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Basic Troubleshooting
for VLT Drives
Troubleshooting Drives

VLT®
• AC drives
(0.18 – 1,400 kW)
• Decentral drives
• Soft starters
• Power options
(filters)
• Software tools
 Reference Material

•User Manual

•Application Manual

•Service Manual

•Customer Connection Diagram

• Touching the electrical parts of the Drive may be fatal.
• The largest models can require a significant amount of time to
discharge it’s internal circuitry to a safe level after being disconnected
from the incoming AC line power.
• Check instruction manual for further warnings.
• Insure AC Power is Locked Out and no Voltage is present
 Required Tools

• Screwdrivers, Standard & Phillips

• Torx drivers T10 to T50

• Metric socket set, 7 – 17 mm

• long extension (must clear 20”)

• Torque wrench, 4 – 170 in./lbs.

 Equipment

• PWM compatible voltmeter

• Clamp-on ammeter
 PWM Compatible Meter

Many Digital Meters will give erroneous

readings due to PWM waveform.

The output voltage of a VFD can be measured

accurately with an analog meter, or a digital
meter designed for PWM compatibility. 1000
VDC scale is recommended
 Possibly Useful Tools

• 1000 Volt Megger

• Cell phone 1-888-Danfoss
• Laptop computer with MCT-10 Software
• Oscilloscope
 What Is Troubleshooting?

• Troubleshooting is nothing more than a

logical approach to determining.......

Why the SYSTEM is not working?

 The Logical Approach

▪ Assess the situation

▪ Perform physical inspection
▪ Narrow down to one section
▪ Zero in on malfunction
 Physical Inspection

•Unit Installed Correctly?

•Are the connections tight?

•Environmental Conditions OK?

Golden rules for:
Motor Cable : (VSD to Motor)
Never use pigtails to
a) Use screened multi-core 3 core + PE terminate the screen
or 3 core + 3PE. (Protective Earth)

b)Size the Motor cable to carry the Full Load

Current of the Motor.

c)Where a single cable is inadequate for the current

rating, use parallel multi-core cables.

d)The PE (Protective Earth) should be inside the

motor cable screen and terminated by a short
connection at both the VSD earth point & motor earth stud.

e)The PE (Protective Earth) be at least

50% of one phase conductor.

f)The Motor cable screen must be

properly terminated both at the VSD and
at the motor end. (EMC cable glands and decoupling plates)
Shielded motor cable connection at the
frequency converter

OK!
Shield not
connected!
Serial Communication
cables
• Correct use of the decoupling plate

Use the right

shielded cable

Do not use
“pig tails”

Keep exposed
cable as short
as possible
Digital and analog control
cables
• Correct use of the decoupling plate

Use the right

shielded cable

Do not use
“pig tails”

Keep exposed
cable as short
as possible
Golden rules for:
Screened Signal Cables :
•Follow the specifications from signal or communication cables
manufacturer

Screened Signal Cable Bonding:

•The signal or communication cable screen should be bonded correctly
at one end with an approved 360 degree EMC gland or clamp. Follow
the installation instructions for the control equipment (PLC, sensor,
Communications etc.).
•The signal or communication cable screen should be bonded at the
screen termination points. This should not be confused with the “0 Volt”
or “Signal Ground” terminals that may also be provided.

Avoid Creating Loop Antennas :

•Tie down all signal or communication cables to the designated cable
routing.
•Do not create loops at the termination points. Keep “tail” wiring as
straight as practical inside the VSD & motor.
• Follow the designated cable paths within the VSD
•Where practical carry on the screen past the approved EMC gland or
clamp to maintain the cancelling & reduce the risk of loops.
Golden rules for VSD installations
Bonding:

a)Use a minimum of AWG #4

Ground cable between control
panels to ensure low impedance,
High Frequency bonding. Multi
stranded cables and braids provide
better high frequency conductance.

b)Use star-washers to mount the

VSD chassis to the painted back-
plate or remove back plate paint to
secure low impendence path from
chassis to back-plate.

c)8” minimum separation between

control and power cables. Use
separate conduit entries for control
and power wires. Cross cables at
right angles 90°.
Example of poor grounding

• Long thin ground wire through the

cable channel (> 3 feet) has a high
impedance at high frequencies.
 Physical Inspection

• Carbon Deposits Inside Drive?

