Danfoss VLT 3032 Manuel utilisateur

Page

Introduction 2

Safety 2

Description of Operation 5

Sequence of Operation 9

Status Messages 11

Warning Messages 12

Alarm Messages 13

Troubleshooting Tips 17

Flow Charts 18

Symptom/Cause Charts 21

Testing the Soft Charge Circuit 23

Testing the Input Rectifiers 25

Testing the Inverter Section 26

Testing the Heatsink Temperature Sensor 27

Testing for Output Phase Imbalance 27

Testing Gate Drive Firing Circuits 28

Testing Input Rectifiers 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 Input Rectifiers 33

Current Limit Trips 35

Unstable Motor Operation 35

Ground Fault Trips 37

Overcurrent Trips 37

Overvoltage Trips 38

Overtemperature Trips 39

Additional Fault Codes I

Spare Parts List II

Block Diagram VLT 3032 III

Block Diagram VLT 3042 IV

Block Diagram VLT 3052 V

Table of Contents

Section Three Dynamic

Test Procedures

Section Three Static

Test Procedures

Section Two

Section One

Section Four

Section Five

Appendix

INTRODUCTION

The purpose of this manual is to provide technical information and

instructions that will enable the user to identify faults and affect repairs

onDanfossseries3000AdjustableFrequencyDrives,VLT3032through

VLT 3052, 230 Volt models.

Themanualhas been divided into fivesections. Thefirst section covers

the description and sequence of operations. Section two covers fault

messages and provides troubleshooting 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 the various components. Section five

discusses application-specific information.

Electrostatic discharge. Many electronic components are sensitive to

staticelectricity. Voltages so lowthat they cannotbe felt, seenor heard

canreduce the life, affectperformance, or completely destroysensitive

electronic components.

When performing service, proper ESD equipment should be used to

prevent possible damage from occurring.

ESD SAFETY

SAFETY

WARNING:

FOR YOUR SAFETY:

The Adjustable Frequency Drive (AFD) contains dangerous voltages

whenconnectedtothe line voltage. Only acompetenttechnicianshould

carry out the service.

1) DO NOT touch the electrical parts of the AFD when the AC line is

connected.AftertheACline is disconnected wait at least 15minutes

before touching any of the components.

2) When repairs or inspection is made the AC line must be

disconnected.

3) The STOP key on the control panel does not disconnect the AC

line.

4) During operation and programming of the parameters the motor

may start without warning.ActivatetheSTOPkeywhenchanging

data.

SECTION ONE

Refer to the overall schematic in the Appendix.

It is not the intention of this manual to enter into a detailed description

of the unit's operation. Moreover, it is intended to provide the reader

withageneral view oftheunit's main assemblies. Withthisinformation,

the repair technician should have a better understanding of the unit's

operation and therefore aid in the troubleshooting process.

The VLT is divided primarily into three sections commonly referred to

as: logic, power, and interface.

The control card itself primarily makes up the logic section. The heart

of the control card is a microprocessor which controls and supervises

all functions of the unit's operation. In addition, a separate PROM

contains the parameter sets which characterize the unit and provide

the user with the definable data enabling the unit to be adjusted to

meet the customer's specific application. This definable data is then

stored in an EEPROM which provides security during power-down and

alsoallowsflexibility for future changesasneeded. Acustom integrated

circuit generates the PWM waveform which is then sent on to the

interface board for distribution to the individual gate drive circuits.

DESCRIPTION OF

OPERATION

LOGIC SECTION

Also, part of the 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 operator/programmer with menu

selection, unit status and fault diagnostic information.

Programming is accomplished through the use of four

of the eight keys available on the keyboard. The

additionalfourkeysprovideLocalStart,Stop,Forward/

Reverse and Jog.

A series of customer terminals are provided for the

input of remote commands such as: Run, Stop and

Speed Reference. Terminals are also provided to

supply outputs to peripheral devices for the purpose

of monitoring and control. Two programmable relay

outputsare also available to interfacetheunitwithother

devices.

In addition, the control card is capable of

communicating via a serial link with outside devices

suchas a personalcomputer ora programmable logic

controller.

