Your DC bus voltage is low. It is typically up towards 678 VDC on a 460 VAC VFD. Have you performed a diode test and IGBT test on this VFD?


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First item: It's extremely funny to fumble inside of a 100 HP VFD which doesn't run. You know nothing about the parametrization of the drive if you didn't use the display.
Second item: In standard parametrization you must apply a wire bridge between the terminals 12 and 27.
Third item: The running will be autorized tu run when you close the contact between the terminals 12 and 18.
Fourth item: You must apply a 0 to 10 voltage between the terminals 53 (+) and 55 (GND).
Fifth item means some parametrization hints: Minimum frequency 10 Hz as there seems to be a software problem that makes the VFD switch off with alert 13 sometimes when the frequency is lower than 10 Hz. The switching frequency should be set to 4.5 kHz.
Keep away your dirty fingers from inside of the VFD. It will be grateful to you.

 

Hi coolingtower139, please tell me if the motor is running with the VFD. If not yet it's possible that you have to apply a wire bridge between the terminals 50 and 54. Usually there is hooked a thermal supervision of the motor windings. In case of failure there is shown an alert but without the display it is difficult to see that...

 

Hello Stability, I have not done anything else with the drive as far as trouble-shooting. I actually isolated all 480VAC power and have removed the drive myself. I planed to have it repaired by Radwell International. The guy that works on drives told me its probably something WAY in behind everything that had failed. I am thinking its probably not the display but I do not know. He did not apply any jumpers to any terminals behind the display mount. I am just guessing but I'm thinking it might be a power modual like Danfoss told me over the phone. The guy DID check the IGBT's and said one of the phases he got a funny reading. So also if the power controller behind everything has partially fried Im thinking this would give a funny reading and if that board was isolated from the circut the funny reading MAY go away. I tried my best over the weekend to search the internet to see if I could find anything and I believe I MAY HAVE and the part costs less than 100USD but would require above normal sodiering skills perhaps OR the whole board a little under 300USD this does not show the actual board not sure why inless they thought someone would try this at home and they are just "Trained" professionals. https://hackaday.io/project/24909-how-to-repair-any-vfd/details but if an integrated power modual fails this could give a pretty funky reading

 

Hi Coolingtower139, since they exist I'm working with the VFD 6000. It has never been necessary to repair or to replace a device. The only problem that arrived several times: If you apply an external voltage >30V relative to ground at the terminals 12, 18 or 27 the control board will crash. Therefore I don't see any use in the fumbling inside of the VFD. Be aware that the DC voltage of the intermediate circuit cannot be higher than the applied AC voltage times about 1.4.

 

Hello Stability,
I do not really work on the VLT6000 drives BUT I really have in my mind this industrial VFD should NOT be discarded just because it does not function. Remembering several years ago when power outages would occur all I needed to do was to go to my MCP and push the start button which controls a 480VAC relay which in-turn sends 3 Phase power to the input VFD terminals. Then the display would just light-up and I just press the AUTO button on the drive and the drive will initiate ramp up. I have my drives controlled all by DDC controllers which send a 4 - 20 MA signal to the control of the drive which programed to maintain .50 CFM in a designated space first, second & third floors. Recently the power inturuptions have been increasing and the drive has not been starting back up the display would be present but there would be no responce from the drive. So I power back down wait about 30 min and power back up then the drive would initiate ramping. This last time I let the drive sit for three or more days and let the other person test it. He did tell me the drive had over 600VDC on the bus but still no display. I am guessing if this person knew more about this specific drive he would of applied jumpers and or 24V to those specified terminals but I will admit this step was not done. What I am concerned about is componets perhaps starting to fail and this is why the drive does not have a fast recovery post power outage. I am thinking someone more versed on this specific drive might know this and perhaps repair two or three problem areas. This drive has been in operation at my facility since 1997 and has been on line 24/7 and I feel has been very dependable this is why I do not want to do away with it so fast. Right now I have it sitting on a dolly ready to be carted out for repair once I get a PO issued. I could re-connect it but not sure if it would be worth my while to do so. It would be so nice to just need a new display modual and a couple of ribbon cables to make this drive functionable again. I really did not want to disturb my other drives by removing those componets. Actually the drive was not as heavy as I initially thought though.

 

Ment to say .50" static pressure not CFM the motors are capable of producing 35,000 CFM but I do not want a wind tunnel just a comfortable building.

 

If the display doen't work you have to check two units: The display itself (interchange with another display) or the control card beside of the display. This card keeps the power supply for all control circuits of the VFD. This power supply has nothing at all to do with the intermediate DC circuit for the alternator IGBT's (where you measure the 600 VDC).
The control circuit power supply is always a little noisy. So you can easily find out if it works.