• Burnt or Damaged Components?
• Blown Fuses?
• NOTE: Do not apply power to test the drive
until a Static Test has been performed!!!
 Input Diodes
The individual diodes that form the three-phase input rectifier bridge can easily be
checked by measuring the forward and reverse resistance of the diodes. Simply use
an analog or digital meter and measure the resistance across each diode. Refer to
the elementary diagram to determine the relationship between the main input
terminals (L1, L2, L3) and the DC bus terminals. By checking the resistance from
each input terminal to the positive bus and the negative bus (then swapping your
meter leads) you can check each of the diodes. Remember, you should see a
resistance reading typical of a diode, with low resistance in one direction and fairly
high resistance after you swap the meter leads.

0.5 OL
Cathode (-) DVM DVM
+ _ + _

Anode (+)

Resistance Readings
 Input Diode Check
Test Equipment - Analog Ohmmeter Set to R X 1 Scale
or Digital Multimeter set to the Diode Check.
Ohmmeter Ohmmeter Expected Expected
Step No. Positive Lead Negative Lead Reading Reading
(Analog Meter) (Digital Meter)
L1 Terminal
1 Terminal labeled (+) Approximately Approximately
L2 Terminal
10 Ohms 0.5 Volts
L3 Terminal
L1 Terminal
2 L2 Terminal Terminal labeled (-) Infinite Ohms 0L displayed
L3 Terminal

L1 Terminal Approximately Approximately

3 Terminal labeled (-) L2 Terminal 10 Ohms 0.5 Volts
L3 Terminal
L1 Terminal
4 Terminal labeled (+) L2 Terminal Infinite Ohms 0L displayed
L3 Terminal
Static Test
 Static Test

◼ Set the ohm meter on the diode check scale.

◼ Connect the + meter lead to the + DC Bus. Place the – meter lead to L1,
L2, L3 and then U, V, W. All readings should be open or capacitor
charging effect.

Positive bus

Negative bus
 Static Test

◼Now change the ohm meter leads and put the negative lead on the + bus
◼The positive meter lead is now placed on L1, L2, L3 and then U, V, W
◼The meter readings should be with in the range of 0.3 to 0.7 Volts

Positive bus

Negative bus
 Output Transistor Check
Test Equipment - Analog Ohmmeter Set to R X 1 Scale
or Digital Multimeter set to the Diode Check.
Ohmmeter Ohmmeter Expected Expected
Step No. Positive Lead Negative Lead Reading Reading
(Analog Meter) (Digital Meter)
T1 Terminal
1 Terminal labeled (+) Approximately Approximately
T2 Terminal
10 Ohms 0.5 Volts
T3 Terminal
T1 Terminal
2 T2 Terminal Terminal labeled (-) Infinite Ohms 0L displayed
T3 Terminal
T1 Terminal Approximately Approximately
3 Terminal labeled (-) T2 Terminal 10 Ohms 0.5 Volts
T3 Terminal
T1 Terminal
4 Terminal labeled (+) T2 Terminal Infinite Ohms 0L displayed
T3 Terminal
Note: When a transistor fails, all the transistors in the failed phase must be
replaced. They must be replaced with the identical transistor manufacturer and
part number.
 Static Test

◼ Place the + meter lead on the – bus

◼ Place the – meter lead on L1, L2, L3 and then U, V, W
◼ The meter readings should be with in the range of 0.3 to 0.7 Volts

Positive bus

Negative bus
 Input and Output shorts
• Use the ohmmeter to check for input AND output shorts
• Line-to-Ground and motor-to-Ground
• Line-to-line Input side and Line-to-line Motor side
 Static Test Completed and Passed
• This Static Test procedure verifies the health of the main power
components of the VFD
• Input Diode Section
• Output IGBT Section
• Line to Line Shorts
• Line to Ground Shorts

• Lets look a little deeper into the VLT VFD Design

VFD Main Function Blocks

The 4 main function blocks of a VFD include the following

❑ Rectifier Section

❑ DC Link Section

❑ Inverter Section

❑ Control & Regulation

 Basic topology of a frequency converter
Mains RFI DC link Motor
Rectifier Inverter Motor
supply filter filter cable