The control card provides two voltages for use from

the customer terminal strip. The 24VDC is used

primarily to control functions such as: Start, Stop and

Forward/Reverse. The 24VDC is provided from a

separate section of the unit's power supply and is

delivered to the control card from the interface board

via the two conductor ribbon cable.

MICROPROCESSOR

ADRESS

DATA

RAM EPROM

EEPROM

VVC

CONTROL

POWER

FEEDBACK

ANALOG

INPUTS

ANALOG

OUTPUTS

DIGITAL

INPUTS

DIGITAL

CHANNEL

KEYBOARD

DISPLAY

RELAY

LOGIC SECTION

(continued) A 10VDC supply is also available for use as a speed reference when

connected to an appropriate potentiometer. These two voltage

referencesare limited in the amount of available current they can provide

(seespecifications in InstructionManual). Attempting to power devices

whichdrawcurrentsin excess of that availablemayresultinan eventual

failure of the power supply. In addition, if the supply is loaded too

heavily, sufficient voltage will not be available to activate the control

inputs.

Duringthe troubleshootingprocess it is important toremember thatthe

control card can only carry out instructions as it has been commanded.

Of course, it is possible that as a result of a failure the control card may

fail to respond to commands. For this reason lies the necessity to

isolate the fault to the control commands, the control program or the

control card itself. If, for example, the unit does not run, but yet an

obvious reason is not apparent, check for proper control signals. Has

a run command been provided on the correct terminal; and if so, has

thatterminalbeen designated as suchintheprogramming of the control

card. In addition, be sure to verify that commands are being received

by testing for the presence of voltage on the appropriate terminals.

Never assume the signal is present because it is suppose to be. If

ever in doubt of whether the remote controls are functioning properly, it

is possible to take local control of the unit to verify if the control card is

operational. Aword of caution here: prior to taking local control, insure

all other equipment associated with the drive is prepared to operate.

Inmany cases, safety interlocks areinstalledwhichcanonlybeactivated

through the use of a normal remote control start. In the same sense

thatthecontrolcardcanonlyrespondtocommands,comesthesituation

that the control card makes a response without the presence of an

actual command. By the term response, it is not meant to infer that the

control card initiates such actions as Run or Stop, but rather suggests

thatthe control card displays unknowndataoritsperformanceisaffected

as in what might be speed instability. In these cases, the first instinct

may be to replace the control card; however, in most instances, this

type of erroneous operation is usually due to electrical noise being

injected onto the remote control signal wiring. Although the control

card has been designed to reject such interference, noise levels of

sufficient amplitude can, in fact, affect the performance of the control

card.

Asmentioned,sufficientlevels of electricalnoise can cause suchthings

asspeedfluctuationsasaresultofinterferencewiththespeedreference

or with the operation of the microprocessor. In these situations it is

necessary to investigate the wiring practices of the installation. For

example,arethecontrolsignalwiresrunningin parallel with other higher

voltage signals such as the input or output power wiring? As wires are

passedin close proximity to oneanother, voltagesare induced through

capacitiveor inductive coupling. Thistype ofproblem can becorrected

by rerouting the wiring or through the use of shielded cable. When

employingtheuse of shielded cable,itisimportant to properly terminate

the drain wire. The drain wire is terminated only at the control card end

of the wire. Specific terminals are designated for this purpose. The

opposite end of the shielded cable drain wire is then cut back and

taped off to prevent it from coming in contact with ground or acting as

an antenna.

LOGIC TO POWER

INTERFACE The logic to power interface isolates the high voltage components of

the power section from the low voltage signals of the logic. This is

accomplishedbyuseoftheinterfaceboard. Allcommunicationbetween

the control logic and the rest of the unit passes through the interface

board. Thiscommunication includes: feedbackfromthecurrentsensors,

input from the heatsink temperature sensor, line voltage monitoring,

DC Bus voltage monitoring, control of the fans , control of the input

thyristor rectifiers and control of the gate drive firing signals. Also on

the interface board is the power supply which provides the unit with

low voltage power such as 24VDC, 16VDC, 13VDC and 5VDC. The

power supply is a Switch Mode Power Supply (SMPS). The switch

mode type supply is used due to its efficiency and linearity. Another

benefit of the switch mode 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.

