Ervice

VLT® 5000 Series Service Instructions
Table of Contents
Introduction ......................................................................................................................... 1
Product Overview ................................................................................................................ 1
Warnings and Cautions ...................................................................................................... 1
Section I Drive Build Up

Description of Operation .............................................................................................. 2
Logic Section ............................................................................................................... 2
Logic to Power Interface .............................................................................................. 3
Power Section .............................................................................................................. 3
Sequence of Operation ................................................................................................ 4
Soft Charge Section ............................................................................................ 4
Intermediate Section ........................................................................................... 5
Inverter Section ................................................................................................... 6
Brake Option ........................................................................................................ 7
Cooling Fans........................................................................................................ 8
Fan Control .......................................................................................................... 8
Specific Power Card Connectors ......................................................................... 8
Load Sharing ....................................................................................................... 8
Section II Diagnostics
Warnings and Alarms .................................................................................................. 9
Fault Flow Chart ......................................................................................................... 15
Symptom and Cause Chart ........................................................................................ 18
Applications ................................................................................................................ 20
Section III Static Checks

Rectifier (Input) Section .............................................................................................. 25
Inverter (Output) Section ............................................................................................ 27
Intermediate (DC Bus) Section ................................................................................... 28
Brake Circuit ............................................................................................................... 28
Motor .......................................................................................................................... 28
Heatsink Temperature Sensor .................................................................................... 29
Inductor Temperature Sensor ..................................................................................... 29
Section IV Dynamic Checks

Output Voltage and Current Balance .......................................................................... 35
Input SCR/Diode Module ............................................................................................ 36
IGBT Gate Drive Signals ............................................................................................ 36
Current Feedback ....................................................................................................... 37
Section V Disassembly
5060-5100 Nema 12 / IP54
Control Card ............................................................................................................... 39
Capacitor Bank ........................................................................................................... 39
Power Card ................................................................................................................. 40
Current Sensor ........................................................................................................... 40
IGBT ........................................................................................................................... 41
Brake IGBT ................................................................................................................. 41
Testing Brake Snubber Board ............................................................................. 41
SCR/Diode Module ..................................................................................................... 42
5060-5100 Chassis / Nema 1 / IP20

Control Card ............................................................................................................... 43
Capacitor Bank ........................................................................................................... 44
Power Card ................................................................................................................. 44
Current Sensor ........................................................................................................... 44
IGBT ........................................................................................................................... 45
Brake IGBT ................................................................................................................. 45
SCR/Diode Module ..................................................................................................... 46
5125-5150 Nema 12 / IP54

Control Card ............................................................................................................... 47
Capacitor Bank ........................................................................................................... 47
Power Card ................................................................................................................. 48
Current Sensor ........................................................................................................... 48
IGBT ........................................................................................................................... 49
Brake IGBT ................................................................................................................. 49
SCR/Diode Module ..................................................................................................... 50
5125-5150 Chassis / Nema 1/ IP20

Control Card ............................................................................................................... 51
Capacitor Bank ........................................................................................................... 52
Power Card ................................................................................................................. 52
Current Sensor ........................................................................................................... 52
IGBT ........................................................................................................................... 53
Brake IGBT ................................................................................................................. 53
SCR/Diode Module ..................................................................................................... 54
5200-5250 Nema 12/ IP54

Control Card ............................................................................................................... 55
Capacitor Bank ........................................................................................................... 56
Power Card ................................................................................................................. 57
IGBT ........................................................................................................................... 57
Brake IGBT ................................................................................................................. 58
SCR/Diode Module ..................................................................................................... 59
Current Sensor ........................................................................................................... 59
5200-5250 Chassis / Nema 1/ IP20

Control Card ............................................................................................................... 60
Capacitor Bank ........................................................................................................... 61
Power Card ................................................................................................................. 62
IGBT ........................................................................................................................... 62
Brake IGBT ................................................................................................................. 63
SCR/Diode Module ..................................................................................................... 64
Current Sensor ........................................................................................................... 64
Block Diagrams
VLT 5060 Process ...................................................................................................... 65
VLT 6075/5075 Aqua .................................................................................................. 66
VLT 5075 Process ...................................................................................................... 67
VLT 6100/5100 Aqua .................................................................................................. 68
VLT 5100 Process ...................................................................................................... 69
VLT 6125/5125 Aqua .................................................................................................. 70
VLT 5125 Process ...................................................................................................... 71
VLT 6150/5150 Aqua .................................................................................................. 72
VLT 5151 Process ...................................................................................................... 73
VLT 6175/5200 Aqua .................................................................................................. 74
VLT 5200 Process ...................................................................................................... 75
VLT 6225/5250 Aqua .................................................................................................. 76
VLT 5250 Process ...................................................................................................... 77
VLT 6275/5300 Aqua .................................................................................................. 78
Torque Specifications
SCR/Diode Module ..................................................................................................... 79
IGBT ........................................................................................................................... 80
Test Equipment
Signal Test Board ........................................................................................................ 81
SCR Gate Drive Test Cable ........................................................................................ 92
Power Card DC Supply Source .................................................................................. 94
Spare Parts List .......................................................................................................... 98
INTRODUCTION WARNING:
The purpose of this manual is to provide technical information The VFD contains dangerous voltages when connected to
and instructions that will enable the user to identify faults the line voltage. Only a competent technician should carry
and perform repairs on the VLT 5000, VLT 5000 AQUA and out the service.
the VLT 6000 series Adjustable Fequency Drives models
VLT 5060-5250, VLT 5075-5300 AQUA and VLT 6075-6275. FOR YOUR SAFETY:
This manual has been divided into five sections. The first 1) DO NOT touch the electrical parts of the AFD when the
section covers the description and sequence of operations. AC line is connected. After the AC line is disconnected wait
Section two covers fault messages, troubleshooting charts, at least 15 minutes before touching any of the components.
and application specific information. Section and four
2) When repair or inspection is made the AC line must be
describe the various tests and methods used to evaluate the
disconnected.
drives condition. Section five covers the removal and
replacement of the various components. 3) The STOP key on the control panel does not disconnect
the AC line.
VLT® PRODUCT OVERVIEW
4) During operation and programming of the parameters the
The VLT 5000, 5000 AQUA and the 6000 Series inverters motor may start without warning. Activate the STOP key
are available in power sizes from 1Hp - 600Hp in the 380 - when changing data.
460V range and 1 - 60Hp in the 200V range. This manual
covers the VLT 5000 60-250Hp, VLT 5000 AQUA 75-300Hp
and VLT 6000 75-300Hp all in the 380-460V range.
CAUTION:
These models are available in Chassis, NEMA 1 or NEMA
12 enclosures. Electrostatic discharge (ESD)- Many electronic components
are sensitive to static electricity. Voltages so low that they
The VLT 5000 series units are programmable for either cannot be felt, seen or heard can reduce the life, affect
constant or variable torque operation. There are three hardware performance, or completely destroy sensitive electronic
configurations available for all sizes of drives, they are: components.
Standard (ST), Standard with Brake (SB), and Extended with
Brake (EB).
The SB and EB units contain all logic and hardware
necessary to connect an external resistor to provide dynamic
braking.
The EB configuration offers connection terminals for load
sharing capabilities between multiple VLT 5000 Series units,
plus input terminals for a remote 24 VDC power supply to
maintain control logic during removal of the AC input power.
The VLT 5000 AQUA is designed primarily for the water
industry for control of variable torque pumping applications.
It is available with the same enclosure possibilities as its
5000 series counterpart but without the choice of hardware
configurations. The VLT 5000 AQUA has specific advantages
over the VLT 5000 series in variable torque applications and
can only be used for such loads.
The VLT 6000 series is designed primarily for the HVAC
industry for control of variable torque fan and pump
applications. It is available with the same enclosure
possibilities as its 5000 series counterparts but has specific
advantages over the VLT 5000 series in HVAC applications
and can only be used on variable torque loads.
When performing service, proper ESD equipment should be

used to prevent possible damage from occurring.
1
SECTION ONE
The PWM waveform is created using an improved control
DESCRIPTION OF OPERATION scheme called VVCplus, which is a further development of
the VVC (Voltage Vector Control) system used in the VLT
It is not the intention of this manual to enter into a detailed 3000 Series. VVCplus provides a variable frequency and
description of the unit's operation. Moreover, it is intended voltage to the motor in such a way that it matches the
to provide the reader with a general view of the unit's main requirements of the motor. The dynamic response of the
assemblies. With this information, the repair technician system is such that it changes to meet the changing
should have a better understanding of the unit's operation requirements of the load.
and therefore aid in the troubleshooting process.
Also, part of the logic section is the LCP (Local Control Panel).
The VLT 5060-5250, VLT 5075-5300 AQUA and the VLT 6075- This is a removable keypad/display mounted on the front of
6275 series units are very similar in construction and design. the unit. The keypad or the MMI (Man/Machine Interface)
For the purpose of troubleshooting two main differences exist: provides the interface between the digital logic and the human
First, the control card and LCP for the 5060-5250 differ from programmer.
that of the VLT 5000 AQUA and 6000 series. Second, the
rating of the power section is sized differently in a constant In addition, The LCP can be removed during operation to
torque drive versus a variable torque drive. For example the prevent undesired program changes. The final shared program
power section of a VLT 5075 AQUA and VLT 6075 would be of the drive can be also uploaded into the EEPROM at the
similar to that of a VLT 5000 series 60HP (VLT5060). To LCP. This function can be helpful in programming multiple
simplify the discussion we will always refer to the drives or if needed to restore a program to a repaired unit.
constant torque drives (VLT 5060-5250). With the addition of a remote mounting kit, the LCP can be
mounted in a remote location of up to three meters away.
The VLT is divided primarily into three sections commonly
referred to as: logic, power, and interface. A series of customer accessible terminals are provided for
the input of such commands as: Run, Stop, Forward, Reverse
and Speed reference. Terminals are also provided to supply
LOGIC SECTION output signals to peripheral devices for the purpose of
monitoring and control.
The control card, Figure 1, contains the majority of the logic
In addition, the control card is capable of communicating
section. The heart of the control card is a microprocessor
via serial link with outside devices such as personal
which controls and supervises all functions of the unit's
computers or programmable logic controllers.
operation. In addition, separate PROM's contain parameter
sets which characterize the unit and provide the user with The control card provides two voltage supplies for use from
the definable data enabling the unit to be adjusted to meet the customer terminal strip. The 24VDC is used for switching
the customers specific application requirements. This data is functions such as: Start, Stop and Forward/Reverse. The
then stored in an EEPROM which provides security during 24VDC supply is capable of supplying 200ma of power, part
power-down and also allows flexibility for future changes as of which may be used to power external devices such as
needed. A custom integrated circuit generates the PWM encoders. A 10VDC supply rated at 17ma is also available
waveform which is then sent on to the interface circuitry for use with speed reference circuitry.
located on the Power Card.
The analog and digital output signals are powered through a
third non customer accessible supply.
All three power supplies are isolated from one another to
eliminate ground loop problems in the control input circuitry.
A single pole low voltage relay is provided on the control
card for the purpose of activating external devices based on
the status of the drive. The contacts of the control card relay
are rated for 50VAC at 1Amp. However, in UL applications
Figure 1
the rating is limited to 30VDC at 1Amp.
Control Card
Provisions have been made on the control card assembly
for the addition of option modules such as: synchronizing
control, serial communication options, additional relays,
cascade controller option or custom operating software.
2
LOGIC TO POWER INTERFACE
The Logic to Power Interface isolates the high voltage In conjunction with the SCR/Diode modules the soft charge
components of the power section from the low voltage signals circuit limits the inrush current when power is first applied
of the Logic Section. This is accomplished on the Power Card. and the DC bus capacitors are charging. This is accomplished
All communication between the control logic and the rest of by the SCR's in the modules being held off while charging
the unit passes through the Power Card. This communication current passes through the soft charge resistors, thereby
includes: DC bus voltage monitoring, line voltage monitoring, limiting the current. The DC bus circuitry smooths the
output current monitoring, temperature sensing, inrush control pulsating DC voltage created by the conversion from the AC
and the gate drive firing signals. supply. The number of DC bus capacitors will vary depending
on the drive size with the VLT 5250 having the most at 20.
The Power Card also contains a Switch Mode Power Supply The DC coil is a single unit with two coils wound on a common
(SMPS) which provides the unit with 24VDC, +14VDC, – core. One coil is placed in the positive side of the bus and
14VDC and 5VDC operating supplies. All logic and interface the other in the negative. The DC coil serves to aid in the
circuitry is powered by the SMPS. Normally the SMPS is fed reduction of line harmonics.
by the DC bus voltage, however, in the Extended version of
the drive, it is possible to power it with an external 24VDC The inverter section is made up of six IGBT's commonly
power supply. This enables operation of the logic circuitry referred to as switches. It is necessary to have one switch
without the power section being energized. Circuitry for for each half phase or a total of six. These six IGBT's may
controlling the cooling fan power auto transformer is also be found incorporated into various packages. In vary small
provided on the Power Card. units, typically under 10Hp, all six IGBT's will be in a single
module called six-packs. In the VLT 5060 - 5100 two switches
In units with Dynamic Brake options, the logic and firing are contained in a single module, called a dual pack, for a
circuitry for the brake operation are also contained on the total of three and in VLT 5125 - 5250 each switch is in a
Power Card. single module for a total of six modules in all.
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. A custom IC called an Application Specific
Integrated Circuit (ASIC) continually monitors output current
conditions with respect to: peak amplitude, rate of rise (di/dt)
and leakage current (ground fault). 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 information.
Also located on the Power Card is a second relay for
monitoring the status of the VLT 5000. The relay is Form C, Figure 2
meaning it has one normally open contact and one normally Typical Power Section
closed contact on a single throw. The contacts of the relay
are rated for a maximum load of 240VAC at 2Amps.
The Motor Coils serve to provide a limit to the rate of current

POWER SECTION rise (di/dt) during peak demands of the output. They serve
their greatest purpose during the high and fast rising currents
The Power Section, Figure 2, contains the Soft Charge experienced during ground faults or short circuits on the
Circuitry, SCR/Diode modules (rectifier), the DC Bus Filter output. The Motor Coil is a single assembly with three coils
Circuitry, often referred to as the Intermediate Circuit, Motor wound on a common core.
Coils, and the Output IGBT (Isolated Gate Bipolar Transistor)
modules which make up the Inverter Section.
3
SEQUENCE OF OPERATION (Also refer to the full block diagrams in the appendix)
Soft Charge Section

When input power is first applied, Figure 3, it enters the VLT
through the RFI option if the unit is so equipped. The SCR's
in the combined SCR/Diode modules are not gated so current
travels down and through the soft charge fuses to the soft
charge rectifier, BR1. Three phase power is also branched
off and sent to the Power Card. It only serves the power card
a reference of the main supply voltage.
During the charging process the top diodes of the soft charge
rectifier conduct and rectify during the positive half cycle.
The diodes in the main rectifier conduct during the negative
half cycle. The DC voltage is applied to the bus capacitors
through F4, the soft charge resistor fuse, and R1, the soft
charge resistor. In units of 150Hp and up, two soft charge
resistors and fuses are placed in parallel.
The purpose of charging the DC bus through these resistors
is to limit the high inrush current that would otherwise be
present.
A thermal switch, SW1, is mounted on each soft charge
resistor. Should the resistor overheat due to repeated power
cycling or a problem in the DC bus circuit the thermal switch
will close causing F4, the soft charge resistor fuse, to blow
thereby opening the charging circuit.
The Metal Oxide Varistor (MOV), MOV1, serves to protect
the soft charge rectifier from transients. R2 and C1 in
conjunction with the lower diodes in the soft charge rectifier
serve as a snubber network for the SCR/Diode modules.
The additional resistor, R13, provides a return path for current
flow should the thermal switch, SW1, close.
Once the charging process is completed and the DC bus
reaches an acceptable level the Power Card will begin
sending gate signals to the SCR/Diode modules, these gate
signals will fire at every zero crossing of the input voltage
waveform. The SCR/Diode module will then act as a typical
uncontrolled rectifier. Phase angle firing of the SCR's is not
used in this configuration. The SCR's are on full at each
R13
firing.
At this point the DC bus capacitors are fully charged. The
DC bus voltage will be approximately 650VDC when the VLT Figure 3
is connected to a nominal 460VAC supply line. This voltage Soft Charge Circuit
is now present in the inverter section. This same DC voltage
is also delivered to the Power Card to operate the Switch
Mode Power Supply (SMPS) which in turn provides all the
low voltage supplies used by the Power and Control Cards.
4
Intermediate Section
Moving left to right in the drawing we come to the Intermediate
Section, Figure 4. Shown first is the DC Bus Inductor, next
is the RFI DC Bus Filter if the unit is equipped with the RFI
Option. Notice the jumper to earth ground, this jumper is
attached to the Printed Circuit Card which is physically placed
at the bottom of the DC Capacitor Bank. This drawing
represents a VLT 5075. So, six DC bus capacitors are present,
connected in a series parallel configuration. Resistors R4 and
R5 are balance resistors for the capacitor bank and also serve
to bleed off the bus voltage after input power is removed.
Due to the size of the capacitor bank in relation to the resistors
it can take up to 15 minutes before the voltage on the
capacitors is fully discharged.
(Also refer to the full block diagrams in the appendix Pages 65-78)
Figure 4
Intermediate Section
5
Inverter Section
As we reach the Inverter Section, Figure 5. Six IGBT's are

packaged in three modules. Gate signals are delivered from
the Control Card, through the Power Card and to the gates of
the IGBT's. The series connection of each set of IGBT's is
delivered to the output, first passing through the output motor
coil and the current senors.
The current sensors are hall effect devices which monitor the
output current and deliver a proportional signal to the Power
Card. These current signals are used by the Control card to
determine proper waveform compensations based on load
conditions. They further serve to detect over current
conditions including ground faults and phase to phase shorts
on the output.
(Also refer to the full block diagrams in the appendix Pages 65-78)
Figure 5
Inverter Section
6
Once a run command and speed reference are present the load causing regenerative energy to be returned to the DC
IGBT's begin switching to create the output waveform, Figure bus.
6. Looking at the phase to phase voltage waveform with an
osilliscope. It can be seen that the Pulse Width Modulation The Brake IGBT gate signal originates on the Control Card
(PWM) principal creates a series of pulses which vary in and is delivered to the Brake IGBT via the Power Card.
width. Basically the pulses are narrower as zero crossing is Additionally the Power and Control Card monitor the Brake
neared and wider the farther you move away from zero IGBT and brake resistor connection for short circuits and
crossing. The resultant current waveform, as shown, overloads.
replicates a true AC sine wave.
Voltage
VOLTAGE WAVEFORM
CURRENT WAVEFORM
Current
Figure 6
Output voltage & current waveforms
This waveform as generated by the Danfoss VVCplus PWM
principle provides optimal performance and minimal losses
in the motor.
During normal operation the Power Card and Control Card
are monitoring various functions within the VLT. The current
sensors are providing current feedback information, the DC
bus voltage and AC line voltage are monitored as well as
the voltage delivered to the motor. A thermal sensor mounted
on the heatsink, Power Card and cap bank (N12 only-5125-
5250) provide temperature feedback.
BRAKE OPTION
The optional Brake is available only on SB and EB models.
The function of the Brake IGBT, Figure 7, is to switch an
externally mounted resistor bank across the DC bus to
remove excess DC voltage present on the bus capacitors. Figure 7
Excess DC bus voltage is generally a result of an overhauling Brake IGBT
7
COOLING FANS Connector MK15 provides access to Relay 01 which is

mounted on the Power Card. This relay provides a status of
Various fans are incorporated in the unit. All VLT 's in this size the VLT based on the programming of Parameter 323.
range are equipped with a heatsink fan. In Chassis and NEMA
1 units this fan is mounted on the top of the unit. In NEMA 12 A Signal Board is provided for accessing various signals which
units the fan is mounted below the heatsink in the bottom of could be useful in troubleshooting the VLT . An adapter card
the unit. The VLT 5125 - 5250 NEMA 12 units are also with test points is available for ease of connection. For a further
equipped with door fans. As the VLT 5060 - 5100 NEMA 12 description of the Signal Board outputs see Appendix III.
units are built without door fans they further incorporate
Only available on EB type units is connector MK4. This
capacitor bank fans mounted internally to the DC capacitor
connection allows for the input of an external 24VDC power
bank.
supply. When connected, a secondary SMPS is powered
All fans, except the capacitor bank fans which are 24VDC, which enables the Control Card functions to remain active
are powered from an auto transformer that provides 230VAC. even after the removal of the main supply. The VLT can be
On/Off and High/Low speed control of the 230VAC fans is run from this power supply however, the IGBT's will not be
provided in an effort to reduce overall acoustical noise and switched on during this mode.
extend the life of the fans.
LOAD SHARING
NOTE: By using the load sharing option of the drive the
FAN CONTROL function of the soft charge circuit is bypassed.
Regardless of heatsink temperature, the fans are started Only available on EB, VLT 5000 AQUA and VLT 6000 type
shortly after main input power is applied to the VLT. If the units are terminals +DC and –DC. These terminals provide
heatsink temperature is below 30°C the fans will turn off after access to the DC bus and are used for load sharing
a short interval. At a heatsink temperature of >45°C, the fans applications. Should these terminals be used as the main
will be switched on at low speed. This will equate to supply input to the VLT, provisions would be required for
approximately 165VAC applied to the fans. At a heatsink powering the 230VAC cooling fans.
temperature of >60°C, full voltage is applied to the fans to
The built in load sharing in the VLT gives the possibility to
obtain full speed. When the heatsink temperature returns to
connect more frequency converters over the DC-bus.
<55°C the fans return to low speed an if the heatsink
temperature should drop below 30°C, the fans will be switched The number of VLT's which can be connected together is in
off. principal infinite, but the VLT's which are connected must be
of the same voltage (200-240V or 380-500V).
Since the internal ambient temperature is maintained by one
or more 230VAC fans, the transition between low and high
speeds can also be made if the internal ambient rises,
regardless of heatsink temperature. The internal ambient
temperature sensor is located on the power card. If the
temperature detected rises to >65°C, the fans will switch to
high speed regardless of heatsink temperature. If the internal
ambient temperature returns to <50°C and the heatsink
temperature remains below 60°C, the fans will return to low
speed.
The fans will be switched to high speed should a heatsink
over temperature trip occur. Any other temperature trip;
internal ambient, output inductor or external disable will result
in the fans running at low speed. For further tests, Reference
Fan Test on page 29 or the Signal Board in Appendix III.
SPECIFIC POWER CARD CONNECTORS