Ldc
Cdc

AC
AC RFI
filter M
AC
Cdc

Ldc

Current
MOV’s and Zener Diode
Transformers –CT’s
VFD Main Function Blocks

Rectifier Section

❑ The rectifier section is used to change AC voltage

into DC voltage

❑ There are 2 main types of rectifier sections

• uncontrolled rectifier sections (diode bridge)

• controlled rectifier sections (thyristor/diode bridge)

VFD Main Function Blocks

Rectifier Section

An uncontrolled rectifier section uses standard diodes to

rectify the AC voltage into DC voltage

AC Ripple Voltage
VFD Main Function Blocks

Rectifier Section

Controlled rectifier sections use gate circuitry to control

firing of SCR’s on the top half of the bridge

AC Ripple Voltage
 Protection from Voltage Spikes
- The Danfoss way

Metal Oxide Varistor

Zener Diodes
VDE 160
2.3 times Line Voltage
1.5 msec
559V on 240VAC
1104V on 480VAC
1322V on 575VAC
Alternative methods for protecting the VFD from
Spikes includes adding an AC line reactor
VFD Main Function Blocks

DC Link Section

❑ The DC Link section is used to filter and store DC

voltage

❑ The DC Link consists of the following parts

• DC link Inductors

• soft charge circuitry

• DC capacitors

• Braking Circuitry – Optional in most cases

VFD Main Function Blocks

DC Link Section

The soft charge circuit is used to gradually bring the

capacitor bank to a full charge

There are 2 different types of soft charge circuits used in

Danfoss drives

• contactor soft charge circuits

• SCR/diode bridge circuits

VFD Main Function Blocks

DC Link Section – Soft Charge Circuits

Contactor Soft Charge

VFD Main Function Blocks
DC Link Section – Soft Charge Circuits

SCR Phase Angle Firing Soft Charge

VFD Main Function Blocks

o DC Link Section – Soft Charge Circuits

SCR/Diode Soft Charge

VFD Main Function Blocks

DC Link Section

The DC inductors are used to filter the DC voltage and help

to reduce power line harmonics
VFD Main Function Blocks

DC Link Section – DC Capacitors

Capacitor banks smooth out and store the DC bus voltage

 “Overhauling Loads”
 When running a motor with an inverter in the motoring
mode, the power flows from the inverter to the motor.

(+)

L1
L2
L3
M

1FU
(-)
 “Overhauling Loads”
 In the regenerative mode, the power flows from the motor
to the inverter.The inverter will allow between 10 – 15%
regeneration before tripping on an Over Voltage fault

(+)

L1
L2
L3
M

1FU
(-)
 “Dynamic Braking”

 Dynamic braking
is a process in
(+)
which regenerative
energy from the L1
L2
M
load is dissipated L3

as heat across a (-)

1FU

bank of resistors. Resistor

HEAT
BTR
VFD Main Function Blocks

DC Link Section – Brake Chopper

The brake chopper is used to burn off regenerative energy

VFD Main Function Blocks

Control and Regulation – Current Sensors

VFD Main Function Blocks

Inverter Section – IGBT Module containing 2 IGBT’s

IGBT’s are used to change the DC bus into AC current for the motor
VFD Main Function Blocks

Inverter Section – PWM (Pulse Width Modulation)

Pulsing the IGBT’s on and off varies the average voltage seen by the motor
VFD Main Function Blocks

Inverter Section – PWM (Pulse Width Modulation)

VFD Main Function Blocks

Control and Regulation – Control Card

VFD Main Function Blocks

Control and Regulation – Power Card

VFD Main Function Blocks

Control and Regulation – Power Card

 Physical Inspection

•Is the Display Lit?

•Fault or Alarm Message Displayed?

•Programmed Correctly?
 Faulted Condition
Alarm/Trip State
and Number

The VFD is Tripped

and the Alarm is
triggered
Info Key Details to Fault
and how to correct it
Pressing the Info
Key will give you a
definition of the
fault and corrective
measures. This key
is active for non
fault issues like
parameter
descriptions
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