Duringthe troubleshooting processit is important todetermine whether

the interface board is receiving or sending the signal that appears to

be at fault. For example, the loss of a gate-drive signal is a waveform

generated by the interface board and conversely a heatsink over-

temperature fault is a result of the interface board receiving an input

from the heatsink temperature sensor. If the signal is of the later type

(received), it is then necessary to isolate the fault to either the sending

deviceorthe interface board. Itisgenerally assumed thatacomponent

within the unit is usually at fault; and although this may in fact be the

case, it is critical to check all possibilities to avoid costly errors and

lengthy downtime. In any case, the interface board is a relatively quick

andeasy assembly to exchange; andsoifitissuspect,aquickexchange

will prove the assumption.

POWER SECTION The power section is made up of the SCR/Diode modules (input

rectifiers), the soft charge circuit, the DC capacitor bank, the gate drive

and snubber cards and the IGBT power devices. Also located in the

power section are the DC Bus coil, the motor coils and, although not

typicallyconsidered part ofthe powersection, the outputphase current

sensors.

During the troubleshooting process, extreme care is required when

probing into the power section components. The DC Bus, when fully

charged, can be as high as 350VDC. Although this voltage begins to

decreaseupon theremoval ofinput power, it takes up to approximately

fifteen minutes to fully discharge the DC capacitor bank. Located on

theinterface board isthe Bus Charged Indicator. The red LED isvisible

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. Afault in the power section will usually result in at least one of

the incoming line fuses being blown. If one or more line fuses have

blown, itis not recommended to replacethemandreapplypowerwithout

further investigation. In a case such as this, it would be suggested to

conduct the tests listed under StaticTest Procedures in SectionThree.

These tests will result in a thorough check of all the components

operating in the power section. In addition, following the identification

and replacement of power section components, it is recommended to

disconnect the motor wires prior to reapplying power. This precaution

opens the path for short circuit currents through the motor in the case

that all faulty components have not been replaced.

3Ø

INVERTER

DC BUSRECTIFIER

SIMPLFIED PWM POWER SECTION

SEQUENCE OF

OPERATION

When input power is first applied, the SCR/Diode modules (input

rectifiers) are not gated so the incoming line voltage is rectified by the

softchargerectifier (BR1). As the DCBuscapacitors charge, the inrush

current is limited by the series soft charge resistors (R2 and R3).

Followingatimedelay of approximately one second,theinterfaceboard

monitorsthe DC Bus voltage and,providingithasreachedanacceptable

level, begins sending gate pulses to the SCR/Diode Modules. Once

the SCR's have been gated on, they remain in this state and the SCR/

Diode modules act as a normal rectifier. This scenario will only be

interrupted if the DC Bus fails to charge. This can be caused by

insufficient line voltage, a fault in the Power Section, a fault in the soft

charge circuit, and also by an open connection at PINS 1 and 2 of

MK15. The SCR Disable input at MK15 is provided as a means to

disable the SCR/Diode modules in the case of an external failure such

as in the Dynamic Brake option. Note that although the SCR/Diode

modulesmay be disabled,line voltageis still appliedto the unitthrough

the soft charge circuit.

Providing the charging process 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 indicate the unit is ready for operation.

Following a run command and a speed reference, the control card

delivers the PWM signals (one for each phase) to the interface board.

The interface board in turn receives these three signals and creates

the six individual gate drive pulses. The gate drive pulses are sent to

the respective gate drive circuits located on the gate drive card. From

here the output power devices (IGBTS) are switched on and off to

develop the PWM waveform which is ultimately delivered to the motor.

As the unit operates, the interface board monitors the status of the

units operating condition. Currents in excess of limits, temperatures

being exceeded, and voltages out of specification will result in the

interface board responding with a fault and sending the appropriate

fault message to the control card. When a fault occurs, the interface

board will indicate the condition via a series of LED's. The control card

will also display a fault message, and in virtually all cases trip the unit

off line. Section 2 of this manual describes the fault LED's and

messages and provides direction in determining the cause and the

solution for the fault condition.

SECTION TWO

FAULT INDICATORS

AND MESSAGES

STATUS MESSAGES

A variety of messages are displayed by the control card. Some of

these indicate the operational status of the unit while others provide

warnings of an impending fault. In addition, there are the alarm

messages which indicate that the unit's operation has stopped due to

a fault condition. In this section we will deal with only those messages

which interrupt the unit's operation. Acomplete list of status messages

can be found in the Instruction Manual. Along with the control card

message, the interface board contains several Light Emitting Diodes

(LED's) which aid in the identification of the fault 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 time delay after which the unit will trip.