Connector MK10 on the Power Card provides for the
connection of an external temperature switch. It is assumed
that such a switch could be used to monitor the temperature
of an external brake resistor. Should the switch change states
the VLT would trip on a thermal overload and the SCR's as
part of the SCR/Diode modules would be disabled.
8
SECTION TWO
The display flashes between normal state and warning. A
FAULT MESSAGES, WARNINGS, ALARMS warning comes up on the first and second line of the display.
See examples below:
A variety of warning and alarm messages may be displayed.
During the warning phase the VLT is operational. The VLT
may however be taking action at that time to reduce the
condition causing the warning. For example, if the warning
displayed were Torque Limit, the VLT would be reducing
speed to compensate for the over current condition. If the
condition is not corrected before the allotted time expires an
alarm condition would be activated. As listed below not all
warnings are associated with an alarm and not all alarms
are preceded by a warning. With some faults it will not be
automatic to move from a warning to an alarm, instead the
choice of a warning or alarm trip is determined by
programming the specific parameter associated with that ALARM MESSAGES
fault condition. The alarm comes up in lines 2 and 3 of the display, see the
example below:
In an Alarm State two reset conditions exist. If the display
shows TRIP (RESET), the alarm can be manually reset or
automatically reset if the Auto Restart Function is enabled.
If the display indicates TRIPLOCK (DISC> MAINS) then
main input power must be removed long enough for the
display to go blank and then reapplied. Following power up
the Triplock will change to TRIP (RESET) and allow for a
manual reset.
Also note that the Local Stop key and Reset key are one in
the same. By pressing the Stop/Rest key the fault is reset
and Local Stop is initiated. To run either local or remote the
Local Start key must be pressed.
WARNING 1
Under 10 Volts (10 VOLT LOW):
The 10VDC supply on terminal 50 of the control card is too
WARNINGS
low. This condition may be caused by overloading terminal
Warning and alarm messages vary depending on the 50 or a short circuit in the Speed Potentiometer or related
particular VLT model. The parameters that effect the warnings wiring. Max capacity of terminal 50 is 17 mA. The 10V DC
and alarms also vary and are noted in the fault descriptions. supply on terminal 50 is supplied from a 13 volt regulator
that supplies option boards and the LCP. If the 10V DC is
missing or low the most common link would be the control
card as the faulty part (after the external wiring was removed
and verified).
WARNING/ALARM 2
Live zero fault (LIVE ZERO ERROR):
The current signal on terminal 60 is less than 50% of the
value programmed in parameter 315, and parameters 317
and 318 have been programmed for the time out function to
be active. It is possible to choose between a warning only or
a warning and trip based on the selection of parameter 318.
Manual reset is possible once the fault is corrected.
9
WARNING/ALARM 3 WARNING /ALARM 10
No motor (NO MOTOR): Motor over temperature (MOTOR TIME):
The motor check function has been activated in parameter The unit's ETR function has calculated an over temperature
122. During stop conditions the motor check is performed. condition in the motor. This calculation is based on motor
This warning will appear if the VLT fails to detect a motor. current, speed and the length of time these conditions exist,
(Not applicable for the VLT 5000 AQUA/6000 series.) based on the settings of parameters 102 through 106. Based
on the selection in parameter 128 the unit will display a
WARNING/ALARM 4 warning or an alarm when the counter reaches 100%. Verify
Phase fault (AC LINE PHASE LOSS): parameters 102 - 106 are set correctly. Also use a clamp on
One phase of the input AC line is missing or extremely low, amp meter to check motor amperage. Manual reset is
or severe waveform distortion is present on the input line. possible after the ETR counter has counted to zero.
An alarm condition will automatically follow the warning. Trip
lock will require power to be cycled before reset. This alarm WARNING/ALARM 11
is derived from reading the AC ripple on the DC Bus. Motor thermistor (MOTOR THERMISTOR):
Measuring the input voltage and verifying the wave form may The motor thermistor function has been activated in parameter
be the first step to restoring proper operation of the drive. 128 and a thermistor is connected to either terminal 53 or 54
Refer to the application section in section II for more and programmed as such in parameter 308 or 311. Parameter
Information. 128 provides a choice of warning or alarm. This warning or
trip indicates the input to terminal 53 or 54 is more than 3K
WARNING 5 Ohms impedance between that terminal and terminal 50. It
Voltage warning high (DC LINK VOLTAGE HIGH): is also possible that the connection has been broken. Manual
The intermediate circuit voltage (DC) is above the upper reset is possible.
warning limit of 825VDC. The VLT is still operational. Refer to
the application section in section II for more Information. WARNING/ALARM 12
Torque limit (TORQUE LIMIT/CURRENT LIMIT):
WARNING 6 The torque requirement of the motor is higher than the value
Voltage warning low (DC LINK VOLTAGE LOW): set in parameter 221 for the VLT 5000 or 215 for the VLT
The intermediate circuit voltage (DC) is below the lower 5000 AQUA/6000(in motor operation) or parameter 222
warning limit of 435VDC. The VLT is still operational. (regenerative operation). The warning will be present until the
WARNING/ALARM 7 time programmed in parameter 409 for VLT 5000 or 412 for
Overvoltage (DC LINK OVERVOLT): the VLT 5000 AQUA/6000 expires. If the current exceeds
The intermediate circuit voltage (DC) is above the overvoltage the VLT continuous rating or motor rating and parameter 128
limit of 850VDC. The voltage detected will be displayed. It is set for ETR trip/thermistor, the drive will trip on either alarm
may be necessary to use dynamic braking. As an alternative 9 or 10. Manual reset is possible.
in the VLT 5000 the Over Voltage Control (OVC) scheme can WARNING/ALARM 13
be activated in parameter 400. For the VLT 5000 AQUA/6000 Over current (OVERCURRENT):
the OVC function is always active. The setting of parameters The peak output current limit of the unit has exceeded 165%
400 and 410 have no effect on this alarm. Manual reset is of the unit's rating. After 1.5 seconds the unit will trip. This
possible. Warns for 5 sec's trips after 25 sec. Refer to the fault may be caused by shock loading or fast accel ramps
application section in section II for more Information. with high inertia loads. Incorrect settings of various group 1
WARNING/ALARM 8 parameters may also be the cause. This fault results in a Trip
Under voltage (DC LINK UNDERVOLT): Locked condition. Refer to the application section in section
The intermediate circuit voltage (DC) is below the Under II for more Information.
voltage limit of 400VDC. The unit will trip after a set period of ALARM 14
time. On the VLT 5000 extended units with an external 24VDC Earth fault (EARTH FAULT):
supply, this message will be displayed as long as input power The unit has sensed output leakage current sufficient enough
is removed, however, the unit will not trip. The voltage level to determine that there is a ground fault in the motor or motor
detected will be displayed. Manual reset is possible. wiring. This fault results in a Trip Locked condition. Refer to
WARNING/ALARM 9 the application section in section II for more Information.
Inverter overload (INVERTER TIME): ALARM 15
The unit has been operating with the output current having been Switch mode fault (SWITCH MODE FAULT):
in the intermittent range (between 100% and 150%) for too long. The internal plus and/or minus 14VDC power supply voltage
A warning will be displayed when the ETR counter reaches 98%. is not within the specified range. This fault results in a Trip
When the counter reaches 100%, the drive will trip. The unit can Locked condition.
be programmed to display the ETR counter. Using a clamp on
amp meter verify current going to the motor. Manual reset is
only possible after the counter has gone below 90%.
10
ALARM 16 LOW P. 105 [1]

Short-circuiting (CURR.SHORT CIRCUIT): The value entered in parameter 105 is too small for the VLT
This indicates the existence of a phase to phase short circuit 5000. Correct the value. Note: the motor nameplate current,
condition in the motor wiring. This fault results in a Trip Locked and that value entered in parameter 105, must be greater
condition. Refer to over current section in the application than 35% of the nominal rating of the VLT in order to carry
section. out AMA.
WARNING/ALARM 17 ASYMMETRICAL IMPEDANCE [2]
Standard bus time out (STD BUS TIMEOUT): AMA has detected asymmetrical impedance in the windings
Indicates the serial communication with the VLT has failed of the motor connected. The motor may be defective.
and the time out function has been activated. The delay time
programmed determines how long the warning will be present MOTOR TOO BIG [3]
before a trip, provided "stop and trip" has been selected. The motor is too large for AMA to be carried out or the setting
Manual reset is possible. in parameter 102 is incorrect.
WARNING/ALARM 18 MOTOR TOO SMALL [4]

HPFB bus timeout (HPFB BUS TIMEOUT): The motor is too small for AMA to be carried out or the
Indicates the communication between a field bus option (such setting in parameter 102 is incorrect.
as DeviceNet) and the VLT has failed and the time out function TIME OUT [5]
has been activated in parameter 804. The delay time AMA has failed after attempting to tune for a period in excess
programmed in parameter 803 determines how long the of what should be normal. It is possible that the signal data
warning will be present before a trip, provided "stop and trip" being returned is noisy. It is possible to make several
has been selected in parameter 804. Manual reset is possible. attempts under these conditions and eventually get the unit
WARNING 19 to pass.
Fault in the EEprom on the power card INTERRUPTED BY USER [6]
(EE ERROR POWER CARD): The AMA function has been interrupted by the user.
A fault exists in the ability of the VLT to read and write
information to the power card EEPROM. The drive will operate INTERNAL FAULT [7]
normal and in most cases once power is cycled the warning A fault has occurred internal to the VLT. Contact the factory.
clears. If the problem halts operation replacement of power
LIMIT VALUE FAULT [8]
card may be needed.
The parameter values programmed for the motor are outside
WARNING 20 the typical characteristics of the VLT's internal motor table.
Fault in the EEprom on the control card AMA cannot be performed on this particular motor.
(EE ERROR CTRL CARD):
MOTOR ROTATES [9]
A fault exists in the ability of the VLT to read and write
The motor shaft rotated during the tuning process. Ensure
information to the control card EEPROM. The drive will operate
the load is not capable of rotating the shaft. AMA may be
normally and in most cases once the power is cycled the
started over.
warning clears. If the problem halts operation replacement
of control card may be needed. WARNING/ALARM 23
Fault during brake test (BRAKE TEST FAILED):
ALARM 21
When a unit with braking is powered-up and a stop command
Auto-optimization OK (AUTO MOTOR ADAPT OK):
is present, a brake test is performed automatically by the
The automatic motor tuning function has been completed
unit. If the result of this test indicates a fault condition in the
successfully. It is necessary to manually reset to resume
brake circuit and parameter 404 is set to warning, a warning
normal operation. (Not applicable for the VLT 5000 AQUA/
will be displayed. If Trip has been set in 404 an alarm will
6000.)
occur. Possible causes for this are: No brake resistor
ALARM: 22 connected, faulty connection to the brake resistor, defective
Auto-optimization not OK (AUTO MOT ADAPT FAIL): brake resistor or a defective brake IGBT. The unit will be
The automatic motor tuning function failed. The possible able to operate in this condition, however, the brake function
causes as shown in the display are listed below. The numbers will be inoperative. Manual reset is possible. (Not applicable
in brackets will be logged as the value in parameter 617. for the VLT 5000 AQUA/6000.)
CHECK P.103, 105 [0]
Parameter 102, 103 or 105 have incorrect settings. Correct
the setting and start AMA all over.
11
WARNING 25 LED 4:
Brake resistor fault (BRAKE RESISTOR FAULT): This LED will be lit when the connection at MK15 (external
The brake resistor or the connection is short circuited. The disable) has been activated. Based on the way MK15 is
unit will be able to operate in this condition, however, the wired this could mean the external input has closed or
brake function will be inoperative. Manual reset is possible. become open. As this input is closed or open, the temperature
(Not applicable for the VLT 5000 AQUA/6000.) displayed will typically be the default value of 139°C. This is
not the actual temperature that has been sensed.
WARNING 26
Brake resistor power 100% (BRK PWR WRN 100%): ALARM 30
The monitoring function has been activated in parameter Motor phase U missing (MISSING MOT. PHASE U):
403. The power transmitted to the brake resistor is monitored The unit has detected an open circuit in the U phase. This
over a 120 second period. The power is based on the values fault may be manually reset. Parameter 234 (VLT 5000 only)
entered in parameters 401 and 402. If the calculated power can disable the triping or missing motor phase.
being dissipated exceeds 100% a warning will occur based ALARM 31
on the choice in parameter 403. If warning is selected the Motor phase V missing (MISSING MOT. PHASE V):
warning will disappear when the dissipated power drops The unit has detected an open circuit in the V phase. This
below 80%. Manual reset is possible. (Not applicable for the fault may be manually reset. Parameter 234 (VLT 5000 only)
VLT 5000 AQUA/6000.) can disable the triping or missing motor phase.
WARNING 27 ALARM 32
Brake transistor fault (BRAKE IGBT FAULT): Motor phase W missing (MISSING MOT. PHASE W):
The brake transistor is shorted. As a result of the shorted The unit has detected an open circuit in the W phase. This
transistor substantial power may be transmitted to the brake fault may be manually reset. Parameter 234 (VLT 5000 only)
resistor. Disconnect main input power to the VLT. It may be can disable the triping or missing motor phase.
possible to run with the brake resistor disconnected but the
braking function will be inoperative. (Not applicable for the ALARM 33
VLT 5000 AQUA/6000.) Quick discharge not failure
(QUICK DISCHARGE NOT OK):
ALARM 29 This indicates that the Quick Discharge feature is not
Heat sink temperature too high functioning. Possible causes are: No 24V external power
(HEAT SINK OVER TEMP.): supply, brake resistors not connected properly. Sequence of
The heatsink temperature has exceeded 95°C. The possible operation not correct. This fault results in a Trip locked
causes are: defective cooling fan, blocked heat sink or air condition. This feature is available only with the VLT 5000
flow path, defective thermal sensor or possibly incorrect EB version.
mounting to a flush surface to ensure proper airflow across
the heatsink. This fault results in a Trip Locked condition. WARNING/ALARM 34
Additionally there are four LED's on the Power Card that are Profibus communication fault
associated with an Over Temperature alarm. Reference (PROFIBUS COMMUNICATION FAULT):
application section. The Profibus option is no longer communicating. In a warning
state this may indicate the cable has been disconnected or
LED 1: the master has stopped. In an alarm state it may indicate
This LED will be lit when the power card temperature sensor the option card is disturbed by noise or possibly defective.
has determined the VLT's internal ambient temperature to A trip can be manually reset.
be above 85°C. The sensor will automatically reset when the
temperature drops below 70°C. WARNING 35
Out of frequency range (OUT OF FREQ. RANGE):
LED 2: This warning will only be displayed when operating in Process
This LED will be lit when the power card temperature sensor Closed Loop and the output frequency of the VLT is above
has determined the VLT's internal ambient temperature to or below the limits programmed in parameters 201 and 202.
be below minus 20°C. The sensor will automatically reset Parameter 455 (VLT 5000 only) can be disabled to eliminate
when the temperature rises above minus 5°C. this warning.
LED 3: WARNING/ALARM 36
This LED will be lit when the thermal switch on the output Mains failure (MAINS FAILURE):
inductor or mounted on the left side of capacitor bank, The mains failure function has been activated in parameter
depending on age of drive, detects a temperature in excess 407. A choice of actions are available including whether or
of 135°C. The sensor will automatically reset. As this sensor not to trip . A trip can be manually reset. (Not applicable for
is a switch, the temperature displayed will typically be the the VLT 5000 AQUA/6000.)
default value of 139°C. This is not the actual temperature
that has been sensed.
12
ALARM 37 WARNING/ALARM 44
Inverter fault (INVERTER FAULT): ENCODER LOSS (ENCODER FAULT)
Indicates an IGBT or the power card is defective. This fault The encoder signal is interrupted from terminal 32 or 33.
results in a Trip Locked condition. Verify signals coming from Check the connections of encoder device.
the power card, also verify the gate to emitter resistance on
the IGBT for problems. The following warning/Alarms are only applicable to
WARNING 39 the VLT 5000 AQUA/6000.
CHECK Parameter 104, 106:
The settings in parameter 102, 104 or 106 are possibly WARNING: 62
incorrect. Check the setting and choose "Continue" or "Stop:. Output frequency high (FOUT>FHIGH)
If stop is selected AMA will have to be started over. The output frequency is higher than parameter 224
Warning: High frequency,fHIGH.
WARNING: 40
CHECK Parameter 103, 105:
WARNING?ALARM: 63
The settings in parameter 102, 103 or 105 are possibly wrong.
Output current low(I MOTOR<I HIGH)
Check the setting and choose "Continue" or "Stop". If stop
The output current is lower than parameter 221 Warning:
is selected AMA will have to be started over.
Low current, ILOW. Select the required function in parameter
WARNING 41 409 function in case of no load.
MOTOR TOO BIG:
The motor is too large for the VLT or the setting of parameter WARNING: 64
102 is incorrect. Check the motor and setting and choose Output current high (I MOTOR>I HIGH)
"Continue" or "Stop". If stop is selected AMA will have to be The output current is higher than parameter 222 Warning:
started over. High current, IHigh.
WARNING 42 WARNING: 65
MOTOR TOO SMALL: Feedback low (FEEDBACK<FDB LOW)
The motor is too small for the VLT or the setting of parameter The resulting feedback value is lower than parameter 227
102 is incorrect. Check the motor and setting and choose Warning: Low feedback, FBLOW.
"Continue" or "Stop". If stop is selected AMA will have to be
started over. WARNING: 66
ALARM 43 Feedback high (FEEDBACK>FDB HIGH)
Brake fault (BRAKE FAULT): The resulting feedback value is higher than parameter 228
A test of the brake function has failed. The possible causes Warning: High feedback, FBHIGH.
as shown in the display are listed below. The numbers in
brackets will be logged as the value in parameter 617. These WARNING: 67
failures result in a Trip Locked condition. (Not applicable for Remote reference low (REF.<REF LOW)
the VLT 5000 AQUA/6000.) The remote reference is lower than parameter 225
Warning: Low reference, REFLOW.
Brake check failed
(BRAKE CHECK FAILED) [0] WARNING: 68
During power up the brake test failed to find a resistor Remote reference high (REF.>REF HIGH)
connected. Verify proper connections have been made to The remote reference is higher than parameter 226
the VLT 5000. Warning: High reference, REFHIGH.
Brake resistor short-circuited
WARNING: 69
(BRAKE RESISTOR FAULT) [1]
Temperature auto derate (TEMP.AUTO DERATE)
During the brake test the VLT 5000 has found a short circuit
The heatsink temperature has exceeded the max value
at the brake terminals. Verify no shorts exist at the terminals
and the auto derating function (par. 411) is active.
and the brake resistor is the proper value for the VLT 5000.
Warning: Temp. auto derate.
Brake Transistor short-circuited
(BRAKE IGBT FAULT) [2] WARNING: 99
The brake transistor is shorted. As a result of the shorted Unknown fault (UNKNOWN ALARM)
transistor substantial power may be transmitted to the brake An unknown fault has occurred which the software is not
resistor. Disconnect main input power to the VLT 5000. It able to handle. Cycle power and or reinitialize the VLT to
may be possible to run with the brake resistor disconnected clear the fault. Possible replacement of control card is
but the braking function will be inoperative. needed.
13
GENERAL TROUBLESHOOTING TIPS
Prior to diving into a repair here a few tips if followed will make the job easier and may prevent unnecessary damage to good
components.
1. First and foremost respect the voltages produced by the drive. Always verify the presence of line voltage and bus
voltage before working on the unit. Also remember that some points in the drive are referenced to the negative
bus and are at bus potential even though you may not expect it.
2. Never power up a unit which has had power removed and is suspected of being faulty. If a short circuit exists
within the unit applying power is likely to result in further damage. The safe approach is to conduct the Static Test
Procedures starting in section three. The static tests check all high voltage components for short circuits. The tests are
relatively simple to make and can save money and downtime in the long run.
3. The safest method of conducting tests 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
failure.
4. Following the replacement of parts test run the unit with the motor disconnected. Start the unit at zero speed and
slowly ramp the speed up until the speed is at least above 40 Hz. Monitor the phase to phase output voltage on all
three motor terminals to check for balance. If balanced the unit is ready to be tested on a motor. If not, further
investigation is necessary.
5. Never attempt to defeat fault protection devices within the drive. This will only result in unwanted component
damage and may result in personal injury as well.
6. Always use factory approved replacement parts. The unit has been designed to operate within certain specifications.
Incorrect parts may effect the tolerance and result in further damage to the unit.
7. 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.
14
Also see "Applications"

''Applications''
Section Two Page 20
See "Testing the Inverter"
Section Three Page 27
See: 21
9)
See section "Fault

See Item 10
Page 16 Messages" Page 9-13
15
10) 11)
Symptom Have soft charge fuses F1,

F2, F3 blown?
No information in
13)
display.
NO YES If one or more fuses F1,
F2, F3 have blown test the
soft charge circuit. Page 25
12)
Disconnect all control

signal plugs on the control
card.
Does the fault Disappear?