 

Hello stability, I started to write this but it all got deleted for some reason. I just hope this information helps you or someone else. I just know this kind of information would be of great value to myself. Perhaps you may already know how to repair these at the board level but my DANFOSS VLT6000 was not functioning and now it functions. I really do not like to see equiptment in the scrap pile I like to see it functioning especialy the heavy duty equiptment such as this. Plus everyone on here is so helpful and provides quality information as well. The folowing componets are the componets that were replaced on my DANFOSS VFD and which made it function once more. There were 9 each 100UF 50VDC 3 each 220UF 25VDC 15 each 120UF 25VDC 1 each 220UF 63VDC 7 each 470UF 25VDC 1 each 1000UF50VDC 1 each UC2844D power IC I think this is surface mount type. I am not sure where the caps were located. I did not see any obvious swollen caps on the primary board, perhaps they are on the other side of the drive. Only Problem I have NOW that I did NOT have when the drive was NEW is that after the drive is POWERED DOWN I have to WAIT maybe 30 minutes or so to re-start it. The drive powers back ON but just will not send current to the motor but if I isolate ALL primary power to the drive for 30 min then power-up everything is just fine. Please let me know.

 

Hello stability, I started to write this but it all got deleted for some reason. I just hope this information helps you or someone else. I just know this kind of information would be of great value to myself. Perhaps you may already know how to repair these at the board level but my DANFOSS VLT6000 was not functioning and now it functions. I really do not like to see equiptment in the scrap pile I like to see it functioning especialy the heavy duty equiptment such as this. Plus everyone on here is so helpful and provides quality information as well. The folowing componets are the componets that were replaced on my DANFOSS VLT6001 VFD and which made it function once more. There were 9 each 100UF 50VDC 3 each 220UF 25VDC 15 each 120UF 25VDC 1 each 220UF 63VDC 7 each 470UF 25VDC 1 each 1000UF50VDC 1 each UC2844D power IC I think this is surface mount type. I am not sure where the caps were located. I did not see any obvious swollen caps on the primary board, perhaps they are on the other side of the drive. Only Problem I have NOW that I did NOT have when the drive was NEW is that after the drive is POWERED DOWN I have to WAIT maybe 30 minutes or so to re-start it. The drive powers back ON but just will not send current to the motor but if I isolate ALL primary power to the drive for 30 min then power-up everything is just fine. Please let me know.[/QUOTE]

 

Hi coolingtower, do you meanwhile dispose of a display unit? I think the problem is an alert that must be resetted by means of the display.

 

Yup, electrolytic capacitors are a maintenance item. Structure internally is very similar to a AGM battery. When I worked on UPS systems there were scheduled changeouts for these and the schedule looked just a little longer than batteries.

 

Hello Stability, On my display there is no indication of any parameter requiring any reset? I know I do not know a lot about these but if anything stops working there is just a reset button on the front. I am however concerned about having to WAIT 30 min after a power down and restart of the drive. Right now I just have to wait the 30 min since I am not understanding the steps of this type of reset. I am really suprised about MaxBurn making the statement of replacement of caps is merely a maintenance requirement. My Lord! I am sure company's throw these drives away and replace with new when they stop functioning they would never figure cap replacement. The only way I would think about it if I had a non functioning VFD and I see swollen caps in-sight.

 

I am really suprised about MaxBurn making the statement of replacement of caps is merely a maintenance requirement. My Lord! I am sure company's throw these drives away and replace with new when they stop functioning they would never figure cap replacement.

Its more than that. Large UPS system will be built with service in mind. Typical VFD, unlikely. Difference between changing a light bulb vs brain surgery. I tore a few dead VFDs down bound for the bin just to see how they were built. Wouldn't say service is much of a design consideration in what I have seen. Maybe you luck out and that specific model has some easy to access problem area. Otherwise its prob not worth the hassle or liability to mess around with it. Drives work with real power and when things go wrong, they have the potential to go really wrong. Just the downtime and labor to pull a VFD off the wall, piss around to fix (likely waiting for parts unless you just happen to have them) and reinstall vs swap out with a locally sourced replacement same day...

 

Hi Coolingtower, I think it would be useful if we will have a phone call as it will be difficult to clarify the situation by a forum discussion. Phoning is faster.
Please send a photo of the display to the following mail address: emeraude@gmx.net. Don't forget to indicate your time zone. Then I'll tell to you my phone number. The results we'll post around here.

 

Hello Stability, I just got your message. I will have to take a photo of display Monday when I go back to work. I am on the eastern standard time zone in the USA. Right now the time is 19:35

 

About the life cycle of electrolytic capacitors: I've big problems with them in switch mode power supplies where they're exposed frequencies higher than 50/60 Hz over more than eight to ten years. On the site where I'm earning my life it's sure and experienced that some SMPS (will) fail when they are switched off for several hours changing the ambiant T° of the parts.
The defective devices are easily to identify by means of an oscilloscope and an insulating transformer.