REF FAULT

This message will flash in the display should any live zero signal be

operatingoutside of its range. Forexample, 4-20ma hasbeenselected

asthe speed reference. Shouldthe currentloop be broken,the display

will flash "REF FAULT". Parameters 414 and 415 may be used to

select the unit's response to this condition.

NO 24 VOLT

This message will flash if the 24 volt power supply is missing or out of

tolerance. The 24 volt supply is used only for the customer's remote

connections.

NO MOTOR

Thismessage will flashif Motor Check hasbeen activated inparameter

313, terminal 27 is enabled and no motor is detected.

Ce manuel convient aux modèles suivants

Table des matières

Autres manuels Danfoss Entraînement CC

Danfoss

Danfoss RAVV Manuel utilisateur

Danfoss

Danfoss VLT CDS 803 Manuel utilisateur

Danfoss

Danfoss vlt fcd 302 Manuel utilisateur

Danfoss

Danfoss VLT AQUA Drive FC 200 Manuel utilisateur

Danfoss

Danfoss VLT AQUA Drive FC 202 Manuel utilisateur

Danfoss

Danfoss VLT Manuel utilisateur

Danfoss

Danfoss VLT Micro Drive FC 51 Series Mode d'emploi

Danfoss

Danfoss VLT HVAC Drive FC 102 Manuel utilisateur

Danfoss

Danfoss VLT Automation VT Drive FC 322 Manuel utilisateur

Danfoss

Danfoss FC 302 Manuel utilisateur

Danfoss

Danfoss VLT AutomationDrive FC 300 Manuel utilisateur

Danfoss

Danfoss VLT 5000 Series Manuel utilisateur

Danfoss

Danfoss VLT CDS 803 Manuel utilisateur

Danfoss

Danfoss 176F3167 Guide de l'utilisateur

Danfoss

Danfoss VLT AQUA Drive FC 200 Manuel utilisateur

Danfoss

Danfoss VLT AutomationDrive FC 300 Manuel utilisateur

Danfoss

Danfoss VLT AQUA Drive FC 202 Manuel utilisateur

Danfoss

Danfoss VLT FC 100 Manuel utilisateur

Danfoss

Danfoss VLT AQUA Drive FC 200 Manuel utilisateur

Danfoss

Danfoss VLT AutomationDrive FC 360 Guide de l'utilisateur

Danfoss

Danfoss VLT HVAC Drive FC 102 Manuel utilisateur

Danfoss

Danfoss VLT Midi Drive FC 280 Manuel utilisateur

Danfoss

Danfoss FC 300 Manuel utilisateur

Danfoss

Danfoss FC 300 Mode d'emploi

Manuels Entraînement CC populaires d'autres marques

Vincent Associates

Vincent Associates UNIBLITZ ED12DSS Manuel utilisateur

EKSMA OPTICS

EKSMA OPTICS DQ-100-4 Manuel de la liste des pièces

Chamberlain Garog

Chamberlain Garog D Series Manuel utilisateur

Parker

Parker PDS Series Manuel utilisateur

Festo

Festo DGC G Series Guide de configuration

Binks

Binks QS-5012-1-CE Manuel utilisateur

ABB

ABB ACQ580-01 Series Manuel d'installation

YASKAWA

YASKAWA CANopen SI-S3 Manuel utilisateur

GE D20A6 Manuel utilisateur

Unex

Unex MC-D-250-1000-050W-TW Manuel utilisateur

Geckodrive

Geckodrive G213V Manuel utilisateur

ABB

ABB RSYC-01 Manuel utilisateur

Rockwell Automation

Rockwell Automation PowerFlex 700S Manuel du propriétaire

WEG

WEG DeviceNet CFW500 Manuel utilisateur

Siemens

Siemens SINAMICS G Fiche technique

Siemens

Siemens SINAMICS SM150 6SL3815-7NP41-0AA1 Mode d'emploi

SOMFY

SOMFY JR RU 30 Manuel utilisateur

Beckhoff

Beckhoff AX8911 Manuel de l'opérateur