15)
NO YES
This fault may be caused
by a short circuit in the
control signals.
14)
Check control, wiring for
17) Is the DC Bus voltage OK? proper connection,
Measure the DC Bus voltage voltages and grounds.
Check voltages on pin
at the +Bus and -Bus
20-12(24 volts DC) &
terminals at the top of the
55-50 (10 volts DC).
cap bank.
Are voltages present?
16)
Test the soft change circuit

YES NO YES NO and input rectifier. Page 25
19) 20)
Replace the Control Card.
Does the fault disappear? 18)
Check LCP with LCP
from other drive if
Replace the Power
possible. YES NO Card. Does the fault
disappear?
YES NO
Resume Consult
operation factory
Resume Consult
operation factory
16
21) 22) 25)
Symptom Start the VLT adjustable Replace the Control Card.

frequency drive by If this does not help, the
Motor stationary, info in pressing "Start" on the fault might be electrical
display but no fault keyboard. noise. Check whether the
message displayed. following precautions have
been taken:
• Have shielded cables
23)
been used?
Is the display frozen, i.e., • Are the shields correctly
the display cannot be terminated?
changed or is undefinable? • Is the unit properly
grounded to earth?
NO YES
24) 26)
Correct motor wiring
Is the motor connected
correctly? Insure motor overloads are
reset, output conductor
YES NO closed and wire terminal
connections are not loose
27)
CAUTION:
Attempt to run the VLT in 28)
local. See caution at left.
Prior to running In Local, Replace the Control card.
Make the following
insure all other
parameter settings:
equipment associated Does the motor run?
parameter 002 = Local
with the VLT is ready to
parameter 013 = LCP Ctrl/
function or has been NO YES
open loop
isolated.
parameter 003 = Freq. ref.
Consult Resume
Does the motor run? factory operation
YES NO 30)
Replace the Power
Card.
29)
Does the motor run?
Verify that the control
signals are connected to
NO YES
the correct terminals and
the appropriate parameter
settings have been
entered. Consult Resume
factory operation
17
SYMPTOM/CAUSE CHARTS
SYMPTOM/CAUSE charts are generally directed towards the more experienced technician. The intent of these charts
is to provide a range of possible causes for a specific symptom. In doing so, these charts provide a direction, but with
limited instruction.
SYMPTOM POSSIBLE CAUSES

1. Control Card Display Is Not Lit. Incorrect or missing input voltage
Incorrect or missing DC bus voltage
Remote control wiring loading the power supply
Defective Control/Power Card
Defective LCP
Defective or disconnected ribbon cables
2. Blown Input Line Fuses Shorted SCR/Diode module
Shorted IGBT
3. Blown Soft Charge Fuses Shorted soft charge rectifier
Shorted DC bus
Shorted brake IGBT
Open/ shorted softcharge resistor
Shorted fan transformer
4. Motor Operation Unstable (Speed Fluctuating) Incorrect settings of motor parameters
Load compensations set incorrectly
Slip Compensation set too high
Improper current feedback
PID Regulator or Auxiliary Reference mis-adjusted
Possible single phase motor
5. Motor Draws High Current But Cannot Start. (May appear Open winding in motor
to rock back and forth.)
Open connection to motor
One inverter phase missing. Test output phase balance.
Ramp up time to short
6. Motor Runs Unloaded But Stalls When Loaded. (Motor One half of one inverter phase missing. Test output phase
may run rough and VLT may trip.) balance.
Over magnetizing motor check motor parameters.
18
SYMPTOM/CAUSE CHARTS
SYMPTOM/CAUSE charts are generally directed towards the more experienced technician. The intent of these charts
is to provide a range of possible causes for a specific symptom. In doing so, these charts provide a direction, but with
limited instruction.
SYMPTOM POSSIBLE CAUSES
7. Unbalanced Input Phase Currents Input line voltage unbalanced

Note: Slight variations in phase currents is normal. Faulty connection on input wiring
Variations greater than 5% require investigation.
Fault in plant power transformer
Input SCR/Diode module faulty or not being gated.
8. Unbalanced Motor Phase Currents Open motor winding

Note: Slight variations in phase currents is normal. Faulty motor connection
Variations greater than 5% require investigation.
Fault in inverter section (see Symptom No. 6.)
Motor parameters
19
APPLICATIONS Parameters 108 and 109 as stated earlier are set by the
AMA function or should be left at their factory default value.
TORQUE LIMIT, CURRENT LIMIT, Never adjust these parameters to any random values even
OR UNSTABLE MOTOR OPERATION though it may seem to improve the operation. Such
adjustments may appear to improve operation under a single
set of circumstances but should the conditions change the
Excessive loading of the VLT may result in the unit displaying result may be unpredictable.
Torque Limit, Over current or possibly tripping on Torque Limit, Parameter 221 sets the level at which the VLT limits torque.
Over current, or Inverter Time. This is not a concern if the The factory setting is 160% and 110% for 5000 Aqua/6000
VLT has been properly sized for the application and and will vary up and down with the setting of motor power.
intermittent load conditions cause anticipated operation in For example, a VLT 5150 programmed to operate a smaller
Torque Limit or an occasional trip. Nuisance unexplained motor will yield a higher torque limit value than the same unit
occurrences may be the result of improperly setting specific programmed to operate an equivalent or larger size motor. It
parameters. The following parameters are critical to the VLT/ is important that this value not be set too low for the
Motor relationship: requirements of the application. In some cases it is desirable
Parameters 100 through 109 and the setting of parameters to have a torque limit set at a lesser value, lets say for example
221 and 409. 120%. This offers protection for the application in that the
VLT will limit the torque to that value. It may however be the
Parameters 100 and 101 configure the VLT for a specific mode case that during initial start up the load requires 130% torque.
of operation. Under these circumstances nuisance tripping may be the
Parameter 100 sets the VLT for open or closed loop operation result.
or torque mode operation. In a closed loop configuration it is
necessary that a feedback signal is received by the unit. In
turn the settings for the PID controller play a key role in the Parameter 409 works in conjunction with parameter 221. This
stable operation of the VLT. parameter allows you to select a time that the VLT will operate
in torque limit and then trip. The factory default value is set to
Parameter 101 sets the VLT for constant or variable torque off. A setting of Off does indeed mean that the VLT will not
operation. Based on the application it is imperative that the trip on torque limit but doesn't mean it will never trip from an
correct torque characteristic is selected. If for example the overload condition. Built into the VLT is the internal Inverter
load type was such that it was constant torque, such as a Thermal Protection circuit. This circuit monitors the output
conveyor, and variable torque was selected, the VLT may load on the inverter. If the load exceeds 100% of the VLT
have great difficulty starting the load if not at all. Consult the continuous rating the counter begins counting. If the load
factory if you are unsure of the torque characteristics of remains there long enough the counter will count to 100%
your application. and the VLT will trip on Inverter Time. No adjustments can be
made to alter this circuit however, the settings of the
Parameters 102 through 106 configure the VLT for the motor
parameters listed above can effect load current and result in
connected. With the VLT Series the accuracy of these
premature trips of this type. You can view the counter in the
parameters are of great importance. For the VLT to be effective
display.
and efficient in controlling the load the unit relies on this
information for making calculations that result in corrections
to the output waveform based on the changing demands of
the application.
Parameter 107 activates the Automatic Motor Adaptation
function. As the VLT queries the motor it sets various
parameters based on the findings. Two key parameter values
which are set by this function are Stator Resistance and
Stator Reactance, Parameters 108 and 109. If you are
experiencing unstable motor operation and have not
performed AMA, it should be done. Remember however, that
AMA can only be performed on a single motor application,
and then only within the programming range of the VLT.
Consult the instruction manual for more on this function.
20
EARTH FAULT TRIPS OVER CURRENT TRIPS

Trips occurring from ground faults are usually the result of The VLT detects over current conditions by monitoring the
short circuits to earth ground either in the motor or the wiring current output of all three phases. An over current condition
to the motor. The VLT detects ground faults by monitoring all exists when the current in an individual phase exceeds 165%
three phases of output current and looking for severe of the units maximum overload rating. At that point the IGBT's
imbalances in those currents. When a "Ground Fault" trip in that phase are turned off. Shortly after turning off, the IGBT's
occurs it is necessary to measure the resistance of the motor will once again be gated on as the current in that phase will
windings and wiring with respect to earth ground. The have dropped. This turning on and off of the IGBT's will
instrument normally used for this purpose is a Megohmmeter continue for up to 1.5 seconds after which time the VLT will
or commonly referred to as a "Megger". Many times these trip on Over current.
resistance readings are taken with a common Ohmmeter,
which is actually incapable of detecting any shorts other than Over current trips may occur as a result of attempting to start
those that are virtually direct. A Megger has the capability of a jammed load, energizing an output conductor while the
supplying higher voltages, typically 500 volts or more, which VLT is already running at a given speed, attempting to start
enables the Megger to detect breakdowns in insulation or a high inertia load with short acceleration ramps, attempting
higher resistance shorts which cannot be picked up through to start windmilling load, or a phase to phase short on the
the use of an Ohmmeter. When making resistance output of the VLT. It may also be the case that the over current
measurements to ground, it is necessary to disconnect the trip is a phantom occurrence caused by incorrect settings of
motor leads from the output of the VLT. The measurements motor parameters as was discussed earlier. Except for the
should then be taken at the point of connection to the VLT so latter all of these conditions are relatively simple to diagnose.
the motor and all associated wiring and connections are The VLT incorporates some features that can be used to
captured in the test. When reading the results of the Megger overcome some of the conditions mentioned. One such
test, the rule of thumb is any reading less than 500 Megohms feature is Flying Start. This feature is helpful in starting
should be suspect. Solid, dry wiring connections normally windmilling loads. An example of such a load is a fan that
result in a reading of infinity. while it is not powered it is being driven by airflow through
the duct work. As the VLT is started it begins ramping from
zero frequency. Since the load is not at zero the VLT must
As stated the VLT detects ground fault conditions by first brake the load to zero and then begin ramping from there.
monitoring the current through the hall effect current sensors This consumes large amounts of current, almost as what
on the output of the unit. The three signals from these sensors could be seen in applying a plug reverse to a motor to bring
is sent to power card and then summed together. When no it to a stop. By enabling the Flying Start function, when a run
earth current is flowing the sum of these three currents will command is given, the VLT searches the frequency range
be zero. A defective current sensor could then be the cause looking for the actual speed of the motor. Once found the
of an Earth Fault. If for example the signal from one sensor is VLT starts its ramp from that frequency and then carries the
missing the sum of the three currents would not equal zero load up or down to the commanded speed.
and an earth fault would occur. This is normally only seen
when the load current is significant since the current imbalance Solving over current trips due to fast acceleration ramps or
must be in excess of the maximum continuous rating of the closing a conductor on the output can be solved easily by
VLT. It could further be the case that the signal from the current adapting the ramp time and sequence of operation to within
sensor is present but offset from zero. The signals midpoint the limits of the VLT. This is not always possible as the methods
must be zero with the maximum peaks reaching the level of used to control the application are required to function in such
the + and – 14 volt sensor power supply. This offset and or a way. It may be the case that given the circumstances the
the lack of a signal can be observed on the signal board. See VLT is undersized for the application requirements. It may
the section on testing current feedback. also be possible to adjust the VLT to perform under these
circumstances. Running the AMA function should be the first
It is also possible that if an earth fault occurs when the motor step in optimizing the VLT to the motor. Following that, an
is under power the result may actually be an Overvoltage adjustment of the load compensations may give favorable
Trip. This is due to the fact that when the earth fault occurs results. If all else fails consult the Application Engineering group
the DC bus can increase rapidly to as much as 200 volts at Danfoss for further assistance.
over its nominal value. Also see the explanation on
Overvoltage Trips later in this section.
21
OVERVOLTAGE TRIPS Remember for the load to become regenerative it must be

running faster than the commanded speed. The same
This trip occurs when the DC bus voltage reaches a level of restriction on the amount of influence applies. The VLT will
approximately 840VDC. Prior to the trip the VLT will display only add 10% to the base speed before a trip occurs.
warnings of high voltage. Most times an over voltage condition Otherwise, in theory, the speed could continue to rise to levels
is due to fast deceleration ramps with respect to the inertia of that may be unsafe.
the load. As an attempt is made to decelerate the load the
inertia of the system will act to sustain the running speed.
Once the frequency of the motor drops below the running
speed the load begins overhauling the motor. At this point
MAINS PHASE LOSS TRIPS
the motor becomes a generator and starts returning energy The VLT actually monitors phase loss by monitoring the
to the VLT. This is called regenerative energy. This return amount of ripple voltage on the DC bus. The VLT uses this
voltage is rectified by the diodes in the IGBT modules and method because although ripple voltage on the DC bus is a
raises the DC bus. If the amount of returned voltage is more product of a phase loss, the main concern is ripple voltage
than the unit can consume the VLT will trip. causes overheating in the DC bus capacitors and the DC
coil. Left unchecked the lifetime of the capacitors and the
There are a few ways to overcome this situation. One method
DC coil would be drastically reduced.
is to increase the deceleration rate so it takes longer for the
VLT to decelerate to a new speed or come to a stop. A general As the voltage becomes unbalanced or a phase should
rule of thumb is that the drive can only decelerate the load disappear completely the ripple voltage will increase and the
slightly faster than it would take for the load to naturally coast VLT will trip. Other than the obvious missing phase voltage
to a stop. A second method is to allow the Overvoltage control increased bus ripple can be the result of line disturbances or line
circuit to take care of the deceleration ramp. When enabled imbalances. Imbalances or oscilations on the output voltages
in parameter 400 the over voltage control circuit will regulate or current will also simulate the Alarm 4 symptoms. Line
the deceleration ramp at a rate that maintains the DC bus at disturbances may be caused by line notching, defective
an acceptable level. One caution with over voltage control, it transformers or other loads that may be effecting the form factor
is set up in such a way that it will not make corrections to of the AC waveform. Line imbalances which exceed 3% will
unrealistic ramp rates. For example if the deceleration ramp cause sufficient DC bus ripple to initiate a Mains Phase Loss
needs to be 100 seconds due to the inertia, and you set the Trip.
ramp rate for 3 seconds, over voltage control will initially
engage and then disengage and allow the VLT 5000 to trip. Severe phase imbalances, or phase losses can easily be
This is purposely done so the units operation is not detected with a volt meter. Line disturbances will most likely
misinterpreted. The third method in controlling regenerated have to be viewed on an oscilloscope.
energy is with a dynamic brake. With this system the optional
brake electronics are built into the VLT and an external resistor
bank is mounted outside of the VLT. The drive monitors the
level of the DC bus. Should the level become too high the
electronics will switch the resistor across the DC bus and
dissipate the unwanted energy into the resistor bank. This is
the only means available to actually increase the rate of
deceleration.
Less often is the case that the over voltage condition is caused
by the load while it is running at speed. In this case the
dynamic brake option can be used but you may also choose
to activate the over voltage control circuit. It works with the
load in this way. As stated earlier regeneration occurs when
the speed of the load is greater than the commanded speed.
If the load should become regenerative while the unit is running
at a steady state speed, the over voltage circuit will increase
the frequency to match the speed of the load.
22
OVER TEMPERATURE TRIPS Following is a description of the 4 LED's associated with an

over temperature fault.
The VLT 5060-5250 monitors the temperature of the heatsink,
the internal ambient, and provides for monitoring the LED 1:
temperature of an external device. In addition, VLT 5125-
This led will be lit when the power card temperature sensor
5250 NEMA 12/IP54 type units have a sensor monitoring
has determined the VLT internal ambient temperature to be
the surface temperature of the motor coil. In newer units the
above 85°C. The sensor will automatically reset when the
AC indicator thermal sensor was moved to the left side of
temperature drops below 70°C.
the capacitor back. This was done because of a charge to
the inductor. The purpose of this sensor was to protect drives LED 2:
internal ambient temperature if door fan filters are clogged or
dirty. This LED will be lit when the power card temperature sensor
has determined the VLT's internal ambient temperature to
For each of the above trip will result in an alarm condition be below minus 20°C. The sensor will automatically reset
with the display indicating HEAT SINK OVER TEMP. It is then when the temperature rises above minus 5°C.
necessary to view the 4 LED's mounted on the power card
to further identify the source of the fault. If the display indicates LED 3:
over temp and none of the power card LED's are lit than the This LED will be lit when the thermal switch on the output
source of the fault is the heatsink thermal sensor. This sensor inductor detects a temperature in excess of 135°C. The
is a Negative Temperature Coefficient (NTC) device. The sensor will automatically reset. As this sensor is a switch, the
sensor delivers a resistance value based on temperature and temperature displayed will typically be the default value of
operates within a range of 787 ohms to 105 Kohms, with 139°C. This is not the actual temperature that has been
787 ohms equal to 95°C. As the temperature rises the sensed.
resistance decreases and as the temperature falls the
resistance increases. A trip caused by the heatsink thermal LED 4:
sensor can be due to the ambient temperature around the
This LED will be lit when the connection at MK15 (external
unit is too high, the path of the air flow for the heatsink fan is
disable) has been activated. Based on the way MK15 is wired
obstructed, the heatsink fan is not operating, or the thermal
this could mean the external input has closed or become
sensor is defective. Since the fans and the sensor have a
open. As this input is closed or open, the temperature
relatively long life expectancy, most failures are due to
displayed will typically be the default value of 139°C. This is
restricted air flow or incorrect installation practices causing
not the actual temperature that has been sensed.
poor air circulation. It is important for all chassis drives to be
mounted flush on a flat surface to provide a proper air channel.
If this is not done the drives fan can only supply air to the
upper portion of the heatsink, instead of drawing it across
the whole heatsink. Consult the instruction manual for proper
installation instructions to ensure spacing and air flow space
is provided.
23
SECTION THREE
NOTE: Remember from discussion in the description of
operation section the variations between variable and
constant torque units was described. The same will hold true
throughout the remainder of this manual. All references will
be made to the constant torque versions, VLT 5060-5250.
The actual frame of the VLT 5000 AQUA or 6000 series
drive will be one size smaller in comparison. For example,
if servicing a VLT 5075 AQUA or 6075 refer to the VLT 5060
sections.
STATIC TEST PROCEDURES

The purpose of performing static tests is to rule out the
possibility of any shorted power components. These tests
should be performed on any unit that is suspected faulty,
prior to applying power. Should any component be found
defective or suspect, it must be replaced before power can
be reapplied to the VLT.
The following static tests are covered in this section: + BUS – BUS
• Soft Charge and Rectifier Circuit
• Inverter Section
• Intermediate Section or DC Bus
• Miscellaneous
All tests will be made with a meter capable of testing diodes.
Use a digital VOM set on the Diode scale or an analog Photo 1
ohmmeter set on R x 100 scale. Before making any checks
disconnect all input, motor and brake resistor connections. NOTE:
CAUTION: Photo is typical of a VLT 5060-5100 Chassis, others will be

Following the removal of input power, it can take up to similar however, polarity of + and - bus connection is opposite
15 minutes for the DC bus capacitors to discharge. Allow on VLT 5125-5250.
sufficient time for the DC bus capacitors to fully discharge
before beginning any testing. The presence of DC bus
voltage can be tested by connecting a voltmeter set to
read up to 1000VDC to the +DC Bus and –DC Bus
terminals, Photo 1, located at the top of the capacitor
bank.
24
TESTING THE SOFT CHARGE AND Incorrect Reading:

