Table Of Contents. Quick Links. Table of Contents. Find the Danfoss VLT at our website:. Previous Page. Next Page. The software version number can be seen from parameter Check that all voltage inputs have been disconnected and that the necessary time has passed before repair work is com- menced. Page 10 Terminal nos. Control card, 24 V DC supply Terminal nos.
Page 12 15 W - 50 W 50 W for start-up, 20 msec. Page 13 Max. For type of fuse see section Fuses. American Wire Gauge. Measured using 30 m screened motor cables at rated load and rated frequency. Page 17 4. Always comply with national and local regulations on min. Aluminum cables with cross-section above 0. Page 18 4. Weight without shipping container.
Connection stud: M8 Brake: M6. Page 21 4. Page 22 4. Page 23 5. Page 24 4. Page 25 4. Connection bolt power supply, motor and load sharing: M10 compression lug , 2xM8 box lug , M8 brake MG. For type of fuses, see section Fuses. Measured using ft [30 m] shielded motor cables at rated load and rated frequency.
Page 28 4. Page 29 4. Page 30 4. Page 31 5. Page 32 4. Page 33 5. Page 34 4. Page 35 4. Page Fuses No. Page 37 Not following the recommendation may result in unnecessary damage of the drive in case of malfunction. YY for further information. Mounting frame for 1 resistor narrow slim bookstyle U Mounting frame for 2 resistors narrow slim bookstyle U MG. Page 39 1. Order 2 pcs. Connect in parallel. Resistors selected for second cycle. See Instruction MI.
Page 40 Mounting frame for 2 resistors narrow slim bookstyle U Mounting frame for 2 resistors broad wide bookstyle U For V and V please contact Danfoss. Page 41 Resistors must be ordered from another See instruction MI. Page 42 Please note that the matching of the typical Danfoss frequency converter and filter is pre-calculated based on V and assuming typical motor load 4 or 2 pole motor : VLT series is based on a max.
Page 43 Please note that the matching of the typical Danfoss frequency converter and filter is pre-calculated based on V and assuming typical motor load. The pre- calculated filter current may be varying from the input current ratings of VLT as stated in the respective operating instructions, as these numbers are based on different operating conditions.
Page Dimensions - - V - - V ab: Minimum space above enclosure' be: Minimum space below enclosure 1 With disconnect, add 44 mm. Page Installation Installation of VLT All frequency converters must be installed in a way that ensures proper cooling. Cooling All Bookstyle and Compact units require a minimum space above and below the enclosure.
Page 48 IP 54 filter mats must be changed when they are dirty. Once the protective cover has been removed, the ac- tual EMC-correct installation can start. See drawings in the section, EMC correct installation. Open RFI switch is only allowed at factory set switching frequencies.
Adjustable frequency drives are able to control several motors connected in parallel. If the motors are to have different rpm values, the motors must have different rated rpm values. Function 88, 89 Load sharing MG. If the drive is supplied by the DC bus loadsharing , the in- ternal fans are not supplied with AC power. In this case they must be supplied with an external AC supply. Where the VLT frequency 68, 69 converter is connected to a bus, switches 2 and 3 switches 1- 4 must be closed on the first and the MG.
On the remaining VLT frequency con- verters, switches 2 and 3 must be open. Page 70 55 and adjust minimum and maximum values in pa- mA V rameters , and or 54 and 55 and adjust minimum and maximum values in parameters and Page Connection Examples [29] [29] [29] [29] [29] 1 If this function is selected for terminal 29, the same function for terminal 17 will not be valid, even if it has been selected to be active.
The control panel is detachable and can - as an alter- native - be installed up to 3 meters away from the adjustable frequency drive, e. Page Control Panel - Leds If the keys for local control have been se- lected as active, they will remain active both when the frequency has been set for Local Control and for Remote Control via parameter , although with the excep- MG.
Page 76 2 bles in line 1 bles in line 1 The table below gives the units linked to the variables in the first and second line of the display. Page Quick Setup The Menu mode is started by pressing the [MENU] changing the selected parameter, following which the key, which produces the following read-out on the dis- underlining in line 4 will flash on the display.
This parameter initializes all except: Operating data NOTE Settings for serial communication and fault logs are reset. Page Programming The set value is saved in the case of a voltage drop- out, see parameter Page 84 must be programmed after copying. Page 85 without resonance dampening multiplied by a factor scaling set in parameter Page 86 Shift between local and The reading can be switched off.