 

Get a measuring device that measures ESR if bad caps are your thing.

 

Never have used a ESR meter before. Is it possible to measure the caps when they are still built in the circuit or is it necessary to take them out or to isolate them? With an isolating transformer and an oscilloscope there is no soldering work if the cap is all right.

 

Hello orion, I really know what you mean about service. But I needed the drive plus I have a failed $28,000.00 heat exchanger I am looking to replace also which is 2000+ pounds and 12 feet ( 4 meters ) up which has been in service since 1978 when building was new that needs replaced I kind of did not want to purchase a 100 HP VFD too on my budget. I was able to take the drive OUT myself send it OUT have it repaired and re-installed it in about a weeks time. It would of took purchasing 2 months to get me a new drive. Im wondering how long it will take for the heat exchanger. I guess when people start getting cold or cold and clammey they will realize they need that even though some might like that coldness I sure know I would not like it in my office without a re-heat coil. I use to have a well still have it but its not in service a 48KV EXCIDE UPS w/ four hundred sixty 1.2V Jar batteries. The company downsized the CR and now there is a super small UPS system sitting there with a lot of room except for the UPS units STILL there LOTS of copper in those with those solid copper internal buss bars. It would be great if someone in another country needed parts from this unit I got cooling fans and other units with caps in them plus the fans. I don't know the terms since I did not work on these systems. I just had to disconnect the batterys so the guys could take them OUT and I made a special tool so they could lift the batterys easer

 

did not want to purchase a 100 HP VFD too on my budget. I was able to take the drive OUT myself send it OUT have it repaired and re-installed it in about a weeks time.

Ya 100HP and up drives get a bit spendy. Where did you send it? Pretty impressed there are outfits out there repairing them and you got it back in a weeks time.

Your purchasing department must be a treat to work with. Not sure I could pickup a 100HP vfd same day, but if it wasn't local I wouldn't expect it to take more than a week to get.

 

Hello stabuility, When I was repairing LCD monitors back in the day I kind of remember checking the switching transistors but I had to de-soilder them to check but now I do not remember what value I was checking I just remember the switching transistors and the power mosfets use to fail in addition to the CAPS. Oh and some on board fuses. NOW when you get to the oscilloscope that is a horse of a different color. I am interested in that however that's a puppy I could never figure OUT on my OWN. I wish I could operate and understand one of those.

 

48KVA Units. I asked the higher ups if they wanted me to dissasemble these two machines but the units still sit as they were. The company used to have 2 CR's and they had those two EXCIDE UPS units plus a lot of copper wire like 2 or 3 AOUT

 

Hello Orion242 Radwell International in New Jersey actually came to my facility and picked the drive up repaired it and brought it BACK the BILL was not low but if the drive lasts another 5 years $1200.00 does not seem too bad. I had this drive in service 24/7 since around year 2000 All I know the drive works and when I purchased it they told me it was a heavy duty VFD

 

Seems pretty damn good if they picked up from your dock and returned that quick. Heard of them, didn't realize they would do VFDs let alone pickup in some areas. Just shipping 100HP+ VFDs around costs a few bucks.

 

Hello stability, I sent you a photo of my display from my 100HP drive from my work email yesterday or the day before. Checking caps with a scope and isolating xformer sounds interesting to me. I was wondering if they had any videos on how its done an how the scope is set up and what to look for. I am wondering if caps could STILL FAIL and LOOK brand new? Most of the caps I've replaced they were quite ovious they were defective

 

Actually sometimes I can not understand how companies can stay in business. Inless they are making millions. To tell you how it really works you would probably FLIP! With " Purchasing " They have a vendors list right and IF I wanted to purchase a VFD I would HAVE to go to ONE of their " Vendors " OK even if Joe Schmoe one hour away had a 100HP drive for $1,000.00 less dallors The company does not care they would purchasing would pay extra and buy from their vendor. Lets say for instance this happend about 6 months ago I need 600 pounds of R-11 Freon OK I found it PLUS deliverd to my loading dock for 4 grand LESS than the approved vendor guess who they purchased it from and paid 4 grand more NOW YOU TELL ME

 

My company where I work is perhaps a hour or so from New Jersey and I myself was a little suprised they picked it up too. I am guessing this drive is about 300lbs I took it down by myself its just held IN one of my old Graham Drive Steel cabinets I just placed a wheeled dolly on the floor chocked the wheels and placed a couple very small pallets atop of it disconnected the beast and walked it OUT then rolled it under a large I-beam picked up up with a come a long and placed it back on the dolly then rolled it out to the truck. I am guessing since I am not too far from Radwell and maybe they figure they could easly repair this type drive also. I just know a new 100 HP drive will cost about five grand and it will be smaller also.