RECTIFIER CIRCUIT: With the "Step 3" test connection, even though the SCR's in
the SCR/Diode modules are forward biased by the meter,
Refer to Photos 2 through 6 starting on page 30 for current will not flow through the SCR's without providing a
location of components and test points. signal to their gates, so they are still blocking current flow.
The upper diodes in the soft charge rectifier are forward biased
In the "Sequence of Operation" section the function of the so the meter reads the voltage drop across those diodes. If
soft charge and rectifier circuits were discussed. The soft an open reading were present it would indicate the upper
charge circuit is made up of the soft charge rectifier, resistor diodes in the soft charge rectifier are open. It could also
fuses and the soft charge resistor. The rectifier circuit is indicate that one or more of the soft charge rectifier or resistor
made up of the SCR/Diode modules and included are the fuses are open. It could further be the case that the soft charge
lower diodes of the soft charge rectifier which serve as resistor(s) are open. To check the soft charge resistors place
snubber diodes for the SCR portion of the module. an ohmmeter across the +DC Bus terminal and the resistor
As the tests are carried out both the rectifier and soft charge fuses. If the unit has a single resistor installed it will read 18
circuits will be tested simultaneously. It is important to pay ohms. Two resistors in parallel will read 9 ohms.
close attention to the polarity of the meter leads to ensure A short circuit reading indicates either the upper soft charge
you can identify a faulty component should an incorrect rectifier diodes are shorted or the SCR's are shorted in the
reading appear. SCR/Diode module. In this case it would be necessary to
Step 1 remove the soft charge fuses in order to isolate the two
Prior to making the test it is necessary to ensure the soft devices. Once the fuses are removed make the same
charge rectifier fuses, F1, F2, F3 and resistor fuses F4, and measurement to confirm the SCR's. To check the soft charge
F5 if applicable, are good. If not, replace them before rectifier make the positive (+) lead connection at the side of
proceeding. the soft charge rectifier fuse block that has the wires which
connect to the rectifier.
Step 2
Connect the positive (+) meter lead to the positive DC bus Step 4
connection. Connect the negative (–) meter lead to terminals Connect the positive (+) meter lead to the negative DC bus
L1, L2, and L3 in turn. Each reading should show infinity. In connection. Connect the negative (–) meter lead to terminals
actuality the meter will start at a low value and slowly climb L1, L2 and L3 in turn. Each reading should show a diode
towards infinity due to capacitance within the drive being drop.
charged by the meter. Incorrect Reading:
Incorrect Reading: With the "Step 4" test connection the diodes in the SCR/
With the "Step 2" test connection the SCR's in the SCR/ Diode modules are forward biased as well as the lower diodes
Diode modules are reverse biased so they are blocking in the soft charge rectifier so the meter reads the diode drops.
current flow. The upper diodes in the soft charge rectifier are If a short circuit exists it would be possible that either the
also reverse biased so they too are blocking current flow. diodes in the SCR/Diode modules or the lower diodes in the
The upper diodes in the rectifier are blocked from this soft charge rectifier are shorted. In this case it would be
measurement by capacitor C1. However, if a diode drop was necessary to remove the soft charge fuses in order to isolate
read, this would indicate that one or both of the soft charge the two devices. Once the fuses are removed make the same
resistor thermal sensors were closed. If a short circuit exists measurement to confirm the diodes in the SCR/Diode
it would be possible that either the SCR's or the diodes in modules. To check the soft charge rectifier make the negative
the soft charge rectifier are shorted. In this case it would be (–) lead connection at the side of the Soft Charge Rectifier
necessary to remove the soft charge fuses in order to isolate fuse block that has the wires which connect to the rectifier.
the two devices. Once the fuses are removed make the same Step 5
measurement to confirm the SCR's. To check the soft charge Reverse the meter leads. Connect the negative (–) meter lead
rectifier make the negative (–) lead connection at the side of to the negative DC bus connection. Connect the positive (+)
the soft charge rectifier fuse block that has the wires which meter lead to L1, L2 and L3 in turn. Each reading should
connect to the rectifier. show infinity. Remember the same is true as before. The meter
Step 3 will move slowly towards infinity as it charges the capacitance
Reverse the meter leads. Connect the negative (–) meter within the drive.
lead to the positive DC bus connection. Connect the positive
(+) meter lead to L1, L2, and L3 in turn. Each reading should
show a diode drop. Note in some new drives BR2 causes a
double diode drop reading .900. Due to the SCR/Snubber
Diode assembly (BR2). Reference Section I soft charge circuit.
25
Incorrect Reading: that one or more of the SCR/Diode modules could be open
With the "Step 5" test connection, the diodes in the SCR/ but this type of failure is extremely rare. See the section on
Diode modules are reversed biased as well as the lower dynamic tests for more on testing the SCR/Diode modules.
diodes in the soft charge rectifier. If a short circuit exists it Refer to the SCR gate driver test cable instruction for further
would be possible that either the diodes in the SCR/Diode testing of SCR gate signals. (This is a service tool that can
modules or the lower diodes in the soft charge rectifier are be used to ease the testing of SCR by breaking out the SCR
shorted. In this case it would be necessary to remove the wire harness that connects to the power card. This cable
soft charge fuses in order to isolate the two devices. Once can be ordered separate 176F1430.)
the fuses are removed make the same measurement to
confirm the diodes in the SCR/Diode modules. To check the Cause 3: Short circuit in the intermediate or inverter
soft charge rectifier make the positive (+) lead connection section:
at the side of the soft charge rectifier fuse block that has the In this case, as the DC bus is attempting to charge all the
wires which connect to the rectifier. energy is being drawn away by the fault. For example: a
shorted brake IGBT would be dumping the DC bus voltage
Step 6 into the external brake resistor as the DC bus is attempting
To complete the testing of the soft charge circuit, measure to charge. Since the soft charge resistors can not sustain
the soft charge resistors to ensure they are the correct value. the amount of current flow that would be present in this
Make this reading by placing the meter across the negative situation, The resistors would overheat, the thermals would
connection of BR2 and the resistor fuses. Remember to reset close and the fuses would blow. Other such faults could be
your meter to read ohms on its lowest scale. One soft charge that the DC bus is being taken to ground through defective
resistor will read 18 ohms. If two resistors are used, they are DC bus capacitors or inverter IGBT's. See more on this fault
connected in parallel so they will read 9 ohms. If a short in the procedure for statically testing the intermediate circuit.
were to be present it could indicate the resistors are shorted
or the thermostats mounted to the resistors have closed. An CONDITION:
open reading of course indicates the resistor is open. An 18
ohm reading on two parallel resistors would indicate one of Blown Soft Charge Rectifier Fuses:
the resistors is open. In any case the faulty components Cause 1: Shorted Soft Charge Rectifier:
must be replaced. This component failure, is most likely the result of a failure
Indications of a failure in this circuit: elsewhere in the soft charge circuitry. Possibly due to shorted
In rare instances a failure of a component in this circuitry soft charge resistors. It would be expected that the resistor
may be just that, a component failure. That is however not fuses would blow following the failure of the resistor. See the
likely. It would be expected that other components in the section above for more details on the possible causes of
drive failed first causing this failure or the conditions of failure.
operating the unit lead to such a failure.
CONDITION:
CONDITION: Shorted SCR/Diode Modules:
Blown Soft Charge Resistor Fuses: Cause 1: Shorted IGBT:
Cause 1: Excessive input power cycling: An IGBT failure, under short circuit conditions, draws
The DC bus capacitors are charged by current flowing through extensive current across the input of the drive. If slow acting
the soft charge resistors. Due to the fact that current flowing interrupting devices (circuit breaker or improper fusing) are
through the soft charge resistors generates heat, excessive installed external to the drive it is likely for an SCR/Diode
power cycling can overheat the resistors, cause the thermal module to short circuit following an IGBT failure.
switches to activate (close) and blow the resistor fuses. For Cause 2: Shorted Brake IGBT:
this reason, input power cycling is limited to once every two In this case the shorted brake IGBT is dumping the DC bus
minutes. Under normal circumstances the thermal switch voltage into the external brake resistors. This will cause
will reset (open) once it cools down. The fuses can then be extensive current to be drawn across the input of the unit as
replaced and operation resumed. the SCR/Diode modules attempt to resupply the DC bus.
Cause 2: SCR/Diode modules not conducting: This should also result in an overheated brake resistor. The
In this case all the power required by the inverter section resistor overload device should open and remove power from
must pass through the soft charge circuitry. The SCR's are the drive or open the circuit to the DB resistors themselves.
controlled by the power card. A failure in the power card
circuitry may be the cause or the cable connections from
the power card to the gates of the SCR's. It could be possible
26
Testing the Inverter Section Step 3

Connect the positive (+) meter lead to the negative DC bus
Refer to Photos 2 through 6 for location of components connection. Connect the negative (–) meter lead to terminals
and test points. U, V and W in turn. Each reading should show a diode drop.
The inverter section is primarily made up of the six IGBT's Incorrect Reading:
used for switching the DC bus voltage to create the output With the "Step 3" test connection the diodes in the negative
to the motor. Depending on the size of the VLT 5000 the six IGBT's and positive snubber diodes are forward biased so
IGBT's will be installed as two per module for a total of three the meter reads the diode drop. If a short circuit exists it
modules or one per module for a total of six IGBT modules. would indicate the negative IGBT in the phase being tested
The VLT 5200 and 5250 also have snubber boards with is defective. In VLT 5200 and 5250 it could further indicate
snubber diodes mounted on each set of two modules. that the positive snubber in that same phase is shorted. To
verify the faulty component it will be necessary to
When testing the inverter section it is important to disconnect
disassemble the unit and isolate the components. See the
the motor leads. With them connected a short circuit in one
section on replacing IGBT's and snubber boards.
phase will be read in the other phases making the diagnosis
more difficult. Step 4
Reverse the meter leads. Connect the negative (–) meter
Step 1
lead to the negative DC bus connection. Connect the positive
Connect the positive (+) meter lead to the positive DC bus
(+) meter lead to U, V and W in turn. Each reading should
connection. Connect the negative (–) meter lead to terminals
show infinity. The meter will move slowly towards infinity as
U, V and W in turn. Each reading should show infinity. In
it charges the capacitance within the drive.
actuality the meter will start at a low value and slowly climb
towards infinity due to capacitance within the drive being Incorrect Reading:
charged by the meter. With the "Step 4" test connection the diodes in the negative
IGBT's and positive snubber diodes are reverse biased so
Incorrect Reading:
they are blocking current flow. If a short circuit exists, it
With the "Step 1" test connection the diodes in the positive
would indicate the negative IGBT in the phase being tested
IGBT's and negative snubber diodes are reverse biased so
is defective. In VLT 5200 and 5250 it could further indicate
they are blocking current flow. If a short circuit exists, it would
that the positive snubber diode in the same phase is shorted.
indicate the positive IGBT in the phase being tested is
To verify the faulty component it will be necessary to
defective. In VLT 5200 and 5250 it could further indicate that
disassemble the unit and isolate the components. See the
the negative snubber diode in that same phase is shorted.
section on replacing IGBT's and snubber boards.
To verify the faulty component it will be necessary to
disassemble the unit and isolate the components. See the Indications of a failure in this circuit:
section on replacing IGBT's and snubber boards. An IGBT failure by itself is generally difficult to explain. In
most cases the IGBT erupts, making it nearly impossible to
Step 2
conduct an analysis on the damaged device. IGBT failures
Reverse the meter leads. Connect the negative (–) meter lead
may be caused by the drive being exposed to repeated short
to the positive DC bus connection. Connect the positive (+)
circuits or ground faults or operation of the unit outside of its
meter lead to U, V and W in turn. Each reading should show
normal operating parameters for extended periods of time.
a diode drop.
Following an IGBT failure it is important to verify the gate
Incorrect Reading: drive signals are present and of the correct waveshape. See
With the "Step 2" test connection the diodes in the positive the dynamic test section on checking IGBT gate signals.
IGBT's and negative snubber diodes are forward biased so
Additional notes when troubleshooting the Inverter
the meter reads the diode drop. If a short circuit exists, it
Section:
would indicate the positive IGBT in the phase being tested is
For VLT 5060-5100 a small gate board is soldered to the
shorted. In VLT 5200 and 5250 it could further indicate that
gate terminals of each IGBT. For VLT 5125-5150 the gate
the negative snubber diode in the same phase is shorted. To
board is attached by screws to the gate terminals. The spare
verify the faulty component it will be necessary to disassemble
part IGBT is supplied with this board attached. Never replace
the unit and isolate the components. See the section on
just the IGBT without including a new gate board. For VLT
replacing IGBT's and snubber boards.
5200-5250 the gate board is part of the snubber card which
mounts to one phase (two modules) via screws. The snubber
board is not provided with spare part IGBT's but must always
be tested if an IGBT is replaced. See the section on replacing
IGBT's and snubber boards.
27
TESTING THE INTERMEDIATE SECTION Step 5

Reverse the meter leads, connecting the negative (–) meter
Refer to Photos 2 through 6 starting on page 30 for lead to the R– terminal and the positive (+) meter lead to the
location of components and test points. DC– connection at the top of the capacitor bank. The meter
should read a diode drop.
The Intermediate section is made up of the DC bus capacitors,
the DC coils and the balance resistors across the capacitors. Incorrect Reading:
Also included in our tests of this section will be the Brake An incorrect reading from the previous 4 steps indicates a
IGBT and Brake Snubber board if the unit is so equipped. fault in the Brake IGBT. Be sure however that the previous
tests of the Inverter, Rectifier, Soft Charge and Intermediate
Step 1
circuit have been performed. A failure in one of these sections
Test for short circuits by setting an ohmmeter on the RX100
could be read at this test since the brake IGBT is across the
scale and read across the +DC and –DC terminals at the top
DC bus. See the section on replacing the Brake IGBT.
of the capacitor bank. With the meter leads in one direction
the meter will start out with low ohms and then move towards MISCELLANEOUS TESTS
infinity as the meter charges the capacitors. Reversing the
meter leads will then peg the meter at zero while the charge Testing The Motor:
in the capacitors is discharged by the meter and then begin While making the various other static checks it is logical to
moving slowly towards infinity as the meter charges the make a resistance reading of the motor windings. Set the
capacitors in the reverse direction. ohmmeter on the highest resistance scale. Read each of
the motor leads, T1 (U), T2 (V), T3 (W) to ground. The reading
Although this test does not ensure the capacitors are fully should be infinity. Any reading at all indicates a breakdown
functional it is a good test to ensure no short circuits exist in the motors insulation system or the wiring to the motor.
in the intermediate circuit. A visual check can also be
conducted. Check for vented capacitors, loose connections Test the phase to phase resistance of the motor. Set the
or damage to exterior of the capacitors. ohmmeter on the lowest resistance scale. Read the phase
to phase resistance on all three motor leads. Typical
Incorrect Reading: resistance readings on small motors such as 1 horsepower
If a short circuit were present and the unit is equipped with a will only be in the range of 3 to 8 ohms. As the motors get
brake perform the test of that circuit next. larger the resistance decreases to a point that only precision
A short circuit could further be caused by a short circuit in measuring instruments can be used to make such a test.
the soft charge, rectifier, or inverter section. Perform those The main objective is to check for short circuits and not to
tests as outlined in this chapter to isolate the cause of the verify a correct resistance reading for a particular motor. If
short circuit. The only other likely cause would be a defective that is your objective, please consult the motor manufacturer
capacitor within the capacitor bank. The capacitor bank would for the correct values.
then have to be removed and individual tests made to identify A high voltage breakdown test should be conducted. This is
the defective component. normally done with a Megohmmeter, commonly referred to
as a megger. This device is capable of suppling up to
500Volts as the resistance measurement is made. In contrast
TESTING THE BRAKE IGBT to a typical ohmmeter using a 1.5 or 9 VDC battery, a megger
can detect insulation breakdowns far more accurately. When
Step 2 making such a test the motor leads must be disconnected
Connect the positive (+) meter lead to the R– terminal and from the VLT. Make the measurement at the wire nearest to
the negative (–) meter lead to the R+ terminal. The meter the VLT. In this way all wiring, connections, and the motor
should read a diode drop. windings will be captured by the test. Keep in mind all
Step 3 connections between drive and motor need to be closed or
Reverse the meter leads, connecting the negative (–) meter the testing will need to be done from each point in the circuit.
lead to the R– terminal and the positive (+) meter lead to the Further isolation of components may be needed to determine
R+ terminal. As with previous tests the meter will climb which component is faulty. (Example motor verse wiring
towards infinity as the meter charges the units internal between drive and motor). Although the readings from motor
capacitance. leads to ground may vary based on the motor design, the
amount of moisture in the windings, and the temperature of
Step 4 the motor it would be expected to see a reading of at least
Connect the positive (+) meter lead to the R– terminal and 500 Megohms or more.
the negative (–) meter lead to the DC– connection at the top
of the capacitor bank. The meter will climb towards infinity
as the units internal capacitance is charged by the meter.
28
Testing The Heatsink Temperature Sensor: Voltage Checks
The temperature sensor is an NTC (Negative Temperature To ensure that the autotransformer and control circuitry is
Coefficient) device. This means that when the temperature operating correctly, the voltage supplied by the
is low the resistance is high. As the temperature rises the transformer to the fan should be measured. To perform this
resistance decreases. The power card reads the resistance check a voltmeter capable of measuring up to 250 VAC
of the device and makes decisions on fan speed and whether and the signal test board(176F1429) should be used.
or not an over temperature condition exists. See the section
on fan control for more on that subject. Connect the voltmeter to the black and blue leads of the
fan motor. Install the signal test board into the test
The temperature sensor is rated as 10K ohms equals 25°C.
connector socket in the VLT according to the instructions.
The range of the sensors ohmic value is 787 ohms to 105K
ohms with 787 ohms equal to 95°C. The easiest method to
Voltage checks should be taken at high and low speeds.
test the sensor is to separate the wire harness connector
High-speed operation can be controlled by the fan test
located just to the right of the capacitor bank. Read the
switch on the signal test board. The fan will run at the low
resistance at the connector that is attached to the wires
speed for a few seconds when the VLT is powered up.
traveling under the capacitor bank. The resistance reading
must correspond to the values described above. You can
Voltage at high speed - 230 VAC
also test the signal from the heatsink thermal sensor while
Voltage at low speed - 165 VAC
the drive is powered up. Refer to the signal board instruction
manual on how to calculate heatsink temp. from the voltage
feedback signal on the power card. (This service tool can be Testing The Inductor Temperature Sensor:
used to breakout different signals located on the power card Only VLT 5125-5250 NEMA 12/IP54 units are equipped with
this sensor. The sensor is physically mounted on the
to verify operation of the drive. This board can be ordered
separate 176F1429.) lamination surface of the output inductor or on the left side of
the cap bank depending on age of drive. It is a simple normally
FAN TEST closed switch that opens when the surface of the inductor
Continuity test reaches 135°C. The sensor itself is an enclosed device but a
measurement can be taken by separating the cable connector
NOTE: All continuity checks are made using an ohmmeter located just inches from the sensor.
set to Rx1 scale. Digital or analog ohmmeters can be used.
With an ohmmeter probe the two pins in the connector
1. Measure the connections from the autotransformer by checking for a short circuit. This would indicate the switch is
measuring from L3 (T) to terminal 1 of the autotransformer. closed as it is normally suppose to be. If the switch were
A reading of <1ohm should be indicated. open it has either reached its trip temperature and has not
2. measure from L2 (S) to terminal 3 of the autotransformer. yet reset, or it is defective.
<1 ohm should be read.
3. measure from terminal 2 of the autotransformer to the
black lead of the fan motor. <1 ohm should be read.
4. Measure between terminals 1 and 3 of the autotransformer.
Approximately 60 ohms should be read.
5. Measure between terminals 1 and 2 of the autotransformer.
6 Measure between terminals 2 and 3 of the autotransformer.
7. Measure the black lead of the fan motor to the blue lead
of the capacitor. <1 oh should be read.
8. Measure the brown lead of the fan motor to the brown lead
of the capacitor. <1 ohm should be read.
9. Measure between the two leads of the capacitor (blue &
brown). A capacitor charging effect should be seen.
29
Photo 2: Actual photo of VLT 5150 Chassis/NEMA 1, VLT 5060-5250 Chassis/NEMA 1 Units are similar.
Local Control Panel

(LCP) Soft Charge
Resistors (R1, R2)
Control Card
Soft Charge (SW1, SW2)
Resistor Thermostats
SCR Snubber
Control Card Capacitor (C1)
Cassette
Soft Charge
Resistor Fuses
(F4, F5)
Soft Charge
Rectifier Fuses
(F1, F2, F3) SCR Snubber
Resistors (R1, R13)
DC Inductor Soft Charge

Motor Coil and Rectifier MOV (MOV1)
Fan Autotransformer
behind this area.
Accessible by Soft Charge
removing top fan. Rectifier (BR1)
+ and – DC
Bus Connections
Input Terminals Heatsink Thermal

below (L1, L2, L3) Sensor Connector
DC Bus
Capacitor Bank
Load Sharing and

Brake Resistor Terminals Current Sensors
would be located in this 1 per phase, 3 total
area if unit is so equipped (U9, U10, U11)
(+DC, –DC, R–, R+)
Output Terminals
(U, V, W,)
30
Photo 3: Actual photo of VLT 5100 NEMA 12, VLT 5060 and 5075 NEMA 12 units are similar.
Soft Charge
Circuitry See
photo 4 for clarity.
Control Card
Output Inductor
below
Control Card + and – DC Bus

Cassette Connections
Upper Capacitor
DC Bus Capacitor Bank Fan
Bank with shield
removed.
Heatsink Thermal
Sensor Connector
Input Terminals
(L1, L2, L3)
Current Sensors
1 per phase 3 total
(U9, U10, U11)
Load Sharing and
Brake Resistor
Terminals directly Output Terminals
below capacitor (U, V, W)
bank if equipped
(+DC, –DC, R–, R+)
Lower Capacitor
Bank Fan
Heatsink Fan
31
Photo 4: Actual photo of VLT 5100 NEMA 12 with + and – DC Bus wires removed for clarity. VLT 5060 and 5075
NEMA 12 units are similar.
SCR Snubber Diode BR2
Soft Charge Resistor Soft Charge Resistor Soft Charge SCR Snubber
Fuse (F4) Thermostat (SW1) Resistor (R1) Capacitor (C1)
Soft Charge Rectifier Soft Charge Rectifier SCR Snubber Resistor

(BR1) and MOV (MOV1) Fuses (F1, F2, F3) (R2, R13)
32
Photo 5: Actual photo of VLT 5200 NEMA 12, VLT 5125-5250 NEMA 12 units are similar.
Upper Door Fans DC Inductor

(L1)
Output Inductor
Local Control Panel Motor Coil (L2)
(LCP)
Output Inductor
Control Card Thermal Sensor
Control Card Cassette + and – DC Bus

Connection directly
behind shield.
DC Capacitor Bank
below shield, remove
three T20 screws (A) Soft Charge Circuitry
to access. A see Photo 6 for clarity
Current Sensors
1 per phase, 3 total
A (U9, U10, U11)
Input Terminals
(L1, L2, L3)
Output Terminals
(U, V, W)
Lower Door Fan
Load Sharing and
Brake Resistor
Terminals if equipped
(+DC, –DC, R–, R+)
Heatsink Fan
not front accessible.
33
Photo 6: Actual photo of VLT 5200 NEMA 12 with Capacitor Bank removed. VLT 5125-2550 NEMA 12 units are
similar.
Soft Charge Resistor