Page 87 This key is used when parameter has been set for Remote control [0] or Local [1]. Description of choice: Select the readout line.
Page 91 Page 92 reference to the 87 Hz application. Page 93 The rated motor speed n is used i. Page 95 Too low setting may lead to a reduced torque on the motor shaft. Page 96 Slip compensation is calculated automatically, i. Page 98 0. The output voltage will corre- 0. TIME Value: 0 - 10 sec.
Description of choice: Select the desired time. Page Special motor characteristics, activated in parameter , use the unit selected in parameter Page Switching from ramp 1 to ramp 2 is effected via a signal on digital input terminal 16, 17, 29, 32 or Page Value: Page See fig.
Page or Description of choice: Set the desired value. Page If Disable is selected, no alarm is given if a motor phase is missing. Page Parameters - Inputs And Outputs 1 If this function is selected for terminal 29, the same function for terminal 17 will not be valid, even if it has been selected to be active.
Page It must be noted that when the frequency loop. Page Description of choice: Terminal 17, input See parameter Page Terminal 53, min.
Page Value: Value: 0. Page , the function selected in parameter will be activated. Description of choice: Set the desired time. Page EXT. Page Page p, a pulse output signal propor- tional to the output frequency in the range Hz. Page Torque control, speed feedback pa- to be programmed for Coasting stop, in- rameter Page In this parameter the function can be activated if the encoder signal is disconnected from terminal 32 or Page Set the desired threshold level. Page Special Functions Select Overvoltage control [2] if the overvoltage control function is required in all cases - also if stop is pressed.
Page par. Page 4. Page and and for feedback in parameters and Page This enables obtaining a pure D-link at low frequencies and a constant D-link at higher frequencies. Only a competent technician should carry out the service. After the AC line is disconnected wait at least 15 minutes before touching any of the components. When repairs or inspection is made the AC line must be disconnected. During operation and programming of the parameters the motor may start without warning.
Activate the STOP key when changing data. These models are available in Chassis, Nema 1 or Nema 12 enclosures. The SB and EB units contain all logic and hardware necessary to connect an external resistor to provide dynamic braking. The typical service transaction in this case would be to exchange the entire unit. Servicing for the larger models can be performed by replacing defective modules.
It is recommended, due to the physical design, that the unit is removed from the installation or panel and placed on a suitable workbench prior to disassembly of the unit. These two screws are protected against loss. Tip: If the control card is equipped with an options card, the latter is mounted on the back of the aluminium carrier. Four strip leads make the connection over the FK1 A-D plug connector to the control card. Detach the external connecting leads to this options card at the options card before removing the carrier.
The control card as a spare part is supplied without LCP, aluminium carrier and Eproms. The converter can also operate without the LCP. Do not press the slides on the right of the dis- play piece marked here. Warning Risk of breakage!
The control card as a spare part is supplied without LCP, aluminium carrier, and Eproms. Printed control board disassembled: The illustration on the right shows the control card as a spare part with Eproms inserted.
The software version can be read off the Eproms stickers. Pay attention to this when changing Eproms. Detailed view, Eproms and option connections: You can see the four plug connectors for connecting option cards on the left near the two Eproms.
The strip leads inserted are contacted by pressing the clamping devices on the plug connectors. Please make sure they are mounted properly.
The heart of the control card is a micropro- controllers. In addition, a separate PROM The control card provides two voltage supplies for use contains the parameter sets which characterize the from the customer terminal strip. The use with speed reference circuitry. A custom through a third non customer accessible supply. VVCplus provides a such as: synchronizing control, special communication variable frequency and voltage to the motor in such a options or custom operating software.
The dynamic response of the system is such that it changes to meet the changing requirements of the motor. Programming is accomplished through the use of nine of the fourteen keys available on the keypad. The additional five keys provide local control and display monitoring functions. The backlit LCD Liquid Crystal Display has a total of four alpha-numeric lines providing the user with menu selection, unit status and fault diagnostic information.
In addition, the LCP can be removed during the ope- ration to prevent undesired program changes. With the addition of a remote mounting kit, the LCP can be mounted in a remote location of up to three meters away. A series of customer accessible terminals are provided for the input such commands as: Run, Stop, Forward, Reverse and Speed reference. Terminals are also provided to supply output signals to peripheral devices for the purpose of monitoring the control.
