is attached to input terminal plate not shown remove retaining screw T40 attaching terminal block insulation otherwise go to step 5 5 If terminal block is not attached to th...

Page 135: ...able stud upon reassembly Remove wiring from studs Figure 7 12 IGBT Modules 1 of 4 5 Remove wire retaining nut 8 mm from SCR output bus bars One from DC bus bar and one from DC bus bar 6 Note color co...

Page 136: ...step 9 If unit is equipped with load sharing load share minus bus bar must be removed as follows a Remove 2 retaining nuts 13 mm connecting load share bus bar to the SCR output bus bar b Remove retai...

Page 137: ...one for each of three phases 13 Remove retaining nut 17 mm or T50 Torx screw depending on unit type connecting IGBT over fan bus bar to current sensor bus bar Output bus bar Retaining screw Step 11 R...

Page 138: ...etaining screws T30 connecting IGBT Ind bus bar IGBT Cap bus bar BB47 Retaining screw Step 15 Snubber capacitor assembly to Brake IGBT Note that there are 2 screws per Brake IGBT module 21 Remove 4 re...

Page 139: ...t provides protection for troubleshooting gate drive signals and other important control signals within the drive than having the DC bus disabled The cable is connected between the soft charge card an...

Page 140: ...an 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 anoth...

Page 141: ...Card to turn fans on and off 0VDC ON command 5VDC OFF command 7 INRUSH Control Card signal Signal from Control Card to start gating SCR front end 5VDC SCRs disabled 0VDC SCRs enabled 8 RL1 Control Car...

Page 142: ...on high 17 FAN_ON Pulse train to gate SCR s for fan voltage control In sync with line freq 7 trigger pulses at 3Khz 5VDC fans off 4 3VDC fans on 18 HI_LOW Control signal from Power Card Signal to swi...

Page 143: ...5 TP30 26 GUN_T IGBT gate signal buffered U phase negative Signal originates on Control Card 2v div 100us div Run 10Hz 2 2 2 5 VDC Equal on all phases TP25 TP30 27 GVP_T IGBT gate signal buffered V ph...

Page 144: ...t Meter 29 GWP_T IGBT gate signal buffered W phase positive Signal originates on Control Card 2v div 100us div Run 10Hz 2 2 2 5 VDC Equal on all phases TP25 TP30 30 GWN_T IGBT gate signal buffered W p...

Page 145: ...tion terminal block connector PCA1 MK101 613X6359 SPARE CC CONNECTOR 9 POS Controll card 9 position terminal block connector PCA1 175Z1158 SPARE CRADLE LCP LCP cradle PCA1 175Z1064 SPARE CONTROL CARD...

Page 146: ...LT6272 VLT6352 VLT6402 VLT8052 VLT8062 VLT8072 VLT8102 VLT8122 VLT8152 VLT8202 VLT8252 VLT8302 VLT8352 VLT8402 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1...

Page 147: ...TROL PCA 30PIN VLT5122 5303 Cables between control card and interface card CBL 3 176F8360 SPARE CABLE INTF PCA 30PIN VLT5122 5302 Cable between interface card and power card CBL 4 176F8361 SPARE CABLE...

Page 148: ...76F8410 SPARE BB STAND OFF PKG10 VLT5202 5302 Bus bar mounting standoff Package of 10 Enclosure Fabrications 176F8429 SPARE FAB IP20 COVER TOP KIT VLT5122 5302 176F8418 SPARE FAB ENCL BOT IP21 VLT5122...

Page 149: ...500A 1600V E1 Frame SCRs fasteners and thermal pad Note does not include Diode 1 per phase D1 2 3 176F8559 Spare Diode Kit 600A 1600V E1 Frame Diode fasteners and thermal pad Note does not include SCR...

Page 150: ...rd to current sensors CBL 9 176F8570 SPARE Cable Softchg RST Prime E1 Frame AC voltage from softcharge to power card CBL12 176F8571 SPARE Cable Fan 5352T5 IP00 Wire harness for all the AC fans on IP00...

Page 151: ...Spare BB Assy IGBT Ind E1 Frame DC Bus Sandwich Connects to the IGBT inputs 1 per drive BB 47 176F8601 Spare BB Assy IGBT Cap E1 Frame Connects the Capacitor Bank to the IGBT inputs 1 per phase BB 48...

Page 152: ......

Page 153: ...02 MK106 MK100 MK105 MK109 EUP2 GUP2 CUP2 GLO2 ELO2 EUP3 GUP3 CUP3 GLO3 ELO3 HF SWITCH RFI SWITCH HF SWITCH RFI SWITCH HS NTC 18 PULSE NTC FU1 FU2 FU3 1 2 1 2 TMP_P TMP_N RFI HF SWITCH ON 1 2 PCA1 TH1...

Page 154: ...0 RFI SWITCH GUN EUN 2 1 A B 1 2 3 CBL15 A C MK550 MK350 MK450 MK650 GUP GUP EUP 3 1 2 GVN EVN 3 1 2 GVN 3 GVP EVP 1 3 2 GVP GWN EWN 1 3 2 GWN RFI SW 2 1 3 4 PRE TEST 6 5 MK111 MK105 DC MK400 DC FK101...

Page 155: ...50 MK750 MK103 U MK102 MK106 MK100 MK105 MK109 EUP2 GUP2 CUP2 GLO2 ELO2 EUP3 GUP3 CUP3 GLO3 ELO3 HF SWITCH HF SWITCH HS NTC 18 PULSE NTC FU1 FU2 FU3 1 2 1 2 TMP_P TMP_N RFI HF SWITCH ON 1 2 PCA1 TH1 C...

Page 156: ...GUN MK101 VDD RL2 MK250 GUN EUN 2 1 A B 1 2 3 A C MK550 MK350 MK450 MK650 GUP GUP EUP 3 1 2 GVN EVN 3 1 2 GVN 3 GVP EVP 1 3 2 GVP GWN EWN 1 3 2 GWN RFI SW 2 1 3 4 PRE TEST 6 5 MK111 MK105 DC MK400 DC...

Page 157: ...K GUN GUP GUP 1 6 2 U GUN 7 PCA5 CBL17 MK106 MK109 MK100 MK103 MK104 TMP TMP 2 1 3 NTC CBL19 CBL18 MK105 15 1 RFI FAN 1 2 6 GND VDD FANO 9 13 12 10 SENS CUR HF SW IU IW MK102 CURRENT SENSORS IV 5 VNEG...

Page 158: ...BP BRN CBL16 MK102 MK750 MK850 GWP EWP 1 3 2 GWP GBP BRN 2 1 3 BRK GUN GUP GUP 1 6 2 U GUN 7 PCA5 CBL17 MK106 MK109 MK100 MK103 MK104 TMP TMP 2 1 3 NTC CBL19 CBL18 MK105 15 1 RFI FAN 1 2 6 GND VDD FAN...

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