Thermostats (SW1, SW2)
Soft Charge Resistors

(R1, R2)
Soft Charge Rectifier

Fuses (F1, F2, F3)
Soft Charge Resistor

Fuses (F4, F5)
Soft Charge Rectifier,

BR1 and
MOV (MOV1)
SCR Snubber Diode BR2
SCR Snubber Resistors

(R2, R13)
SCR Snubber Capacitor

(C1)
Heatsink Thermal
Sensor Connector
34
DYNAMIC TEST PROCEDURES

Testing For Output Phase Imbalance
Checking the balance of the output voltage and current can
give you an indication of whether or not the VLT is functioning
correctly. When testing the output, both voltage and current
are monitored. If the voltage is balanced but the current is
not, It indicates the motor is drawing an uneven load. This
could be the result of a defective motor, defective contacts
in an overload conductor, or a poor connection in the wires
feeding the motor. If the output current is unbalanced as well
as the voltage, then the indication is the VLT is not gating
the output properly. This could be the result of a defective
power card, the connections from the power card to the
IGBT's, or a poor connection within the VLT.
The voltage tests can be made with the motor connected
however this is a good test to make following a repair, prior
to connecting the motor wires. Further more it would be typical
that if both output voltage and current were unbalanced the
VLT would most likely be tripping on an over current fault
when attempting to run the load. The voltage test could then
only be made with the motor leads disconnected.
NOTE: When monitoring output voltage use an analog
voltmeter. Digital voltameters are sensitive to the
waveform and switching frequency and commonly
return erroneous readings.
Photo 1
Step 1
Remove AC input power to the VLT. NOTE:
CAUTION: The DC bus capacitors remain charged for Photo is typical of a VLT 5060-5100 Chassis, others will be
approximately 15 minutes following the removal of the similar however, polarity of + and - bus connection is opposite
main supply. Allow sufficient time for the capacitors to on VLT 5125-5250.
discharge before entering the unit. Test for the presence
of bus voltage by connecting a voltmeter set to read
1000VDC to the terminals at the top of the capacitor bank, Step 5
labeled +BUS and –BUS. Read the phase to phase output voltage of all three phases.
The actual value is less of a concern than the balance of all
Step 2 three phases. All three phases should be within 8VAC of
Disconnect the motor leads from the output terminals of the each other. If a greater imbalance exists proceed to the
VLT. Testing IGBT Gate Drive Signal section and check for loose
Step 3 connections within the drive.
If you have not yet run the static tests on the inverter section Step 6
perform that procedure now. If the voltage is balanced, remove power, allow the DC bus
Step 4 to discharge, reconnect the motor, return to running at a
If the inverter section test is successful, apply main power speed close to or above 40Hz and monitor the output current
to the VLT, initiate a run command with a speed greater than of all three phases. The output current should be balanced
40Hz. within 2 to 3% of each other. If an imbalance exists, check
for poor connections to the motor or the quality of the motor
Note: the speed of 40 Hz is only significant with regards to itself.
the clamp on device being used to read current. Some test
equipment of this type is only specified to be accurate above
a frequency of 40Hz.
35
In most units the gate wiring and SCR/Diode modules are

physically located below the capacitor bank. The only means
TESTING THE INPUT SCR/DIODE MODULES: to access the gate leads is through the use of the SCR gate
Theoretically the current drawn on each of the three input lead break out wiring assembly. This assembly, available from
phases of the VLT should be equal. Some imbalance may Danfoss, inserts between the power card and the cable
be seen however due to variations in phase to phase input assembly from the SCR/Diode modules. On some units the
voltage and some single phase loads within the unit. SCR/Diode modules are located at the bottom of the unit
Reference figure 8 and are easily accessed (see photo 7). For those units place
the current probe around the white gate wire. With the unit
A simple test of monitoring input current can be made to rule running the SCR gate current should appear as in Figure 9:
out any suspicion of a problem in this area but a more
thorough test may be warranted if the SCR/Diode module or
the gate signals are thought to be at fault.
Given that the input voltage is balanced, monitor the three
input phases with a clamp on ampmeter. The current readings
should be within 5% of each other. An imbalance of greater
than 5% may indicate that either the input voltage is not
balanced or the SCR/Diode modules are not conducting
properly. If the latter is true this may be due to a defective
power card, wiring connection from the power card to the Figure 9
devices or the SCR/Diode modules themselves. SCR Gate Signal
One step would be to swap two of the input leads to verify if TESTING IGBT GATE DRIVE SIGNALS:
the imbalance follows or stays in the same phase of the
drive. If the problem follows it is possible the input voltage The gate drive signals, one for each IGBT for a total of six,
supply should be in question. If the problem stays in the originate on the control card. They are delivered to the power
same phase proceed to verify proper SCR/Diode operation card, isolated, and then sent to each IGBT. A defective gate
by monitoring the SCR/Diode gate signal. drive signal can cause an IGBT failure, over current trips, or
an imbalance in the output of the VLT. Tripping caused by
Monitoring the actual SCR gate signals can be difficult imbalances will most likely be the result of a gate drive signal
depending on the specific model of VLT. In order to view the missing completely. Any other form of distortion in one of the
gate signal an oscilloscope and a current probe are required. gating signals will normally result in a shorted IGBT. The signal
The VLT must be running at some minimum load, at least board can be used to monitor these signals. As seen on the
above magnetizing current by 10 to 20%. An unloaded motor signal board, these signals are on the isolated side of the
may not draw sufficient current to generate gate signals with power card. A good signal here does not rule out a defective
adequate aplitude so they can be easily identified. signal on the IGBT side of the power card. To test that portion
of the signal it would be necessary to carry out the following
procedure. The gate drive signals can be tested in two ways.
One method is with the signal board allowing you to view the
signal as it is distributed to the individual gate drivers on the
power card. This is explained later in this section. However,
following a repair it would be beneficial to monitor the gate
drive signals directly at the gates of the IGBT's. This can only
be carried out with the capacitor bank removed and the VLT
powered by means of an external DC bus supply. Danfoss
makes available such a power supply for making these
measurements. Reference Appendix V Pages 94-97.
CAUTION: The gate drive signals are referenced to the
negative DC bus. Line powered test equipment such as an
oscilloscope must be isolated from ground when making
measurements. Failure to do so will cause damage to the
VLT. Also, depending on the method used to isolate the test
equipment, the chassis of the test equipment may be at DC
Figure 8 bus potential when connected to the VLT.
Typical input current wave form 5075 at 100 amp load
36
With the VLT powered by the external bus supply use an OTHER SIGNALS:
oscilloscope to monitor the gate drive signals. Place the unit
in run with a speed reference of 0Hz. Connect the ground of Many other signals can be monitored via the signal board.
the scopethe emitter (E) terminal of the IGBT. Place the probe Among the signals that can be observed:
on the gate (G) terminal of the IGBT(see photos 8,9,10). The Low voltage power supplies; Fan speed control; Over voltage
signal should appear as in Figure 10: limits; Temperature trip signal; Brake control signal; Inrush
control signal. See Appendix III for more on using the signal
board.
Figure 10
IGBT Gate Signal
Note: The waveform above was taken with the VLT 5000
carrier frequency set to 3.0Khz. Higher carrier frequencies
will result in a waveform with a higher frequency.
Although an oscilloscope is the test instrument of choice in
the absence of such equipment a volt meter can be used to
obtain a reading that will give you a reasonable indication
that the gate signals are functioning correctly. Set the volt
meter to read 10VDC. Connect the positive (+) meter lead to
the gate (G) terminal of the IGBT. Connect the negative (–)
meter lead to the emitter (E) terminal of the IGBT. Place the
VLT in run at 0Hz. The meter should read approximately 2
VDC. Compare all six gates to one another. If the readings
are not similar further investigation is required.
NOTE:
The following signals will be monitored by use of the
signal board. Danfoss makes available a signal board
for ease of monitoring these signals.
TESTING FOR CURRENT FEEDBACK:
In each phase of the output resides a hall effect current sensor.

These devices provide a current signal that is scaled down
but proportional to the current being drawn by the output.
The power card and the control card use this current feedback
to make corrections to the waveform and protect the VLT
from output short circuits and severe overload conditions. A
defect in this circuit may also cause the VLT to erroneously
trip on over current and ground fault alarms.
If you have verified that the application is not overloading the
unit and the motor is not shorted phase to phase or to ground
and the VLT still trips, you may want to conduct a test on
current feedback. The signal from the current sensors are
available on the signal board. Reference Appendix III Pages
81-91.
37
PHOTO 9
IGBT VLT 5125-5150
PHOTO 7
SCR Gate Connections
VLT 5125-5150 Zenner Diodes Gate
Emitter For gate transient
protection
Gate signals
Gate
Emitter
PHOTO 10
IGBT With Snubber Board
VLT 5200-5250
PHOTO 8
IGBT VLT 5060-5100 Snubber Diode
Emitter/Gate
Zener Diodes Snubber Resistors

For Gate Transient Protection Emitter/Gate Emitter/Gate
38
SECTION FOUR Removing the control card:

Note: In Appendix II a quick reference to all Torque
Specifications for the IGBT and SCR modules, throughout
DISASSEMBLY INSTRUCTIONS the disassembly section the torque specifications are
referenced.
VLT 5060-5100
NEMA 12/IP54 1. Disconnect the cable going to the local control panel.
2. Loosen the two T20 torx captive screws to free the
cassette.
3. Lift the cassette from the bottom until its approximately
at a 45° angle.
4. Unplug the two ribbon cables from the control card.
5. Push the cassette upwards to free it from the top hooks.
6. To replace the control card follow the instructions included
with the spare part.
To reinstall the control card reverse the procedure.

Torque specifications: T20 screws to 8 Lb-In (1 NM).
Cable placement: The ribbon cables are made such that when
laid flat the correct cable will be aligned to the proper
connector or as installed the top power card connector mates
to the lower control card connector.
Removing the capacitor bank:

1. Remove the black shield covering the capacitor bank by
removing the three T20 torx screws.
2. Remove the three T20 torx screws securing the grounding
bracket to the power card.
3. Remove the two T30 torx screws from the +Bus and
–Bus connections.
4. Unplug the capacitor bank fan cable from the power card.
5. Remove the six T30 torx screws from the cap bank to
IGBT connections.
6. Remove the wires from the three M8 studs at the bottom
of the capacitor bank.
7. While supporting the capacitor bank, remove the three
M10 locknuts.
8. Carefully remove the capacitor bank from the VLT and
set upright.
To reinstall the capacitor bank reverse the procedure.

Torque specifications:
T20 screws to 8 Lb-In (1 NM)
T30 screws for IGBT's 35 Lb-In (4 NM)
T30 screws for + and –Bus 27 Ib-In (3 NM)
M8 locknuts to 16 Lb-In (2 NM)
Cable placement: Reconnect the wires to the studs at the
bottom of the capacitor bank. First connect the white wire to
Photo 11
the center stud. The shorter black wire from that same cable
VLT 5060 - 5100 NEMA 12/IP54 assembly connects to the inner most stud and the longer
black wire to the outer most stud. If a brake is installed in
the VLT then there will also be a 10 gauge wire attached to
the inner most stud and a 4 gauge wire attached to the outer
most stud. Reconnect the capacitor bank fan cable to
connector MK 7 on the power card.
39
Removing the power card: Removing the current sensors:
1. Unplug the three cable assemblies that attach to the The spare current sensor assembly is provided as a complete
IGBT's. If a brake is installed there will be 4. unit with the three sensors, output terminals, splicer block,
2. Unplug the DC bus supply cable. and wires all mounted on a common base plate. It is done in
3. Remove the M10 locknut from the top of the power card this way since the three current sensors have integrated leads
mounting bracket to the heatsink. that all combine into a common cable assembly within the
4. Tilt the power card towards the middle of the unit and VLT. It is also of prime importance that the correct sensor is
remove the connectors. placed in the right output phase. Providing the assembly in
5. Lift the power card from the VLT. this way ensures correct placement of the sensors and makes
installation easier.
Note: If the power card is being replaced you must remove
the power card mounting bracket from the power card. A 1. Remove the motor leads from the output terminals.
new bracket is not supplied with the spare part. The bracket 2. Loosen the 3/16 hex screws in the splicer block to free
is secured to the power card by means of two T20 screws the motor cables.
and 2 nylon swags. 3. Unplug the heatsink thermal sensor connector from the
cable harness.
To reinstall the power card reverse the procedure. 4. Unplug the other end of the cable assembly at MK12 on
Torque specifications: M10 locknuts to 27 Lb-In (3 NM). the power card.
Cable placement: As the power card is installed the gate cable 5. Cut any tie wraps securing the cable assembly.
assemblies align to the IGBT's from top to bottom. If a brake 6. Remove the four 7mm lock nuts securing the base plate
is installed the bottom cable attaches to the brake IGBT. to the VLT enclosure.
Connect MK6, MK11 and MK12. The style and arrangement 7. Remove the entire assembly
of the cables makes it impossible to make an incorrect
connection. Connect the two ribbon cables from the control Note: For installing the wire into splicer block refer to photo
card. The top power card connector mates to the lower below.
control card connector. Connect the DC bus supply cable to
the mating connector. MK7 will be connected after the To reinstall the current sensor assembly reverse the procedure.
capacitor bank is reinstalled. Replace the tie wraps to secure the cable in place. Remember
to reconnect the heatsink thermal sensor to the new cable
harness and plug the cable harness into MK12 of the power
card.
Torque the 7mm lock nuts to 16 Lb-In (2 NM).

Torque the 3/16 hex screws to 120 Lb-In (14 NM).
40
Removing the IGBT's: Now that the snubber board is removed this is a good time
to check the components on the board to ensure they are
1. Remove the T30 torx screw that secures the output cable functional.
to the IGBT.
2. Remove the four T30 torx screws that secure the IGBT to Testing the Brake Snubber Board:
the heatsink.
3. Do not remove the small circuit board mounted to the 1. The two diodes, D1 and D2, provide transient suppression
gate connections of the IGBT. The new spare part will be for the gate of the IGBT. With a VOM set to read diodes,
supplied with this circuit board attached. measure the two diodes and look for a voltage drop in
one direction, infinity in the other.
Reinstalling the IGBT's: 2. Resistors R1 - R6 are 1ohm resistors in parallel. Place
an ohmmeter across terminal K1 and Cap 2. The
1. Remove the old thermal pad and insure the heatsink is resistance value will be equal to .16ohm. Most meters
free of dirt and remaining thermal compound. will not read this low resistance accurately so the
2. Align the new thermal pad over the mounting holes in the important thing is to insure the resistance value is close
heatsink. without a short circuit or open being present.
3. Align the IGBT so the gate connections point towards the 3. The large diode on the board is the snubber diode. With a
middle of the unit. VOM set to read diodes measure the diode and look for a
4. Insert the four T30 torx mounting screws, finger tight. voltage drop in one direction, infinity in the other.
5. Torque the four T30 torx mounting screws following the
pattern shown. Reinstalling the Brake IGBT:
1. Remove the old thermal pad and insure the heatsink is
free of dirt and remaining thermal compound.
2. Align the new thermal pad on the heatsink.
3. Align the IGBT so the gate connections point towards
the upper left hand side of the unit.
Tighten screws flush with the IGBT and torque initially to 4. Insert the four T30 torx mounting screws, finger tight.
9 Lb-In (1 NM) 5. Torque the four T30 torx mounting screws following the
pattern shown.
Final torque to 22-30 Lb-In (2.5-3.5 NM)

Tighten screws flush with the IGBT and torque initially to
6. Mount the output lead to the furthest terminal to the right 9 Lb-In (1 NM)
on the IGBT.
7. Torque the T30 torx screw to 31-39 Lb-In (3.5-4.5 NM).
Removing the Brake IGBT:

1. Remove the two T30 torx screw that make the bus
connection from the snubber card to the IGBT. Final torque to 22-30 Lb-In (2.5-3.5 NM)
2. Remove the two T20 torx screws that make the gate
connection from the snubber card to the IGBT.. 6. Insert the M4 standoffs in the IGBT gate connections
3. Remove the T20 torx screw at the K1 position, remove and torque to 13 Lb-In (1.5 NM).
the bus wire. 7. Align the bus bars over the IGBT connections and place
4. Remove the snubber card. the snubber board on the IGBT.
5. Remove the four T30 torx screws that secure the IGBT to 8. Insert the two T30 screws in the power connections
the heatsink. making sure the bus bar and IGBT connections are made.
6. Remove the IGBT. Also remove the two M4 standoffs from Torque to 35 Lb-In (4 NM).
the gate connections of the IGBT. The new spare part 9. Insert the two T20 screws, with washers, in the gate
does not include these standoffs. connections and torque to 13 Lb-In (1.5 NM).
10. Reconnect the bus wire to K1 with one T20 screw and
torque to 13 Lb-In (1.5 NM).
41
Removing the SCR/Diode modules:
1. Remove or loosen the six T30 torx screws
that secure the bus bars to the top of the modules.
Remove the input line connection to the failed or
defective SCR.
2. Remove the two T30 torx screws that secure the module
to the heatsink.
3. Unplug the gate connector from the module.
Reinstalling the SCR/Diode modules:

2. Align the new thermal pad over the mounting holes in the
heatsink.
3. Align the module so the gate connections point towards
the outside of the unit.
4. Insert the two T30 torx mounting screws, finger tight. For VLT 5060 - 5075
5. Torque the two T30 torx mounting screws following the
pattern shown.
6. Insert the six bus bar screws and secure finger tight.
7. Torque each module following the patterns shown:
8. Plug the gate connector on to the module. Tighten screws flush with the IGBT and torque initially to:
Torque A; 15 Lb-In (1.5 NM) Torque B; 9 Lb-In (1 NM)
Final torque to:

Torque A; 44 Lb-In (5 NM) Torque B; 26 Lb-In (3 NM)
For VLT 5100
Tighten screws flush with the IGBT and torque initially to:
Final torque to:

42
DISASSEMBLY INSTRUCTIONS Removing the control card:
VLT 5060 - 5100 1. Disconnect the cable going to the local control panel.
CHASSIS/NEMA1/IP20 cassette.
at a 45° angle.

Removing the cable tray:

On these units the removal of the capacitor bank and power
card will be much easier if the control wiring cable tray is
removed first.
1. Remove the black front plastic cover.
2. Remove the plexi-glass cover from the tray by removing
the four T20 torx screws.
3. Remove the two bottom M10 standoffs.
4. Remove the T20 screw that secures the stiffener to the
cable tray at the bottom of the unit.
5. Unplug the ribbon cables from the power card.
6. Remove the two T20 screws at the top of the cable tray.
7. The cable tray is now free. Rotate the right edge of the
tray to the left and lift out the tray.
To reinstall the cable tray reverse the procedure. Torque the

T20 and M10 hardware to 16 Lb-in or 1.8 NM.
Photo 12
VLT 5060 - 5100 CHASSIS/NEMA 1/IP20
43
Removing the capacitor bank: To reinstall the power card reverse the procedure.
Torque specifications: M10 locknuts to 27 Lb-In (3 NM).
1. Remove the three T28 torx screws securing the power
Cable placement: As the power card is installed the gate cable
card bracket to the capacitor bank.
assemblies align to the IGBT's from top to bottom. If a brake
is installed the bottom cable attaches to the brake IGBT.
Connect MK6, MK11 and MK12. The style and arrangement
3. Remove the two T30 torx screws from the +Bus and
–Bus connections.
connection. Connect the two ribbon cables from the control
card. The top power card connector mates to the lower
IGBT connections.
the mating connector.
6. While supporting the capacitor bank, remove the three
Removing the current sensors:
M10 locknuts.
7. Carefully remove the capacitor bank from the VLT. The spare current sensor assembly is provided as a complete
unit with the three sensors, output terminals, and wires all
To reinstall the capacitor bank reverse the procedure. mounted on a common base plate. It is done in this way
Torque specifications: since the three current sensors have integrated leads that all
T20 screws to 8 Lb-In (1 NM) combine into a common cable assembly within the VLT. It is
T30 screws for IGBT's 35 Lb-In (4 NM) also of prime importance that the correct sensor is placed in
T30 screws for + and –Bus 27 Ib-In (3 NM) the right output phase. Providing the assembly in this way
M8 locknuts to 16 Lb-In (2 NM) ensures correct placement of the sensors and makes
M10 locknuts to 27 Lb-In (3 NM) installation easier.
bottom of the capacitor bank. First connect the white wire to 1. Remove the motor leads from the output terminals.
the center stud. The shorter black wire from that same cable 2. Remove the T30 torx screws securing the 3 internal motor
assembly connects to the inner most stud and the longer cables to the output inductor.
black wire to the outer most stud. If a brake is installed in the 3. Unplug the heatsink thermal sensor connector from the
VLT then there will also be a 10 gauge wire attached to the cable harness.
inner most stud and a 4 gauge wire attached to the outer 4. Unplug the other end of the cable assembly at MK12 on
most stud. the power card.
5. Cut any tie wraps securing the cable assembly.
6. Remove the four 7mm lock nuts securing the base plate
Removing the power card: to the VLT enclosure.
1. Unplug the three cable assemblies that attach to the 7. Remove the entire assembly
IGBT's. If a brake is installed there will be 4.
2. Unplug the DC bus supply cable. To reinstall the current sensor assembly reverse the procedure.
3. Remove the M10 locknut from the top of the power cord Replace the tie wraps to secure the cable in place. Remember
mounting bracket to the heat sink. to reconnect the heatsink thermal sensor to the new cable
4. Tilt the power card towards the middle of the unit and harness and plug the cable harness into MK12 of the power
remove the connectors. card.
5. Lift the power card from the VLT.
Torque the 7mm lock nuts to 16 Lb-In (2 NM).
Note: If the power card is being replaced you must remove Torque the T30 Torx screws to 27 Lb-In (3 NM).
the lower mounting bracket from the power card. A new
bracket is not supplied with the spare part. The bracket is
secured to the power card by means of two T20 screws and
2 nylon swags.
44
1. Remove the T30 torx screw that secures the output cable functional.
to the IGBT.
the heatsink.
3. Align the IGBT so the gate connections point towards the 3. The large diode on the board is the snubber diode. With a
middle of the unit. VOM set to read diodes measure the diode and look for a
4. Insert the four T30 torx mounting screws, finger tight. voltage drop in one direction, infinity in the other.
pattern shown. Reinstalling the Brake IGBT:
the upper left hand side of the unit.
Tighten screws flush with the IGBT and torque initially to 4. Insert the four T30 torx mounting screws, finger tight.
9 Lb-In (1 NM) 5. Torque the four T30 torx mounting screws following the
pattern shown.

Tighten screws flush with the IGBT and torque initially to
6. Mount the output lead to the furthest terminal to the right 9 Lb-In (1 NM)
on the IGBT.

3. Remove the T20 torx screw at the K1 position, remove and torque to 13 Lb-In (1.5 NM).
the bus wire. 7. Align the bus bars over the IGBT connections and place
10. Reconnect the bus wire to K1 with one T20 screw and
torque to 13 Lb-In (1.5 NM).
45
Removing the SCR/Diode modules:
defective SCR.
2. Remove the two T30 torx screws that secure the module
to the heatsink.

heatsink.
the outside of the unit. For VLT 5060 - 5075
4. Insert the two T30 torx mounting screws, finger tight.
pattern shown.
7. Torque each module following the patterns shown: Tighten screws flush with the IGBT and torque initially to:
8. Plug the gate connector on to the module. Torque A; 15 Lb-In (1.5 NM) Torque B; 9 Lb-In (1 NM)
Final torque to:

For VLT 5100
Final torque to:

46
Removing the control card:

DISASSEMBLY INSTRUCTIONS 1. Disconnect the cable going to the local control panel.
VLT 5125 - 5150 cassette.
NEMA 12/IP54 3. Lift the cassette from the bottom until its approximately
at a 45° angle.

Cable placement: The ribbon cables are made such that
when laid flat the correct cable will be aligned to the proper

3. Remove the four T30 torx screws from the +Bus and
–Bus connections.
IGBT connections.
6. While supporting the capacitor bank, remove the four
M10 locknuts.
7. Carefully remove the capacitor bank from the VLT and
set upright.