This is accom- plished on the Power Card. All communication be- tween the control logic and the rest of the unit passes through the Power Card. This communication includes: DC bus voltage monitoring, line voltage monitoring, output current monitoring, temperature sensing, inrush control and the gate drive firing sig- nals.
All logic and interface circuitry is powered by the SMPS. This enables operation of the logic circuitry without the power section being energized. Circuitry for controlling the cooling fan power auto transformer is also provided on the Power Card.
In units with Dynamic Brake options, the logic and fi- ring circuitry for the brake operation are also contained on the Power Card. In addition to passing the communication pertaining to output current to the control logic, much of the fault processing of output short circuit and ground fault conditions is done on the Power Card. At the point that any of these conditions are considered critical, the gate drive signals are immediately shut-off and an alarm signal is sent to the control logic for displaying the fault infor- mation.
The relay is Form C, meaning it has one normally open contact and one normally closed contact on a single throw. The contacts of the relay are rated for a maximum load of V AC at 2 Amps.
The DC coil is a single unit with two coils wound on a common core. One coil is placed in the positive side of the bus and the other in the negative. The DC coil serves to aid in the reduction of line harmonics. It is necessary to have one switch for each half phase or a total of six. They serve their greatest purpose during the high and fast rising currents experienced during ground faults or short circuits on the output.
The Motor coil is a single assembly with three coils wound on a common core. When the replacement card is powered initially, it automatically starts in the "Service Mode". In this mode there are 11 parameters which must be set according to the VLT being serviced.
Once the correct value is selected, pressing the "OK" key enters the value and goes to the next parameter. See the Service mode table for the correct settings. Bookmark not defined. Inrush after load sharing. Lists the menu parameter after a power-up only the first time with a spare part power card. If the settings of Motor Voltage parameter the wiring to the motor.
The VLT detects ground faults or Stator Reactance parameter are incorrect, the by monitoring all three phases of output and looking result can be excessive current draw by the motor. The instrument normally to ensure that they have not been changed or tampe- used for this purpose is a Megohmmeter or red with. Many times these resistance readings are taken with a common Instantaneous overcurrent trips are caused by the Ohmmeter, which is actually incapable of detecting current rising so fast on the output that the unit any shorts other than those that are virtually direct.
A cannot respond. One example of this situation is in Megger has the capability of supplying higher applications where the unit is running at speed and voltages, typically volts or more, which enables an output contactor is closed between the unit and the Megger to detect breakdowns in insulation or the motor. At the point the contactor is closed, the higher resistance shorts which cannot be picked up motor is effectively seen as a short circuit to the unit. When using a During this time the unit will attempt to gain control of megger, it is necessary to disconnect the motor leads the motor by employing current limits.
If the current li- from the output to the VLT. The wiring and connections are captured in the test. Solid, dry wiring connections normally result in a reading of infinity. A second example of instantaneous overcurrent is that experienced in applications with windmilling Since the VLT monitors output current to detect loads.
When the unit is started it must first drive the VLT could also be the cause of a ground fault. Tests fan to zero speed and then begin the acceleration can be made on this circuitry to isolate the possibilities. Consult the factory for additional mit function cannot control the process. The result is assistance. Short circuit trips are Regenerative energy is created when the load easily diagnosed by removing the motor leads from overhauls the motor.
This means that the motor is the unit and performing a phase-to-phase resistance being forced by the inertia of the load to rotate at the test on the motor leads. This resistance read in ohms speed greater than the command speed.
When will normally be quite low so it is important to have the overhauling occurs, the motor acts as a generator and ohmmeter set on its lowest resistance scale to avoid the voltage generated is returned to the DC capacitor mis-interpreting the readings observed. Consult your local representative decelerating ramps. However, even an unloaded mo- or the factoy for assistance in selecting the tor ramped down fast enough can cause regeneration appropriate Dynamic Brake option and dynamic to occur.
In some installations the input three phase power is feed from a transformer with a Delta secondary Since the unit can absorb approximately 15 percent of configuration. This voltage, exceeds the upper voltage limit, the unit normally only occurs in smaller units, typically Hp. If the returned energy is occuring during ramp down to In this event, the RFI filter capacitors must be stop or to lower speed , the unit will automatically disconnected from ground.