T20 screws to 8 Lb-In (1 NM)
T30 screws for + and –Bus 27 Ib-In (3 NM)
bottom of the capacitor bank. First connect the white wire
to the center stud. The shorter black wire from that same
cable assembly connects to the inner most stud and the
longer black wire to the outer most stud. If a brake is installed
in the VLT then there will also be a 10 gauge wire attached
to the inner most stud and a 4 gauge wire attached to the
outer most stud.
Photo 13
VLT 5125 - 5150 NEMA 12/IP54
47
Removing the power card: Removing the current sensors:
1. Unplug the three cable assemblies that attach to the Each of the three current sensors is provided with a plug in
IGBT's. If a brake is installed there will be 4. connector so they can be replaced individually. It is of prime
2. Unplug the DC bus supply cable. importance that if more than one sensor is removed, when
3. Remove the M10 locknuts from the top and bottom of installing the sensors ensure the correct cable is associated
the power cord to the heat sink mounting bracket. with the correct output phase.
4. Tilt the power card towards the middle of the unit and
remove the connectors. 1. Loosen the 3/16 hex screw securing the internal motor
5. Lift the power card from the VLT 5000. cable to the splicer block.
2. Unplug the wire connector at the current sensor.
Note: If the power card is being replaced you must remove 3. Remove the two 8mm lock nuts securing the sensor to
the power cord mounting bracket from the power card. A the base plate.
new bracket is not supplied with the spare part. The bracket 4. Slide the sensor off the end of the cable.
is secured to the power card by means of two T20 screws
and 2 nylon swags. Note: For installing the wire into splicer block refer to photo
below.
To reinstall the power card reverse the procedure.
Torque specifications: M10 locknuts to 27 Lb-In (3 NM). To reinstall the sensor reverse the procedure. Be sure the
Cable placement: As the power card is installed the gate cable arrow on the top of the current sensor points towards the
assemblies align to the IGBT's from top to bottom. If a brake output of the VLT.
Torque the 8mm lock nuts to 16 Lb-In (2 NM)

Torque the 3/16 hex screws to 120 Lb-In (14 NM)
48
1. Remove the two T30 torx screw that secures the output functional.
cable to both upper and lower IGBT.
the heatsink.
3. Align the IGBT so the gate connections point towards the 3. The two large diodes on the board is the snubber diode.
middle of the unit. With a VOM set to read diodes measure the diode and
4. Insert the four T30 torx mounting screws, finger tight. look for a voltage drop in one direction, infinity in the
5. Torque the four T30 torx mounting screws following the other.
pattern shown.
Reinstalling the Brake IGBT:
Tighten screws flush with the IGBT and torque initially to the upper left hand side of the unit.
9 Lb-In (1 NM) 4. Insert the four T30 torx mounting screws, finger tight.
pattern shown.
6. Mount the output lead to the furthest terminal to the right Tighten screws flush with the IGBT and torque initially to
on the IGBT. The lower IGBT will be mounted on the left 9 Lb-In (1 NM)
terminal refer to photo 9.

3. Remove the two T20 torx screw at the K1 and K2 and torque to 13 Lb-In (1.5 NM).
positions, remove the bus wire. 7. Align the bus bars over the IGBT connections and place
10. Reconnect the bus wire to K1 and K2 with two T20 screws
and torque to 13 Lb-In (1.5 NM).
49
Removing the SCR/Diode modules: For VLT 5060 - 5075
defective SCR. Tighten screws flush with the IGBT and torque initially to:
2. remove the two T30 torx screws that secure the module Torque A; 15 Lb-In (1.5 NM) Torque B; 9 Lb-In (1 NM)
to the heatsink.

free of dirt and remaining thermal compound. Final torque to:
2. Align the new thermal pad over the mounting holes in the Torque A; 44 Lb-In (5 NM) Torque B; 26 Lb-In (3 NM)
heatsink.
pattern shown.
6. Insert the six bus bar screws and secure finger tight. For VLT 5125-5150
8. Plug the gate connector on to the module.
Final torque to:

50

1. Remove the black front plastic piece.
VLT 5125 - 5150 2. Loosen the two T20 torx captive screws to free the
at a 45° angle.

Cable placement: The ribbon cables are made such that
when laid flat the correct cable will be aligned to the proper

removed first.
3. Remove the four M10 standoffs.

Photo 14
51
Removing the capacitor bank: To reinstall the power card reverse the procedure.
1. Remove the three T20 torx screws securing the power Cable placement: As the power card is installed the gate cable
card bracket to the capacitor bank . assemblies align to the IGBT's from top to bottom. If a brake
2. Remove the three T20 torx screws securing the grounding is installed the bottom cable attaches to the brake IGBT.
bracket to the power card. Connect MK6, MK11 and MK12. The style and arrangement
3. Remove the four T30 torx screws from the +Bus and of the cables makes it impossible to make an incorrect
–Bus connections. connection. Connect the two ribbon cables from the control
4. Remove the six T30 torx screws from the cap bank to card. The top power card connector mates to the lower
IGBT connections. control card connector. Connect the DC bus supply cable to
M10 locknuts. Removing the current sensors:
7. Carefully remove the capacitor bank from the VLT. Each of the three current sensors is provided with a plug in
connector so they can be replaced individually. It is of prime
To reinstall the capacitor bank reverse the procedure. importance that if more than one sensor is removed, when
Torque specifications: installing the sensors ensure the correct cable is associated
T20 screws to 8 Lb-In (1 NM) with the correct output phase.
T30 screws for + and –Bus 27 Ib-In (3 NM) 1. Remove the T40 torx screw securing the internal motor
M8 locknuts to 16 Lb-In (2 NM) to the output inductor.
M10 locknuts to 27 Lb-In (3 NM) 2. Unplug the wire connector at the current sensor.
Cable placement: Reconnect the wires to the studs at the 3. Remove the two 8mm lock nuts securing the sensor to
bottom of the capacitor bank. First connect the white wire to the base plate.
the center stud. The shorter black wire from that same cable 4. Slide the sensor off the end of the cable.
assembly connects to the inner most stud and the longer
black wire to the outer most stud. If a brake is installed in the To reinstall the sensor reverse the procedure. Be sure the
VLT then there will also be a 10 gauge wire attached to the arrow on the top of the current sensor points towards the
inner most stud and a 4 gauge wire attached to the outer output of the VLT.
most stud.
Removing the power card: Torque the T40 torx screw to 64 Lb-In (7.2 NM)
1. Unplug the three cable assemblies that attach to the
IGBT's. If a brake is installed there will be 4.
2. Unplug the DC bus supply cable.
3. Remove the M10 locknuts from the top and bottom of
the power cord to the heat sink mounting bracket.
remove the connectors.

2 nylon swags.
52
1. Remove the two T30 torx screw that secures the output functional.
cable to both upper and lower IGBT.
the heatsink.
3. Align the IGBT so the gate connections point towards the 3. The two large diodes on the board is the snubber diode.
middle of the unit. With a VOM set to read diodes measure the diode and
4. Insert the four T30 torx mounting screws, finger tight. look for a voltage drop in one direction, infinity in the
5. Torque the four T30 torx mounting screws following the other.
pattern shown.
Tighten screws flush with the IGBT and torque initially to the upper left hand side of the unit.
9 Lb-In (1 NM) 4. Insert the four T30 torx mounting screws, finger tight.
pattern shown.
6. Mount the output lead to the furthest terminal to the right Tighten screws flush with the IGBT and torque initially to
on the IGBT. The lower IGBT will be anchored on the left 9 Lb-In (1 NM)
terminal. Refer to photo 9.

3. Remove the two T20 torx screw at the K1 and K2 and torque to 13 Lb-In (1.5 NM).
positions, remove the bus wire. 7. Align the bus bars over the IGBT connections and place
53
Removing the SCR/Diode modules: For VLT 5060 - 5075
1. Remove or loosen the six T30 torx screws that secure
the bus bars to the top of the modules.
defective SCR. Tighten screws flush with the IGBT and torque initially to:
2. Remove the two T30 torx screws that secure the module Torque A; 15 Lb-In (1.5 NM) Torque B; 9 Lb-In (1 NM)
to the heatsink.

free of dirt and remaining thermal compound. Final torque to:
2. Align the new thermal pad over the mounting holes in the Torque A; 44 Lb-In (5 NM) Torque B; 26 Lb-In (3 NM)
heatsink.
pattern shown.
6. Insert the six bus bar screws and secure finger tight. For VLT 5125-5150
Final torque to:

54

1. Disconnect the cable going to the local control panel.
VLT 5200 - 5250 2. Loosen the two T20 torx captive screws to free the
NEMA 12/IP54 cassette.
at a 45° angle.

Photo 15
VLT 5200 - 5250 NEMA 12/IP54
55

–Bus connections.
IGBT connections.
IGBT snubber board connections.
6. If a brake is installed, remove the wires from the three M8
studs at the bottom of the capacitor bank.
M10 locknuts.
8. Carefully remove the capacitor bank from the VLT.
NOTE: Now that the capacitor bank has been removed this
is a good time to test the condition of the snubber boards. Photo 16
IGBT with Snubber Board VLT 5200 - 5250
Testing snubber boards:
Only in the VLT 5200 and 5250 is the snubber board a
removable spare part. Part of this board are the snubber
diodes, capacitors and resistors. Also found on the board
are two smaller devices which appear to be diodes but are
actually transorbs, transient suppression devices. These two
transorbs are marked D3 and D4 and are placed across the
gate of the IGBT to suppress transient energy. For this reason
as soon as the snubber card is removed from the IGBT's the
gates of the IGBT's should be shorted together to protect
them from transient static electricity. Refer to photo 16.
56
Use a digital ohmmeter set on diode scale or an analog meter Removing the power card:
set on RX100.
Checking the snubber diodes, D1 and D2: IGBT's. If a brake is installed there will be 4.
1. Connect the positive (+) meter lead to the large tab and
the negative (–) meter lead to the small tab. The result
the lower mounting bracket.
should be a diode drop.
2. Reverse the meter leads, the reading should be infinity.
3. Repeat the same procedure on all the snubber diodes.
Should the diodes read incorrectly the entire snubber board
is to be replaced. If a snubber diode is found shorted, the
the power card mounting bracket from the power card. A
IGBT in that phase should also be replaced even if they have
new bracket is not supplied with the spare part. The bracket
tested good. See "Removing the IGBT's".
is secured to the power card by means of two T20 screws
and 2 nylon swags.
Checking the transorbs, D3 and D4:
1. Set your ohmmeter to read on the highest scale. Check
each device with the meter leads in one direction and then
in the other. Both readings should be infinity.
2. Repeat this same procedure on all transorbs.
Should a transorb read incorrectly the entire snubber board
is to be replaced. If a transorb is shorted it is likely that its
corresponding IGBT is also defective. It too should be
replaced. See "Removing the IGBT's".
Removing the IGBT's:
T20 screws for the IGBT's snubber board 14 Lb-In (2 NM)
Other T20 screws to 8 Lb-In (1 NM) Caution: IGBT's are sensitive to static electricity. Once the
T30 screws for IGBT's 84 Lb-In (9.5 NM) snubber board is removed a jumper must be placed across
T30 screws for + and –Bus 27 Ib-In (3 NM) the gate leads of the IGBT.
M10 locknuts to 27 Lb-In (3 NM) Note: If an IGBT is found defective ensure the snubber board
Cable placement: Reconnect the wires to the studs at the has been tested as described above. Always replace both
bottom of the capacitor bank. First connect the white wire to IGBT's in the damaged phase even if the other IGBT tested
the center stud. The shorter black wire from that same cable good.
black wire to the outer most stud. If a brake is installed in the 1. Remove the snubber board by removing the four T20
VLT then there will also be a 10 gauge wire attached to the screws from the gate connections and the two T20 screws
inner most stud and a 4 gauge wire attached to the outer securing the board to the jumper bus bar.
most stud. 2. Remove the two T30 torx screw that secure the bus bar
jumper to the two IGBT's.
3. Remove the four T30 torx screws that secure the IGBT to
the heatsink.
57
Reinstalling the IGBT's: Now that the snubber board is removed this is a good time
1. Remove the thermal pad and insure the heatsink is free of
functional.
dirt and remaining thermal compound.
Testing the Brake Snubber Board:
heatsink.
3. Align the IGBT so the gate connections point towards the 1. The two diodes, D1 and D2, provide transient suppression
middle of the unit. for the gate of the IGBT. With a VOM set to read diodes,
4. Insert the four T30 torx mounting screws, finger tight. measure the two diodes and look for a voltage drop in
5. Torque the four T30 torx mounting screws following the one direction, infinity in the other.
pattern shown. 2. Resistors R1 - R12 are 1ohm resistors in parallel. Place
resistance value will be equal to .08ohm. Most meters
will not read this low resistance accurately so the
important thing is to insure the resistance value is close
without a short circuit or open being present.
3. The two large diodes on the board is the snubber diode.
Tighten screws flush with the IGBT and torque initially to With a VOM set to read diodes measure the diode and
10 Lb-In (1.5 NM) look for a voltage drop in one direction, infinity in the
other.

Final torque to 31-39 Lb-In (3.5-4.5 NM) 2. Align the new thermal pad on the heatsink.
6. Mount the bus bar jumper to the two IGBT's. Reference the upper left hand side of the unit.
photo 10. 4. Insert the four T30 torx mounting screws, finger tight.
7. Torque the T30 torx screws to 66-84 Lb-In (7.5-9.5 NM). 5. Torque the four T30 torx mounting screws following the
8. Install the snubber board aligning the wholes with the pattern shown.
IGBT's.
9. Torque the 6 T20 screws to 12-15 Lb-In (1.3-1.7 NM).

connection from the snubber card to the IGBT. Tighten screws flush with the IGBT and torque initially to
2. Remove the two T20 torx screws that make the gate 9 Lb-In (1 NM)
connection from the snubber card to the IGBT..
3. Remove the T20 torx screws at the K1, K2 and K3
positions, remove the bus wire.
4. Remove the snubber card.
the heatsink.
6. Remove the IGBT. Also remove the two M4 standoffs from Final torque to 22-30 Lb-In (2.5-3.5 NM)
the gate connections of the IGBT. The new spare part
does not include these standoffs. 6. Insert the M4 standoffs in the IGBT gate connections
7. Align the bus bars over the IGBT connections and place
the snubber board on the IGBT.
8. Insert the two T30 screws in the power connections
making sure the bus bar and IGBT connections are made.
Torque to 35 Lb-In (4 NM).
9. Insert the two T20 screws, with washers, in the gate
connections and torque to 13 Lb-In (1.5 NM).
58
Removing the SCR/Diode modules: Removing the current sensors:

1. Remove or loosen the six T30 Drive Dependent torx Each of the three current sensors is provided with a plug in
screws that secure the bus bars to the top of the modules. connector so they can be replaced individually. It is of prime
Remove the input line connection to the failed or importance that if more than one sensor is removed, when
defective SCR. installing the sensors ensure the correct cable is associated
2. Remove the additional T30 torx screws from the module with the correct output phase.
being replaced.
3. Remove the four T30 torx screws that secure the module 1. Loosen the 5/16 (8mm) hex screw securing the internal
to the heatsink. motor cable to the splicer block.
4. Unplug the gate connector from the module. 2. Unplug the wire connector at the current sensor.
5. Slide the module out from under the bus bars. 3. Remove the two 8mm lock nuts securing the sensor to
the base plate.
Reinstalling the SCR/Diode modules: 4. Slide the sensor off the end of the cable.
1. Remove the thermal pad and insure the heatsink is free of Note: For installing the wire into splicer block refer to photo
dirt and remaining thermal compound. below.
heatsink. To reinstall the sensor reverse the procedure. Be sure the
3. Align the module so the gate connections point towards arrow on the top of the current sensor points towards the
the bottom of the unit. output of the VLT.
4. Insert the four T30 torx mounting screws, finger tight.
5. Torque the mounting screws following the pattern shown.
7. Torque each module following the pattern below:
Tighten screws flush with the IGBT and torque initially to: Torque the 8mm lock nuts to 16 Lb-In (2 NM)
Torque A; 15 Lb-In (1.5 NM) Torque B; 26 Lb-In (3 NM) Torque the 5/16 (8mm) hex screws to 120 Lb-In (14 NM)
Final torque to:

59
VLT 5200 - 5250 1. Remove the black front plastic piece.

at a 45° angle.


removed first.
3. Remove the four M10 standoffs.

Photo 17
60

1. Remove the three T20 torx screws securing the power
card to the capacitor bank.
–Bus connections.
IGBT connections.
5. Remove the six T20 torx screws from the cap bank to the
IGBT snubber board connections.
6. If a brake is installed, remove the wires from the three M8
studs at the bottom of the capacitor bank.
M10 locknuts.
8. Carefully remove the capacitor bank from the VLT and set
upright.
NOTE: Now that the capacitor bank has been removed this IGBT with Snubber Board VLT 5200 - 5250
is a good time to test the condition of the snubber boards. Photo 18
Testing snubber boards:

Only in the VLT 5200 and 5250 is the snubber board a
removable spare part. Part of this board are the snubber
diodes, capacitors and resistors. Also found on the board
are two smaller devices which appear to be diodes but are
actually transorbs, transient suppression devices. These two
transorbs are marked D3 and D4 and are placed across the
gate of the IGBT to suppress transient energy. For this reason
as soon as the snubber card is removed from the IGBT's the
gates of the IGBT's should be shorted together to protect
them from transient static electricity. Reference photo 18.
61
Use a digital ohmmeter set on diode scale or an analog meter Removing the power card:
set on RX100.
Checking the snubber diodes, D1 and D2: IGBT's. If a brake is installed there will be 4.
1. Connect the positive (+) meter lead to the large tab and
the negative (–) meter lead to the small tab. The result
the lower mounting bracket.
should be a diode drop.
2. Reverse the meter leads, the reading should be infinity.
3. Repeat the same procedure on all the snubber diodes.
Should the diodes read incorrectly the entire snubber board
is to be replaced. If a snubber diode is found shorted, the
IGBT in that phase should also be replaced even if they have
tested good. See "Removing the IGBT's".
2 nylon swags.
Checking the transorbs, D3 and D4:
1. Set your ohmmeter to read on the highest scale. Check
each device with the meter leads in one direction and then
in the other. Both readings should be infinity.
2. Repeat this same procedure on all transorbs.
Should a transorb read incorrectly the entire snubber board
is to be replaced. If a transorb is shorted it is likely that its
corresponding IGBT is also defective. It too should be
replaced. See "Removing the IGBT's".
Removing the IGBT's:
T20 screws for the IGBT's snubber board 14 Lb-In (2 NM)
Other T20 screws to 8 Lb-In (1 NM) Caution: IGBT's are sensitive to static electricity. Once the
T30 screws for IGBT's 84 Lb-In (9.5 NM) snubber board is removed a jumper must be placed across
T30 screws for + and –Bus 27 Ib-In (3 NM) the gate leads of the IGBT.
M10 locknuts to 27 Lb-In (3 NM) Note: If an IGBT is found defective ensure the snubber board
Cable placement: Reconnect the wires to the studs at the has been tested as described above. Always replace both
bottom of the capacitor bank. First connect the white wire to IGBT's in the damaged phase even if the other IGBT tested
the center stud. The shorter black wire from that same cable good.
black wire to the outer most stud. If a brake is installed in the 1. Remove the snubber board by removing the four T20
VLT then there will also be a 10 gauge wire attached to the screws from the gate connections and the two T20 screws
inner most stud and a 4 gauge wire attached to the outer securing the board to the jumper bus bar.
most stud. 2. Remove the two T30 torx screw that secure the bus bar
jumper to the two IGBT's.
the heatsink.
62
Reinstalling the IGBT's: Now that the snubber board is removed this is a good time
1. Remove the thermal pad and insure the heatsink is free of
functional.
dirt and remaining thermal compound.
Testing the Brake Snubber Board:
heatsink.
3. Align the IGBT so the gate connections point towards the 1. The two diodes, D1 and D2, provide transient suppression
middle of the unit. for the gate of the IGBT. With a VOM set to read diodes,
4. Insert the four T30 torx mounting screws, finger tight. measure the two diodes and look for a voltage drop in
5. Torque the four T30 torx mounting screws following the one direction, infinity in the other.
pattern shown. 2. Resistors R1 - R12 are 1ohm resistors in parallel. Place
resistance value will be equal to .08ohm. Most meters
will not read this low resistance accurately so the
important thing is to insure the resistance value is close
without a short circuit or open being present.
3. The two large diodes on the board is the snubber diode.
Tighten screws flush with the IGBT and torque initially to With a VOM set to read diodes measure the diode and
10 Lb-In (1.5 NM) look for a voltage drop in one direction, infinity in the
other.