In more severe instances, the ramp may even Instruction manual for location of this switch. To prevent a trip from occuring, one solution is to lengthen the decelerating ramp. In very high inertia applications where a short decelerating time is required an SB or EB unit may be needed.
The Dynamic Brake function combines a power IGBT, the electronics for controlling it and a resistor bank of sufficient wattage to dissipate the unwanted energy. When the voltage level exceeds permissible limits, the IGBT is switched on and the excess DC Bus voltage is dissipated in the resistor bank.
With the diagnostic information available in the unit, an idea 1. First and foremost respect the voltages can easily be formulated as to which direction to look produced by the drive. Always verify the to find the cause of the problem. Also remember that some One can determine with this information whether the points in the drive are referenced to the negative problem is, for instance, in the motor wiring or if it is a bus and are at bus potential even though you defective brake resistor, etc.
The absence of any may not expect it. Even the absence of a 2. Never power up a unit which has had power fault message can indicate the direction to look for a removed and is suspected of being faulty. If a problem. If, for instance, the relay that closes to pro- short circuit exists within the unit, applying vide a run command to the drive is not functioning, power is likely to result in further damage. The there will be no fault condition sensed by the drive. It safe approach is to conduct the Static Test merely has not received a run command.
The static tests check all high volt- age components for short circuits. The tests are When troubleshooting, it is important to remember relatively simple to make and can save money that the control logic can only respond to the and downtime in the long run.
The possibility exists that due to a failure in control card, the commands do not 3. The safest method of conducting tests on the reach the C. For this reason it is drive is with the motor disconnected. In this way necessary to isolate the fault to the control a faulty component that was overlooked or the commands, programming or the drive itself. The unfortunate slip of a test probe will generally control commands shall be checked first.
This result in a unit trip instead of further damage. Following the replacements of parts, test run the drive. Start the unit at zero speed and slowly ramp the speed up Never assume that a signal is present because it is until the speed is at least above 40 Hz.
Monitor supposed to be. A meter should be used to confirm the phase output voltage on all three motor the presence of signals at the drive terminals. If balanced, the unit is Secondly, the programming of the drive should be ready to be tested on a motor.
If not, further confirmed to insure that the terminals used are set to investigation is necessary. Each digital and analog input terminal can be programmed to respond in very 5. Never attempt to defeat fault protection devices different ways. If there is a concern whether the within the drive. This will only result in unwanted remote controls are functioning correctly it is possible component damage and may result in personal to take control of the drive at the keypad to confirm injury as well.
A word of caution here: prior to taking control of the unit at the keypad, insure that all 6. Always use factory approved replacement parts. In many cases safety interlocks are certain specifications.
Incorrect parts may effect installed which can only be activated through the use performance and result in further damage to the of the normal control start. Read the instruction and service manuals. A thorough understanding of the unit is the best approach. If ever in doubt consult the factory or an authorized repair center for assistance. For instance, incorrect settings of one or more of the motor parameters can result in poor performance of the mo- tor drawing excess current, even causing the unit to trip when there is no real fault condition.
As there must be a command for the control card to respond, there may also be situations where the control card displays unknown information or that the performance be affected in an unknown manner, such as speed instability.
In these cases the first thought may be to replace the control card. However, this type of erroneous operation is usually due to electrical noise injected into control signal wiring. Although the control card has been designed to reject such interference, noise of sufficient amplitude can, in fact, affect the performance of the control card. In these situations it is necessary to investigate the wiring practices used.
For example, the control wiring should never be run in parallel with higher voltage wiring, including power, motor, and brake resistor leads. Shielded cable should also be used if the control wiring is to be run long distances.
Termination of the shield should be done according to the installation manual. In the event that one or more of the customer supplied line fuses blow, it is not recommended to replace the fuse and reapply power without further investigation. Blown line fuses usually indicate a pro- blem in the power section of the drive.
The Static Test Procedures as outlined in this manual should be per- formed to check for any shorted power components. Adjust set- ting. Contact Danfoss if the new set- ting does not make the motor runs evenly. Disconnect all control signals wires on the control card. Remove control plugs. Does that remove the fault? Perhaps the 24 V supply has short circuited. Verify that they are approximately 1. Is the DC Bus voltage within range?
Does 15 the problem disappear? Rectifier, and DC Bus Does the problem disappear? Does the pro- blem disappear?
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