Final torque to 31-39 Lb-In (3.5-4.5 NM) 2. Align the new thermal pad on the heatsink.
6. Mount the bus bar jumper to the two IGBT's. Reference the upper left hand side of the unit.
photo 10. 4. Insert the four T30 torx mounting screws, finger tight.
7. Torque the T30 torx screws to 66-84 Lb-In (7.5-9.5 NM). 5. Torque the four T30 torx mounting screws following the
8. Install the snubber board aligning the wholes with the pattern shown.
IGBT's.
9. Torque the 6 T20 screws to 12-15 Lb-In (1.3-1.7 NM).

connection from the snubber card to the IGBT. Tighten screws flush with the IGBT and torque initially to
2. Remove the two T20 torx screws that make the gate 9 Lb-In (1 NM)
connection from the snubber card to the IGBT..
3. Remove the T20 torx screws at the K1, K2 and K3
positions, remove the bus wire.
4. Remove the snubber card.
the heatsink.
6. Remove the IGBT. Also remove the two M4 standoffs from Final torque to 22-30 Lb-In (2.5-3.5 NM)
the gate connections of the IGBT. The new spare part
does not include these standoffs. 6. Insert the M4 standoffs in the IGBT gate connections
7. Align the bus bars over the IGBT connections and place
the snubber board on the IGBT.
8. Insert the two T30 screws in the power connections
making sure the bus bar and IGBT connections are made.
Torque to 35 Lb-In (4 NM).
9. Insert the two T20 screws, with washers, in the gate
connections and torque to 13 Lb-In (1.5 NM).
63
Removing the SCR/Diode modules: Removing the current sensors:
1. Remove or loosen the six T30 Drive Dependent torx Each of the three current sensors is provided with a plug in
screws that secure the bus bars to the top of the modules. connector so they can be replaced individually. It is of prime
Remove the input line connection to the failed or importance that if more than one sensor is removed, when
defective SCR. installing the sensors ensure the correct cable is associated
2. Remove the additional T30 torx screws from the module with the correct output phase.
being replaced.
3. Remove the four T30 torx screws that secure the module 1. Loosen the 5/16 (8mm) hex screw securing the internal
to the heatsink. motor cable to the splicer block.
4. Unplug the gate connector from the module. 2. Unplug the wire connector at the current sensor.
5. Slide the module out from under the bus bars. 3. Remove the two 8mm lock nuts securing the sensor to
the base plate.
Reinstalling the SCR/Diode modules: 4. Slide the sensor off the end of the cable.
1. Remove the thermal pad and insure the heatsink is free of Note: For installing the wire into splicer block refer to photo
dirt and remaining thermal compound. below.
heatsink. To reinstall the sensor reverse the procedure. Be sure the
3. Align the module so the gate connections point towards arrow on the top of the current sensor points towards the
the bottom of the unit. output of the VLT 5000.
4. Insert the four T30 torx mounting screws, finger tight.
5. Torque the mounting screws following the pattern shown.
7. Torque each module following the pattern below:

Tighten screws flush with the IGBT and torque initially to: Torque the 5/16 (8mm) hex screws to 120 Lb-In (14 NM)
Final torque to:

64
VLT 5060
65
VLT 6075 and 5075 Aqua
66
VLT 5075
67
68
VLT 5100
69
70
VLT 5125
71
72
VLT 5150
73
74
VLT 5200
75
76
VLT 5250
77
78
VLT® 5060 - 5250

SCR/Diode Installation and Torque Specifications
Installation
Note: For the VLT 5060 - 5250, the SCR/Diode module ia a single package that contains both devices.
1. Prior to installing the SCR/Diode module ensure the surface area of the heatsink is clean of dirt and excess
thermal compound.
2. Before installing the SCR/Diode module, place the thermal pad provided on the surface of the heatsink, aligning it
with the SCR/Diode mounting holes.
3. Place the SCR/Diode module in position. Install the mounting screws and tighten by hand until the head is flush
with the surface of the module.
4. Identify the SCR/Diode module style and adhere to the following tightening patterns and torque specifications as
each connection to the module is made.
VLT Torque A Torque B

VLT 5060 44 LB•IN (5 NM) 27 LB•IN (3 NM)
VLT 5200-5250 44 LB•IN (5 NM) 80 LB•IN (9 NM)
The following figures indicate torque designation, A and B:
The following figures show tightening patterns. First, hand tighten until the screw head is flush. Second, torque to
one-third of the value listed above in the pattern shown. Final torque in the same pattern to the values listed above.
79
VLT® 5060 - 5250

IGBT Installation and Torque Specifications
Caution: The gate of the IGBT is static sensitive. The Inverter IGBT's used in the VLT 5060-5150 have gate drive
boards mounted to the gate terminals. These are not to be removed. Gate drive boards are provided with the
replacement spare part IGBT.
The Inverter IGBT's used in the VLT 5200 and 5250 and all brake IGBT's will have the gate connections exposed
when the snubber board is removed. Immediately after removing the snubber board a jumper must be placed
across the gate leads to prevent the IGBT from being damaged by static electricity.
Installation
1. Prior to installing the IGBT ensure the surface area of the heatsink is clean of dirt and excess thermal compound.
2. Before installing the IGBT, place the thermal pad provided on the surface of the heatsink aligning it with the IGBT
mounting holes.
3. Place the IGBT in position. Install the mounting screws and tighten by hand until the head is flush with the surface
of the IGBT.
4. Identify the IGBT style and adhere to the following tightening patterns and torque specifications as each
connection to the IGBT is made.
IGBT Position and VLT Torque A Torque B Torque C

Inverter VLT 5060-5075 22-30 LB•IN (2.5-3.5 NM) 31-39 LB•IN (3.5-4.5 NM) N/A
Inverter VLT 5100 22-30 LB•IN (2.5-3.5 NM) 31-39 LB•IN (3.5-4.5 NM) N/A
Inverter VLT 5125-5150 22-30 LB•IN (2.5-3.5 NM) 31-39 LB•IN (3.5-4.5 NM) 12-15 LB•IN (1.3-1.7 NM)
Inverter VLT 5200-5250 31-39 LB•IN (3.5-4.5 NM) 66-84 IB•IN (7.5-9.5 NM) 12-15 LB•IN (1.3-1.7 NM)
Brake VLT 5060-5100 22-30 LB•IN (2.5-3.5 NM) 31-39 LB•IN (3.5-4.5 NM) 12-15 LB•IN (1.3-1.7 NM)
The following figures indicate torque designation, A,B or C:
OR OR
The following figures show tightening patterns. First hand tighten until the screw head is flush. Second torque to one-
third of the value listed above in the pattern shown:
OR
The following figures show final tightening patterns. Final torque to the value listed above in the pattern shown:
OR
80
The Signal Test Board can be used to monitor a variety of signals that are available from the power card. Refer to the
following pages for test point and signal information. Order the Signal Test Board using part number 176F1429.
TYPICAL CHASSIS TYPICAL NEMA 12
81
Signal Description and Voltage Levels:

Other than power supply measurements most of the signals being measured are made up by a waveform. Though in
some cases a digital voltmeter can be used to verify the presence of such signals, it cannot be relied upon to verify the
waveform is correct. An oscilloscope is the instrument of choice, however when similar signals are being measured at
multiple points a digital voltmeter can 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
another and therefore are correct.
Power Supplies:
Four separate power supplies are available using the Signal Board.
+5 volt DC Green LED indicates voltage present
±14 volt DC Red LED indicates voltage present
+24 volt DC Yellow LED indicates voltage present
+5 volt DC (RS485) No LED present
Test Point Schematic

No. Color Acronym Function Comments Reading from Digital Volt Meter
7 Red +5V +5.0 VDC regulated Green LED indicates voltage +5.0 VDC regulated supply
supply. +4.75-5.25 VDC is present. +4.75 to 5.25 VDC
9 Red +14V1 +14 VDC supply. Red LED indicates voltage is +14 VDC supply.
+12 VDC to +15 VDC present between +14 and –14v +12 to +15 VDC
terminals.
10 Red –14V1 –14 VDC supply See +14v comment. –14 VDC supply.
–12 to –15 VDC –12 to –15 VDC
8 Black COMMON Logic common This common is for all signals
except TP31 and TP33.
31 Yellow +24V +24 VDC power supply +21 to +27 VDC Yellow LED +21 to +27VDC
indicates voltage is present
+21 to +27 VDC between
pins 31 and 32.
32 Black COMMON +24 VDC common Use only for TP31
33 White VCX +5.0 VDC regulated 5.0 VDC regulated supply is 5 VDC between TP33 and
supply for RS 485. reserved for the RS 485 com- and TP34.
+4.75 to 5.25VDC munications link on the control
card.
34 White GX 5v common for RS 485 Use only for TP33
82
Gate Signals:
The gate signals available on the Signal Board are monitored at the low voltage side of the opto-isolator on the Power
Card. The presence of the gate signal on the Signal Board does not ensure the signal is making it through the opto and
to the gate of the IGBT. Reference figures 1 and 2.
Test Point Schematic Average Waveform Reading

No. Color Acronym Function Comments when using a Digital Volt Meter
1 White BWN IGBT gate signal, buf- Compare each Gate signal, 2.3 - 2.4 VDC
fered, W phase, neg- looking for consistency between Equal on all phases TP1-TP6
ative. Signal originates each phase.
on Control Card.
2 White BWP IGBT gate signal buf- Compare each Gate signal, 2.3-2.4 VDC
fered, W phase, pos- looking for consistency between Equal on all phases TP1-TP6
itive. Signal originates each phase.
on Control Card.
3 White BVN IGBT gate signal, buf Compare each Gate signal, 2.3-2.4 VDC
fered, V phase, neg- looking for consistency between Equal on all phases TP1-TP6
on Control Card.
4 White BVP IGBT gate signal, buf- Compare each Gate signal, 2.3-2.4 VDC
fered, V phase, pos- looking for consistency between Equal on all phases TP1-TP6
on Control Card.
5 White BUN IGBT gate signal, buf- Compare each Gate signal, 2.3-2.4 VDC
fered, U phase, neg- looking for consistency between Equal on all phases TP1-TP6
on Control Card.
6 White BUP IGBT gate signal, buf- Compare each Gate signal, 2.3-2.4 VDC
fered, U phase, pos- looking for consistency between Equal on all phases TP1-TP6
on Control Card.
except TP31, TP33 & TP34.
Figure 1. Figure 2.
Typical gate drive signal when using an oscilloscope. VLT 5000 in run mode, running at zero speed.
83
Current Feedback Signals

Current feedback signals consist of both non-conditioned and conditioned signals. Non-conditioned (IU1, IV1, IW1) are
the non-buffered signals that come straight from the current sensor to the power card. Conditioned (IU, IV, IW) are the
buffered non-conditioned signals that are sent from the Power Card to the Control Card. Reference figures 3 and 4.

11 White IU1 Current sensed, U All current feedback signals Less than 15mV at zero current
phase, not conditioned. should be compared to each 890mV AC (VLT 5100 at 87A)
other. All measurements will be
within mV's from each other in
normal operation.
12 White IV1 Current sensed, V All current feedback signals Less than 15mV at zero current
normal operation.
13 White IW1 Current sensed, W All current feedback signals Less than 15mV at zero current
normal operation.
14 White IU Current sensed, U All current feedback signals Less than 15mV at zero current
phase, conditioned. should be compared to each 890mV AC (VLT 5100 at 87A)
normal operation.
15 White IV Current sensed, V All current feedback signals Less than 15mV at zero current
normal operation.
16 White IW Current sensed, W All current feedback signals Less than 15mV at zero current
normal operation.
8 Black COMMON Logic common This common is for all signals except TP31 and TP33.
Figure 3. Figure 4.
Typical current feedback waveform when using an oscilloscope. VLT 5100 at 84 amps.
84
Brake Signals
The DBGATE signal is enabled by signal (BRPWM) originating from the Control Card. The DBGATE signal is monitored
at the low voltage side of the opto-isolator on the Power Card. The presence of the gate signal on the Signal Board does
not ensure the signal is making it through the opto and to the gate of the IGBT. The DBRTON signal is the low voltage
feedback indicating the brake IGBT is conducting by a flow of current through the collector to the emitter.
Reference figures 5 and 6.
Test
1) Insure drive is running at zero speed.
2) For SB and EB drives only, change parameter 400 to Resistor.
A resistor must be hooked up to the drives R+ and R– terminals.
3) Display DC Link Voltage in the LCP. (Parameter 009-012 can be changed to customize display).
4) Close Over Volt Test switch (down position).
5) Monitoring voltage in display, increase the DC Link Voltage by turning the potentiometer counter clockwise.
a) check brake operation message in LCP and verify signal (DBGATE DBRTON)
~795vDC Brake turn on voltage (380-500 volt units)
6) Upon completion of the tests turn potentiometer fully clockwise and open switch (up position).
7) Return all changed parameters to original settings.

17 White DBGATE Brake IGBT gate pulse Pulse wave form. May use 4.04 volt DC level with brake
train. OVERVOLTAGE TEST switch turned off. Voltage drops to
and potentiometer to force brak- zero when brake is turned on.
ing.
18 White DBRTON Brake IGBT 5V logic Pulse wave form. May use 5.10 volt DC level with brake
level signal. OVERVOLTAGE TEST switch turned off. Voltage drops to
and potentiometer to force brak- zero when brake is turned on.
ing.
except TP31 and TP33.
Figure 5. Figure 6.
Typical waveform when using an oscilloscope. VLT 5060 at zero speed using the Overvolt Test switch to force braking.
85
Fan Signals
FAN-ON - Is active anytime the fan is running, either high or low speed. The waveforms falling edge is synchronized with
AC line (S & T). If the fan is off, this signal is pulled to –14 volt DC.
45°C the fan is turned on low speed
60°C the fan is turned on high speed
55°C the fan is turned from high to low speed
<30°C the fan is turned off
HI-LOW - This signal changes the fans speed to high speed.
Test
1) Power must be applied to drive, but RUN command is not necessary.
2) Display Heatsink Temp in LCP. (Parameter 009-012 can be changed to customize display).
3) Monitor FAN-ON and/or Monitor HI-LOW
4) Close Fan Test switch (down position).
a) Verify FAN-ON signal (high speed only)
b) Verify HI-LOW voltage
5) Open Fan Test switch (up position), view heatsink temperature in LCP if <55°C verify if fan is running in low speed by
the FAN-ON signal. If fan is off start and run drive if possible, to heat up the heatsink. Once the heatsink temperature
is >45°C fan will be on low speed, verify FAN-ON signal.
6) Upon completion of tests insure Fan Test switch is open (up position).

23 White FAN-ON Fan speed control TRIAC Rectangular pulses Is turned off by FANO signal (heat sink
gate pulse train. temperature < 45°C) from control card at which time FAN-ON
is forced to –14v.
24 White HI-LOW Commands the fan Commands the fan speed con- 0 vDC with fan off.
speed control circuit to trol circuit to run the fans fast 14 vDC with fan on high.
run the fans fast . when the hear sink is over 60°C
or other conditions warrant or
when the POWER CARD TEST-
ER FAN TEST switch is closed.
Fast ~230VAC, slow ~165VAC
at the fan terminals.
Figure 7. Figure 8.
Typical waveform when using an oscilloscope. Fan On - High was forced by using the Fan Test Switch. Fan On - Low
was with the drive running at 60Hz and the heatsink above 45°C.
86
DC Bus Signals
Use the following signal to verify actual DC Bus voltage (UINV) or determine if the upper limit of the DC bus has been
reached (HVLIM).
UNIV - A scaled low voltage representation of the DC bus voltage.
Use the formula [256 • (meter voltage) = DC Bus voltage] to determine if the power card is relaying the
correct information to the processor.
HVLIM - This signal is high when an upper limit is reached.
HVLIM set points in the drive.
380-500 volt units 815 volts DC
200-240 volt units 400 volts DC
Test
1) Insure drive is running at zero speed.
2) Display DC Link Voltage in the LCP. (Parameter 009-012 can be changed to customize display).
3) Disconnect brake resistors R+ and R– if applicable, turn Parameter 400 off (SB and EB units only).
4) Close Over Volt Test switch (down position).
5) Monitor voltage in display, increase the DC Link Voltage by turning the potentiometer counter clockwise.
a) Record Warning and Alarm voltage set points, verify signal voltage once high voltage limit is reached (HVLIM)
Warnings: 200-240 volt units 384 w/o brake — 405 w/brake ±5%
380-500 volt units 801 w/o brake — 840 w/brake ±5%
Alarms: 200-240 volt units 425 volts DC ±5%
380-500 volt units 855 volts DC±5%
b) Verify DC Link voltage (UNIV)
[256 • (meter voltage) = DC Bus voltage]
6) Upon completion of tests turn potentiometer fully clockwise and open switch (up position).
7) Return all changed parameters to original settings.

27 White HVLIM High bus voltage limit Nominal bus voltage threshold –6 VDC no high voltage fault
has been exceeded. is ~815v (790-840v). 6 VDC with active high voltage
~+6v indicates over fault
threshold, ~–6v indi-
cates under.
28 White UINV Bus voltage scaled down @ 500v bus, 1.953v, (1.924v to Formula for determining DC bus
to 1/256 ±3% 1.98v) @ 800v bus, 3.125v, voltage [256 • (meter voltage) =
(3.078v to 3.172v) DC bus level]
87
Auxiliary Signals
OTFLT - PCB-OT (Power Card Over Temp Signal), PCB-UT (Power Card Under Temp Signal), IND-OT (Inductor Over
Temp Signal), and EXTDIS (MK10 jumper terminals 106 & 104) are inputs to a four input Nor Gate that gives an Over
Temperature fault on the Power Card. The OTFLT is also sent to disable the input SCR's.
INRUSH - This signal is sent from the Control Card to a 4 input NOR gate that is then sent to the low voltage side of the
opto-isolator for the SCR's gate. It is also used for gating the internal 24 volt fans. Reference figure 9.
SYNC - This is the carrier frequency signal. This could be used as an external trigger function for an Oscilloscope.
SCR-DIS - This signal is on the low voltage side of the input SCR's and internal fan Gate signals, which forces the signal
low turning the input SCR's off.
TEMP - This signal is the analog voltage from the NTC. It can be used to determine correct feedback from heatsink
thermal sensor through the acquired voltage on test point 30, using this formula [2.82 – (∆ T • .035) = VTEMP ] ∆T = heatsink
temperature –30°C
Test
1) Power must be applied to the drive, but a RUN command is not necessary.
2) Display Heatsink Temp in LCP. (Parameter 009-012 can be changed to customize display).
a) Measure and verify TEMP with displayed temperature.
[2.82 – (∆ T • .035) = VTEMP ] ∆T = heatsink temperature –30°C
3) Close Fan Test switch, view heatsink temperature in LCP and compare temperature with voltage from signal using
the formula above.

19 White OTFLT Combined inductor Verify jumper is present in term- Fault = 0v, no fault = 5v
(LED3), brake resistor inal block of MK10 of the Power
(LED4), and power card Card. Terminals 106 to 104.
over temperature (LED1)
faults plus power card
under temperature
(LED2) fault.
(LED1) faults plus power

under temperature
(LED2) fault. OTFLT will
turn off front end SCRs
and inverter IGBTs.
20 White INRUSH Signal from BCC enabl- Use oscilloscope
ing turning on the front
end SCRs.
21 White SYNC The carrier frequency of This is the carrier frequency signal. This could be used as an
the drive. external trigger function for an oscilloscope.
25 White SCR-DIS 0v indicates SCRs and SCRs and internal fans are turn-
internal fans (24vdc) dis- ed on by INRUSH signal
abled. Enabled signal from the control card
level is 0.6 to 0.8 volts.
30 White TEMP Provides a low voltage Will read ~3.267 volts if the cir- Formula for determining heat-
analog signal propor- cuit to the NTC on the heat sink sink temp
tional to heat sink temp- is open. As heatsink tempera- [2.82 – (∆ T • .035) = VTEMP]
erature. ture increases the TEMP signal (∆T = heatsink Temp. –30°C)
decreases.
88
Figure 9
Figure 10 Figure 11
89
Switches / Potentiometer
Three switches on the Signal Board are used in conjunction with select signals to either force conditions or verify signals
are operational.
Fan Test - This switch will force the fan on high speed. This enables you to check the FAN-ON, HI-LOW signals. Also use
the TEMP signal to verify the change in heatsink temperature.
1) Power must be applied to the drive, but a RUN command is not necessary.
2) Display Heatsink Temp in LCP. (Parameter 009-012 may be changed to customize display).
3) Monitor FAN-ON and/or Monitor HI-LOW
4) Close Fan Test switch (down position).
a) Verify FAN-ON signal (high speed only)
b) Verify HI-LOW voltage
c) Measure and verify TEMP signal is changing with displayed temperature.
[2.82 – (∆ T • .035) = VTEMP ] ∆T = heatsink temperature –30°C
5) Open the Fan Test switch (up position), view heatsink temperature in LCP if ≤55°C verify if fan is running in low
speed by the FAN-ON signal. If fan is off, start and run drive if possible, to heat up the heatsink. Once the heatsink
temperature is >45°C fan will be on low speed, verify FAN-ON signal.
Inverter Dis - This switch will cause the drives output section to be disabled. This is only functional in Rev E power cards.
OverVolt Test - This switch can be used to check the DBGATE, DBRTON, HVLIM< and UINV are in working order.
1) Insure the drive is running at zero speed.
2) Display DC Link Voltage in the LCP. (Parameter 009-012 may be changed to customize display).
3) Disconnect brake resistors R+ and R– if applicable, turn Parameter 400 off (SB and EB units only).
4) Close the Over Voltage Test switch (down position).
5) Monitoring voltage in display, increase the DC Link Voltage by turning the potentiometer counter clockwise.
a) Record warning and Alarm voltage set points, verify signal voltage once high voltage limit is reached (HVLIM)
Warnings:
Alarms:
200-240 volt units 425 volts DC ±5%
380-500 volt units 855 volts DC ±5%
b) Verify the DC Link Voltage (UNIV)
[256 • (meter voltage ) = DC Bus voltage]
6) Turn the potentiometer full clockwise and open the switch (up position).
7) For SB and EB drives only, change parameter 400 to Resistor. A resistor must be hooked up to the drives R+ and
R– terminals.
8) Close the Over Volt Test switch (down position).
9) Monitoring the voltage in the display, increase the DC Link Voltage by turning the potentiometer counter clockwise.
a) Check Brake operation and verify signal (DBGATE DBRTON)
10) Upon completion of tests turn the potentiometer fully clockwise and open the switch (up position).
11) Return all parameters to original settings.
90
91
SCR Gate Driver Test Cable

The SCR Gate Driver Test Cable gives the technician the ability to breakout and extend the
length of the cable supplying the gate signals from the power/IF cards to the SCR’s. The breakout
enables the technician access to the gate signal wires away from high voltages (both AC input
and DC bus) and a 2 inch gap in the shield enables proper placement of test equipment . By
using a clamp-on current probe, attached to an oscilloscope, the proper firing signals of SCR can
be both verified and measured. With out this cable the ability to verify the proper firing of the
SCR’s is next to impossible due to the close proximity of components in the drives.
92
Installation
Once the voltages are removed the SCR gate lead connection needs to be removed. This is done
by removing:
MK14 -VLT 3060-3250 500 Volt, VLT 3032-3052 200 Volt
MK6 -VLT 5060-5250 500 Volt, VLT 5032-5052 200 Volt, VLT 5075-5300 Aqua 460 Volt,
VLT 5042-5062 Aqua 200 Volt, VLT 6075-6275 460 Volt VLT 6042-6062 200 Volt
MK5 - VLT 5300-5500 500 Volt, VLT 5350-5600 Aqua 460 Volt, VLT 6350-6550 460 Volt
Now, proceed by plugging the SCR Gate Driver Test Cable into the applicable MK connector on the
power/IF card. The other end is then plugged into the original SCR gate lead closing the loop from
the SCR’s to the power/IF card. Once the cable is hooked up use a current probe and an
oscilloscope connecting the probe around the white wire of the SCR Gate Driver Test Cable. Now it
is time AC power can be reconnected and the proper gate signal wave form can be verified.
The current pulse should have a waveform as shown at left with:
A1 > 1.1 A
A2 > 0.40 A
T1> 300 µs
Figure 1: SCR Gate Current Pulse Waveform
Figure 2: SCR Gate Current Pulse Waveform with a 112 Amp load.
93
Power Card DC Supply Source
The Power Card DC Supply Source is an alternate means of powering up the inverter section of
the VLT without applying DC bus voltage to the remainder of the unit. In VLT 5000, 6000 and
5000 AQUA Series units, it also makes it possible to power the inverter section while the
capacitor bank is removed. This can be helpful in troubleshooting, enabling the technician to
make a variety of tests without the risk of damage or injury due to a fully charged DC bus. One
such example is the ability to test IGBT gate drive signals right at the IGBT connection. Such a
test can only be made with the capacitor bank removed and the power card powered from an
alternative source. The Power Card DC Supply Source does not in itself perform any diagnostic
tests.
Safety Notice
Keep in mind the voltage levels in the drive are still maintained through the Power Card DC
Supply Source. Both AC and DC voltage are present in the drive while servicing, so close
attention is required to prevent either personnel injury and/or equipment damage. The use of the
Power Card DC Supply Source should be done by a qualified technician familiar with the voltage
levels inside the VLT.
94
VLT 5000, 6000 and 5000 AQUA Installation
For Power Card DC Supply Source installation in the following drives:

VLT 5060-5250
VLT 5032-5052 (230 VAC)
VLT 5075-5300 AQUA
VLT 5042-5062 (230 VAC) AQUA
VLT 6075-6275
VLT 6042-6062 (230 VAC)
Note: After the AC voltage is removed and prior to servicing, all voltages (AC and
DC) should be verified with a meter.
1. Disconnect power to the drive. Wait at least 15 minutes after AC voltage is disconnected
before servicing to ensure the DC bus capacitors are fully discharged.
2. Remove DC capacitor bank, if necessary, to perform test on drive. When removing DC
capacitor bank, follow these instructions dependent on enclosure type:
• NEMA 12 - Remove the DC+ and DC- leads coming from the DC link inductor to the top
of the capacitor bank (See Figure 5). Ensure these leads are taped off and adequately
insulated to protect personnel and equipment.
• Chassis and NEMA 1 - Remove the two Torx head screws from the DC link inductors
while keeping the wire assemblies attached to the DC bus assembly (See Figure 5). It
may be easier to first remove these wires from the DC capacitor bank, then remove the
two Torx head screws.
DC + and DC - leads to
capacitor bank
DC link inductor
connections
Figure 5. DC capacitor bank connections
95
3. Remove the three soft charge fuses from the soft charge fuse block (See Figures 6 and 7).
Input Side of Soft Charge Fuses
Figure 6. Soft charge fuses - Horizontal Mount
Input Side of Soft Charge Fuses
Figure 7. Soft charge fuses - Vertical Mount
4. Connect the VLT 5000/6000 wire harness assembly, supplied with the Power Card DC
Supply Source, to the common connector at the bottom of the Power Card DC Supply Source
box.
5. Connect the three fast-on connectors to the input side (left side or bottom end) of the soft
charge fuse block (See Figures 6 and 7).
96
6. Connect the DC bus connections of the Power Card DC Supply Source to the 3-pin Molex
connector attached to the Power Card.
7. Remove the SCR cable assembly from MK6 of the Power Card.
8. Short the SCR Gate-Cathode connections by inserting the SCR Jumper Plug into the end of
the MK6 cable (See Figure 9).
9. Reapply power and perform necessary tests.
97
SPARE PARTS LIST
VLT 5060 - 5250 380/500V, 5075 - 5300 Aqua, 6075 - 6275 380/460V
DESCRIPTION 5060 5075 5100 5125 5150 5200 5250
Aqua Aqua Aqua Aqua Aqua Aqua Aqua
5075 5100 50125 5150 5200 5250 5300
6075 6100 6125 6150 6175 6225 6275
Control Card, Process, includes software 176F1400 176F1400 176F1400 176F1400 176F1400 176F1400 176F1400
Control Card, Process (conformal coated) 176F1452 176F1452 176F1452 176F1452 176F1452 176F1452 176F1452
Control Card, HVAC/Aqua, includes software 176F1405 176F1405 176F1405 176F1405 176F1405 176F1405 176F1405
Control Card, AQUA/HVAC (conformal) 176F1453 176F1453 176F1453 176F1453 176F1453 176F1453 176F1453
Local Control Panel Process 175Z0401 175Z0401 175Z0401 175Z0401 175Z0401 175Z0401 175Z0401
Local Control Panel HVAC/Aqua 175Z7804 175Z7804 175Z7804 175Z7804 175Z7804 175Z7804 175Z7804
Power Card ST/HVAC/Aqua Revised 176F1466 176F1467 176F1468 176F1469 176F1470 176F1471 176F1472
Power Card ST/HVAC/Aqua Rev CONF 176F2349 176F2350 176F2351 176F2352 176F2353 176F2354 176F2355
Power Card EB Revised 176F1473 176F1474 176F1475 176F1476 176F1477 176F1478 176F1479
Power Card EB Revised Conformal 176F2356 176F2357 176F2358 176F2359 176F2360 176F2361 176F2362
Brake Snubber Card 176F1122 176F1122 176F1122 176F1123 176F1123 176F1124 176F1124
Brake Snubber Card Conformal 176F2446 176F24446 176F2446 176F2447 176F2447 176F2448 176F2448
IGBT Snubber Card 176F1121 176F1121
IGBT Snubber Card Conformal 176F2460 176F2460
DC Bus RFI Filter Card 176F1187 176F1187 176F1187 176F1187 176F1187 176F1187 176F1187
DC Bus RFI Filter Card Conformal 176F2458 176F2458 176F2458 176F2458 176F2458 176F2458 176F2458
IGBT Assembly 176F1125 176F1125 176F1126 176F1129 176F1129
IGBT Assembly, Conformal 176F2402 176F2402 176F2403
IGBT Assembly, Lower 176F1127 176F1127
IGBT Assembly, Lower Conformal 176F2405 176F2405
IGBT Assembly, Upper 176F1128 176F1128
IGBT Assembly, Upper Conformal 176F2404 176F2404
Brake IGBT 176F1130 176F1130 176F1130 176F1131 176F1131 176F1132 176F1132
SCR/Diode Input Rectifier 176F1133 176F1134 176F1135 176F1136 176F1137 176F1138 176F1139
DC Bus Capacitor 176F1139 176F1139 176F1139 176F1139 176F1139 176F1139 176F1139
Mylar Insulator, DC Capacitor Bank 176F1321 176F1321 176F1321 176F1323 176F1323 176F1325 176F1325
Bus Plate +, DC Capacitor Bank 176F1290 176F1290 176F1290 176F1293 176F1293 176F1296 176F1296
Bus Plate -, DC Capacitor Bank 176F1291 176F1291 176F1291 176F1294 176F1294 176F1297 176F1297
Bus Plate +/-, DC Capacitor Bank 176F1292 176F1292 176F1292 176F1295 176F1295 176F1298 176F1298
Bottom Insulator, DC Capacitor Bank 176F1322 176F1322 176F1322 176F1324 176F1324 176F1326 176F1326
Front Shield, DC Cap Bank, IP54/N12 176F1287 176F1287 176F1287 176F1288 176F1288 176F1289 175F1289
Front Shield, DC Cap Bank, IP20/N1 176F1357 176F1357 176F1357 176F1358 176F1358 176F1359 176F1359
Front Shield, Soft Charge, IP20/N1 176F1360 176F1360 176F1360 176F1361 176F1361 176F1361 176F1361
DC Bus Capacitor Bank Assembly 176F1275 176F1276 176F1277 176F1278 176F1279 176F1280 176F1281
Current Sensor Assy IP20/CHM/N1 176F1140 176F1140 176F1140
I Sensor Assy IP20/CHM/N1 CONF 176F2400 176F2400 176F2400
Current Sensor Assy IP54/N12, Pkg of 3 176F1143 176F1143 176F1143
I Sensor Assy IP54/N12, Pkg of 3 CONF 176F2401 176F2401 176F2401
Current Sensor 176F1141 176F1141
Current Sensor Conformal 176F2461 176F2461
Current Sensor IP54 176F1142 176F1142
Current Sensor IP54 Conformal 176F2462 176F2462
Current Sensor w/Output Wire (U) IP20 176F1488 176F1488
I Sensor w/Output Wire (U) IP20 Conformal 176F2463 176F2463
Current Sensor w/Output Wire (V) IP20 176F1489 176F1489
I Sensor w/Output Wire (V) IP20 Conformal 176F2464 176F2464
Current Sensor w/Output Wire (W) IP20 176F1490 176F1490
I Sensor w/Output Wire (W) IP20 Conformal 176F2465 176F2465
DC Bus Balance Resistor 176L3423 175L3423 175L3423 175L3423 175L3423 175L3550 175L3550
SCR Snubber Capacitor 175L3424 175L3424 175L3424 175L3424 175L3424 175L3424 175L3424
SCR Snubber Resistor 176F1145 176F1145 176F1145 176F1145 176F1145 176F1145 176F1145
Heatsink Thermal Sensor Assembly 176F1273 176F1273 176F1273 176F1273 176F1273 176F1273 176F1273
Soft Charge Rectifier 175L3421 175L3421 175L3421 176F1146 176F1146 176F1146 176F1146
Soft Charge Resistor, include thermostat 176F1144 176F1144 176F1144 176F1144 176F1144 176F1144 176F1144
Soft Charge Rectifier Fuse, Pkg of 3 176F1147 176F1147 176F1147 176F1148 176F1148 176F1148 176F1148
Soft Charge Rectifier Fuse Block 175L3418 175L3418 175L3418 175L3418 175L3418 175L3418 175L3418
SCR Snubber Diode 176F1343 176F1343 176F1343 176F1343 176F1343 176F1343 176F1343
Soft Charge Resistor Fuse 176F1192 176F1192 176F1192 176F1192 176F1192 176F1192 176F1192
98
SPARE PARTS LIST
VLT 5060 - 5250 380/500V, 5075 - 5300 Aqua, 6075 - 6275 380/460V Continued
DESCRIPTION 5060 5075 5100 5125 5150 5200 5250
5075 5100 50125 5150 5200 5250 5300
6075 6100 6125 6150 6175 6225 6275
Soft Charge Resistor Fuse Block 176F1193 176F1193 176F1193 176F1193 176F1194 176F1194 176F1194
DC Link Inductor IP20/CHM/N1 176F2324 176F2328 176F2332 176F2336 176F2340 176F2343 176F2345
DC Link Inductor IP54/N12 176F2326 176F2330 176F2334 176F2338 176F2342 176F2346 176F2348
Output Inductor IP20/CHM/N1 176F2323 176F2327 176F2331 176F2335 176F2339 176F2344 176F2344
Output Inductor IP54/N12 176F2325 176F2329 176F2333 176F2337 176F2341 176F2347 176F2347
Fan, Heatsink IP20/CHM/N1 176F1177 176F1177 176F1177 176F1178 176F1178 176F1178 176F1178
Cap, Fan Heatsink IP20/CHM/N1/IP54/N1 176F1179 176F1179 176F1179 176F1180 176F1180 1876F1180 176F1180
Inlet Ring, Heatsink Fan, IP20/N1/CHM 176F2397 176F2397 176F2397 176F2397
Fan Assy. Heatsink IP54/N12 176F1181 176F1181 176F1181 176F1182 176F1182 176F1182 176F1182
Fan, Cap Bank IP54/N12 176F1245 176F1245 176F1245
Fan, Cap Bank IP54/N12 Conformal 176F2457 176F2457 176F2457
Fan, Door, Lower IP54/N12 176F1184 176F1184 176F1184 176F1184
Fan, Door, Upper IP54/N12 176F1223 176F1223 176F1223 176F1223
Fan Guard, Upper IP54/N12 176F1224 176F1224 176F1224 176F1224
Autotransformer, Fan Supply 176F1243 176F1243 176F1243 176F1244 176F1244 176F1244 176F1244
Filter, Door Fan IP54/N12 176F1185 176F1185 176F1185 176F1185
Grill, Door Fan IP54/N12, includes filter 176F1186 176F1186 176F1186 176F1186
SMPS Fuse 175L3437 175L3437 175L3437 175L3437 175L3437 175L3437 175L3437
Terminals, Line 176F1188 176F1188 176F1188 176F1189 176F1189 176F1189 176F1189
Terminals, Motor 176F1190 176F1190 176F1190 176F1191 176F1191 176F1191 176F1191
Terminals, Brake (SB/EB Only) 176F1212 176F1212 176F1212 176F1213 176F1213 176F1213 176F1213
Terminals, DC (EB Only) 176F1214 176F1214 176F1214 176F1215 176F1215 176F1215 176F1215
Terminal Kit, Control Card 176F1210 176F1210 176F1210 176F1210 176F1210 176F1210 176F1210
Terminal Kit, Power Card 176F1211 176F1211 176F1211 176F1211 176F1211 176F1211 176F1211
Terminals, Aux Fan Supply, HVAC/Aqua 176F1338 176F1338 176F1338 176F1338 176F1338 176F1338 176F1338
DC Terminal Repair Kit, Cap Bank 176F2381 176F2381 176F2381 176F2382 176F2382 176F2382 176F2382
Top Cover IP20/CHM/N1 176F1263 176F1263 176F1263 176F1264 176F1264 176F1264 176F1264
Front Door w/Screws IP20/CHM/N1 176F1266 176F1266 176F1266 176F1267 176F1267 176F1267 176F1267
Front Cover (Plas) Process IP20/CHM/N1 176F1268 176F1268 176F1268 176F1265 176F1265 176F1265 176F1265
Front Cover (Plas) HVAC IP20/CHM/N1 175Z3010 175Z3010 175Z3010 176F1339 176F1339 176F1339 176F1339
Front Cover (Plas) Aqua IP20/CHM/N1 176F1348 176F1348 176F1348 176F1349 176F1349 176F1349 176F1349
Front Logo (Plastic) IP20/CHM/N1 175Z3001 175Z3001 175Z3001 175Z3001 175Z3001 175Z3001 175Z3001
Front Door w/Hardware Process IP54/N12 176F1269 176F1269 176F1269 176F1328 176F1328 176F1270 176F1270
Front Door w/Hardware HVAC IP54/N12 176F1340 176F1340 176F1340 176F1341 176F1341 176F1342 176F1342
Front Door w/Hardware Aqua IP54/N12 176F1353 176F1353 176F1353 176F1354 176F1354 176F1355 176F1355
Hinge Kit, Front Door IP54/N12 176F1216 176F1216 176F1216 176F1216 176F1216 176F1216 176F1216
Latch Kit, Front Door IP54/N12 176F1217 176F1217 176F1217 176F1218 176F1218 176F1218 176F1218
Bottom Access Plate Assy. IP20/IP54 175L3592 175L3592 175L3592 175L3592 175L3592 175L3592 175L3592
Conduit Bracket IP20/CHM/N1 176F1246 176F1246 176F1246 176F1247 176F1247 176F1247 176F1247
Display Cradle IP20/CHM/N1 175Z1158 175Z1158 175Z1158 175Z1158 175Z1158 175Z1158 175Z1158
Control Card Cassette 176F1240 176F1240 176F1240 176F1240 176F1240 176F1240 176F1240
Control Card Mtg. Bracket IP55/N12 176F1299 176F1299 176F1299 176F1299 176F1299 176F1299 176F1299
Power Card Bracket Top 176F1259 176F1259 176F1259 176F1261 176F1261 176F1261 176F1261
Power Card Bracket Bottom 176F1260 176F1260 176F1260 176F1262 176F1262 176F1262 176F1262
Ribbon Cable Set, IP20/CHM/N1 176F1225 176F1225 176F1225 176F1226 176F1226 176F1226 176F1226
Ribbon Cable Set, IP54/N12 176F1227 176F1227 176F1227 176F1228 176F1228 176F1228 176F1228
RFI Assembly, IP20/CHM/N1 176F1201 176F1201 176F1201 176F1202 176F1202 176F1203 176F1203
RFI Assembly, IP20/CHM/N1 Conformal 176F2451 176F2451 176F2451 176F2452 176F2452 176F2453 176F2453
RFI Assembly, IP54/N12 176F1282 176F1282 176F1282 176F1283 176F1283 176F1284 176F1284
RFI Assembly, IP545/N12 Conformal 176F2454 176F2454 176F2454 176F2455 176F2455 176F2456 176F2456
Soft Change Thermostat 176F1274 175F1274 176F1274 176F1274 176F1274 176F1274 176F1274
Bus Bar SCR + 176F1285 176F1285 176F1256 176F1253 176F1253 176F1251 176F1251
Bus Bar SCR - 176F1286 176F1286 176F1255 176F1254 176F1254 176F1252 176F1252
Bus Bar SCR AC 176F1257 176F1257 176F1257 176F1248 176F1248
Kit, SCR Bus Bar Insulator 176F1494 176F1494 176F1494 176F1494 176F1494 176F1494 176F1494
Bus Bar IGBT E-1-C2 176F1249 176F1249 176F1250 176F1250
Barrel Lug, Screw terminal, IP54/N12 176F2386 176F2386 176F2386
Lifting Hook 176F1258 176F1258 176F1258 176F1258 176F1258 176F1258 176F1258
99
SPARE PARTS LIST
VLT 5060 - 5250 380/500V, 5075 - 5300 Aqua, 6075 - 6275 380/460V Continued
DESCRIPTION 5060 5075 5100 5125 5150 5200 5250
5075 5100 50125 5150 5200 5250 5300
6075 6100 6125 6150 6175 6225 6275
Cable Assy. Control to LCP IP54/N12 176F1220 176F1220 176F1220 176F1221 176F1221 176F1221 176F1221
Wire Assy. Pwr Card to SCR 176F1229 176F1229 176F1230 176F1231 176F1231
Wire Assy. Pwr to SCR IP20/CHM/N1 176F1232 176F1232
Wire Assy. Pwr Card to SCR IP54/N12 176F1233 176F1233
Wire Assy. Pwr to I Sense IP54/N12 176F1234 176F1234 176F1234 176F1234
Wire Kit, Input to SCR, incl 3 Phases IP20 176F2372 176F2372 176F2372 176F1486 176F1486 176F2374 176F2374
Wire Kit, Input to SCR, incl 3 Phases IP54 176F2373 176F2373 176F2373 176F1487 176F1487 176F2375 176F2375
Use Use
Wire Kit, Motor Coil to Output Terminals, Use Use Use 176F1488 176F1488
incl. 3 Phases IP20 176F1140 176F1140 176F1140 176F2370 176F2370 176F1489 176F1489
176F1490 176F1490
Wire Kit, Splicer Block to Output
Terminals, incl 3 Phases IP54 176F2385 176F2385 176F2385 176F2371 176F2371 176F2369 176F2369
Splicer Block for Output Wires IP54 176F2383 176F2383 176F2383 176F2383 176F2383 176F2384 176F2384
Wire Assy, MK7-Cap Bank Fans IP54/N12 176F1493 176F1493 176F1493
Wire Assembly, MOV1 176F1464 176F1464 176F1464 176F1465 176F1465 176F1465 176F1465
Wire Assy, Pwr to I Sense IP20/CHM/N1 176F1235 165F1235 176F1235 176F1235
SPARE, WIRE Assy SFT CH 176F2387
SPARE, WIRE Assy R13 Soft Charge 176F2388
SPARE, WIRE Assy L1-Cap 176F2389
SPARE, WIRE Assy L1-Cap 176F2390
SPARE, WIRE Assy DC Bus 176F2391
SPARE, WIRE Assy +Bus to R 176F2392
SPARE, WIRE Assy -Bus to R 176F2393
SPARE, BUS Bar 400A Brake option 176F2394
SPARE, WIRE Assy BR2 to F4 176F2395
SPARE, WIRE Assy BR2 to R1 176F2396
EMC Ground Plate Chassis 176F5453 176F5453 176F5453 176F5454 187F5454 176F5454 176F5454
100

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VLT® 5000 Series Service Instructions

Product Overview ................................................................................................................ 1

Warnings and Cautions ...................................................................................................... 1

Section I Drive Build Up

Section III Static Checks

Section IV Dynamic Checks

5060-5100 Chassis / Nema 1 / IP20

5125-5150 Nema 12 / IP54

5125-5150 Chassis / Nema 1/ IP20

5200-5250 Nema 12/ IP54

5200-5250 Chassis / Nema 1/ IP20

When performing service, proper ESD equipment should be

The Motor Coils serve to provide a limit to the rate of current

Soft Charge Section

As we reach the Inverter Section, Figure 5. Six IGBT's are

COOLING FANS Connector MK15 provides access to Relay 01 which is

SPECIFIC POWER CARD CONNECTORS

ALARM 16 LOW P. 105 [1]

WARNING/ALARM 18 MOTOR TOO SMALL [4]

Also see "Applications"

See section "Fault

Symptom Have soft charge fuses F1,

Disconnect all control

Does the fault Disappear?

Test the soft change circuit

21) 22) 25)

Symptom Start the VLT adjustable Replace the Control Card.

SYMPTOM POSSIBLE CAUSES

SYMPTOM POSSIBLE CAUSES

7. Unbalanced Input Phase Currents Input line voltage unbalanced

8. Unbalanced Motor Phase Currents Open motor winding

EARTH FAULT TRIPS OVER CURRENT TRIPS

OVERVOLTAGE TRIPS Remember for the load to become regenerative it must be

OVER TEMPERATURE TRIPS Following is a description of the 4 LED's associated with an

STATIC TEST PROCEDURES

CAUTION: Photo is typical of a VLT 5060-5100 Chassis, others will be

TESTING THE SOFT CHARGE AND Incorrect Reading:

Testing the Inverter Section Step 3

TESTING THE INTERMEDIATE SECTION Step 5

Local Control Panel

DC Inductor Soft Charge

Input Terminals Heatsink Thermal

Load Sharing and

Control Card + and – DC Bus

Soft Charge Rectifier Soft Charge Rectifier SCR Snubber Resistor

Upper Door Fans DC Inductor

Control Card Cassette + and – DC Bus

Soft Charge Resistor

Soft Charge Resistors

Soft Charge Rectifier

Soft Charge Resistor

Soft Charge Rectifier,

SCR Snubber Diode BR2

SCR Snubber Resistors

SCR Snubber Capacitor

DYNAMIC TEST PROCEDURES

In most units the gate wiring and SCR/Diode modules are

Typical input current wave form 5075 at 100 amp load

TESTING FOR CURRENT FEEDBACK: